Per Larsen DISA Industries A/S

Flow in Gating Systems Real Life and Simulation

Cooperation between DISA Industries A/S and The Technical University of Denmark

Program:
Introduction Back ground and main tasks Casting of thin plates Casting of brake discs Conclusion

Back ground
Growing demand for saving resources The most general way of saving resources is to save weight As it is applicable together with all other means of saving resources

Back ground
A big potential exists for optimizing iron cast parts from a weight saving point of view This can be done by designing with: Small wall thicknesses Ribs Hollow sections

Back ground
This means casting of parts with very small wall thicknesses becomes important Hence it is also important to possess knowledge about melt flow in: Very thin sections Gating systems

Main task
Investigate melt flow in thin sections and in runner systems Partly to gain a better understanding of flow patterns in thin sections and in runner systems Partly to explore the possibilities to fill very thin sections

Trials
Why ?

Thin Plates

Casting of thin plates

Simple geometry, but at the same time the basis for all thin walled parts Good possibilities for analysing the flow patterns in thin sections

Trials
Why ?

Thin Plates

Casting of thin plates

Investigate the flow properties in some conventional gating systems Basis for designing new gating systems

Trials

Thin Plates

Conventional gating system

Trials
Vertical down runner

Thin Plates
Plates 2, 3 and 4 mm thick

Down runner well

Horizontal runner

Trials

Thin Plates

Investigations has been made with the aid of video recordings of the melt flow through glass plates

Trials

Thin Plates

Trials

Thin Plates

Trials

Thin Plates

Trials

Thin Plates

Pressure shock waves during filling

Pressure shock waves can be initiated at two different stages in the filling sequence: 1. When the melt hits a dead end in the gating system if the runner cross section is completely filled behind the melt front 2. When the last air pocket in the runner is closed

Trials

Thin Plates

Pressure shock waves during filling

Both types of pressure shock waves can result in breaking up of the melt front

Pressure shock when the melt hits a blind end in the runner:
Will be shown at the brake disc trials

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:
3 mm plates

Trials

Thin Plates

Pressure shock waves when the last air pocket in the runner is closed:

Trials

Thin Plates

When calm flow is desired, velocity criterions are normally used But low velocities can also result in pressure shock waves Hence there is a need for at criterion taken pressure shock waves into account when designing for calm flow

Trials

Thin Plates

The best way is to remove the basis for pressure shock waves, i.e. to: Avoid dead ends in the runner system Avoid partly filled runner cross sections

Trials

Thin Plates

Stability in the flow patterns from mould to mould at a conventional gating system
3 mm plates Mean melt velocity in the plates: 300 mm/s

Trials

Thin Plates

3 runs of the same trial:

Trials

Thin Plates

3 runs of the same trial:

Trials

Thin Plates

Stability in the flow patterns from mould to mould at a conventional gating system
It is possible to get very different flow patterns at this conventional gating system Even at very similar pouring conditions This means low process stability

Trials

Thin Plates

Summing up on the plate trials:

Conventional gating systems: Good possibilities for improvements seen from a flow point of view exists

Program:
Introduction Back ground and main tasks Casting of thin plates Casting of brake discs Conclusion

Trials
Why ?

Brake Discs

Pouring trials with brake discs

The competition on price is very hard, meaning a small improvement will have a relatively large influence on the profit Knowledge about how conventional gating systems work is a good basis for the development of new gating systems

Trials

Brake Discs

Pouring trials with brake discs

6 different layouts for pouring of the same brake disc 5 conventional layouts 1 non conventional layout

Trials

Brake Discs

Trials

Brake Discs

Trials

Brake Discs

Similarity with the thin plates

Trials

Brake Discs

The flow patterns are investigated via video recordings of the melt through glass plates The technique used at the trials with the plates are partly reused

Trials

Brake Discs

Trials

Brake Discs

Trials

Brake Discs

1. Layout
Conventional

Depressurized

1. Layout

1. Layout

1/10 of real velocity

1. Layout
Powerful splashed are seen when the melt hits the end of the horizontal runner, i.e. a pressure shock waves occurs The heat distribution is very asymmetrical Uneven balance between dynamic and braking forces

1. Layout
Vena contracta is seen at the exit of the down runner well Good possibilities exist to improve the flow patterns The vena contracta can act as an artificial choke

6. Layout
None - conventional

Depressurized

6. Layout

6. Layout

1/10 of real velocity

6. Layout
Relative calm flow when the melt enters the disc cavity only two droplets are seen

The heat distribution is very symmetrical side to side The balance between the dynamic and braking forces is not in control

6. Layout
The melt stream splits up into two otherwise are the cross sections completely filled The flow patterns are well controlled but still possibilities for improving the flow exist

Trials

Brake Discs

Big differences in the performance of the gating systems are seen, i.e. how: the first melt fills the runners the first melt enters the disc cavity the final heat distribution in the disc is

Trials

Brake Discs

Initial filling of the disc cavity

Trials

Brake Discs

Heat distribution after the filling

Trials

Brake Discs

The flow patterns in the mould cavities are far from optimal I.e. at conventional gating systems good possibilities exist for optimizing from a flow point of view A more calm flow means better and more uniform quality

Program:
Introduction Back ground and main tasks Casting of thin plates Casting of brake discs Conclusion

Conclusion
Brake discs:
Different gating systems used in praxis result in significantly different flow patterns Big amounts of splashes are seen at most of the tested gating systems I.e. good possibilities exist for optimizing the gating systems from a flow point of view

Conclusion
Conventional gating systems:
Can result in very different flow patterns from mould to mould Means low process stability The balance between the dynamic and the braking forces controls the flow patterns to a large extend

Conclusion
Conventional gating systems:
Are likely to give pressure shock waves Either when the melt hits a dead end in the gating system Or when the last air pocket in the gating system is closed

Conclusion
Conventional gating systems:
To obtain calm flow is it not enough to design with the aid of velocity criterions Pressure shock waves have to be avoided also The runner cross sections have to be completely filled with the first melt Dead ends have to be avoided