Optimization of Multi-Gate Systems in Casting Process: Experimental and Simulation Studies

This paper proposes an improved gating system design for casting process using experimental and simulation studies. The principle motivation behind optimization of gating system is to overcome the defects like shrinkage, gas porosity, slag, inclusion, cold shuts and misruns etc. Four different designs having different sprue location and runner cross-sectional area are taken into considerations for study. Discharge through multiple gates which are connected to horizontal runner has been evaluated as a performance parameter for comparing the designs. Experiments are conducted by tap and collect method using water and the volume of flow through each gate is observed for all designs. A simulation-based study is carried out for all four designs on finite-volume commercial code FLUENT. Boundary and initial conditions, such as velocity, pressure, temperature, etc., was reasonably set. It is found that the flow rate, as well as average velocity through the farthest gate, is higher for the parallel runner while this difference gets reduced with a tapered runner. Furthermore, design with a central position of sprue also minimizes the difference in flow rates as well as velocity. Finally, a design with a tapered cross-sectional area and justified position, as well as orientation of different gates, is finding out to be optimum having balance flow rate through the four gates with less filling time.