Scribd
Upload
3K views

How To Calculate Feeders

1. The document provides guidelines for calculating feeders for casting processes based on determining the modulus, number of feeders, feedable casting weight, and feeder neck dimensions. 2. The modulus is used to calculate the required feeder modulus and determine preliminary feeder size from tables. 3. The number of feeders is calculated based on casting length/circumference, provisional feeder diameter, and a feeding distance factor. 4. The feedable casting weight is calculated based on shrinkage percentage, feeder weight, and the feeding capacity of the feeder type.

Uploaded by

mecaunidos7771
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
3K views

How To Calculate Feeders

1. The document provides guidelines for calculating feeders for casting processes based on determining the modulus, number of feeders, feedable casting weight, and feeder neck dimensions. 2. The modulus is used to calculate the required feeder modulus and determine preliminary feeder size from tables. 3. The number of feeders is calculated based on casting length/circumference, provisional feeder diameter, and a feeding distance factor. 4. The feedable casting weight is calculated based on shrinkage percentage, feeder weight, and the feeding capacity of the feeder type.

Uploaded by

mecaunidos7771
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 6

Date: December 2003

Feeding Systems Product Data Sheet

How to calculate feeders


Part 1: Determination of feeders for steel, malleable iron, light and copper-base alloy castings 1. Determination of modulus
1.1 Divide the casting into sections and determine the important volume-to-surface ratios according to table 1. Use centimetres (cm) as unit of dimensions.
M= V ( cm3 ) S (cm2 ) = (cm)

M = modulus, V = volume, S = cooling surface

1.2 Determine the required feeder modulus (MF) using the factor 1.2
M F = M C 1.2

MF = modulus feeder, MC = modulus casting

1.3 Provisional determination of the feeder from the feeder tables.

2. Determination of the number of feeders

2.1 Determination of the feeding distance factor (FD) from tables 2 and 2a. 2.2 Calculation of the number of feeders (nF). Use millimetres (mm) as unit of dimensions.
nF = L (m m) d (m m ) + FD T (m m )

nF = number of feeders, L = casting length or mean circumference, d = provisional feeder diameter, FD = feeding distance factor, T = thinnest section through which feeding is to be ensured

3. Calculation of the feedable casting weight

The feeders obtained from the calculation of modulus and of number of feeders do not always satisfy the shrinkage requirements. In these cases feeders must be increased. For their calculation the following data are required: 3.1 Weight of the casting or casting cluster to be fed 3.2 Feeder weight 3.3 Shrinkage in percent (see table 3) 3.4 Feeding capacity of the feeder. If exothermic/insulating feeder sleeves are used this is at least 33 %. Pour-through sand feeders render up to 16 %, all others 14 %. 3.5 Feedable casting weight (W)
W= 1 Feeder weight (kg ) 100 3 Shrinkage (%)

4. Determination of the feeder neck

4.1 Top feeder: No determination of feeder neck required. If possible, feeder sleeves should be used with breaker core. 4.2 Side feeder: The required feeder neck (N) is obtained from the calculation of modulus using the bar equation or diagram table 5.
MN = ab 2(a + b)

MC : MN : MF = 1 : 1 : 1.2

Foseco (FS) Limited, Tamworth, Staffordshire, B78 3TL Tel: +44 (0)1827 289999 Fax: +44 (0)1827 250806 www.foseco.co.uk

Part 2: Determination of feeders for flake graphite and spheroidal graphite iron castings 1. Modulus consideration to ensure that the feeder will remain fluid sufficiently longer than the casting/casting section

i CASTING MODULUS
MC = V (cm3 ) S (cm )
2

= (cm)

MC = Casting modulus, V = Volume, S = Cooling surface area For simple modulus calculation Table 1 should be used.

ii FEEDER MODULUS CONSIDERATION Determination of shrinkage time from diagram 4. With known C-content move along IsoCarbon line to the appropriate (Si + P) content at point A. Extrapolate this line vertically until it intersects the casting modulus line at point B. Extend the line horizontally on the left hand side until it intersects with the line representing estimated casting temperature of the iron in the mould at point D. Read off shrinkage time (ST) in percentage of solidification time. This graph attempts to estimate during which proportion of the solidification time shrinkage occurs. Effective feeder modulus is determined as follows:

M F = M C 1.2

ST 100

MF = Feeder modulus, MC = Casting modulus, ST = shrinkage time

2. Feeding distance consideration

- to determine the number of feeders required to feed the casting/casting sections. Table 2 and Table 2a help to estimate feeding distance.

nF =

dF

L (m m ) (m m ) + FD T (m m )

nF = number of feeders required, L = casting length or mean circumference of casting, dF = calculated feeder diameter, FD = feeding distance factor, T = thinnest casting section through which feeding is to be ensured

3. Feed metal consideration

- to ensure that an adequate volume of metal is available in the feeder to feed the solidifying casting/casting sections. Feeders so far determined may not be necessarily large enough from a shrinkage point of view. In such a case larger feeders must be used. i ii iii iv Determination of shrinkage percentage from Diagram 4 on the right hand side. From point B on the casting modulus line draw a horizontal line till it cuts the casting temperature line at C. Read vertically contraction/expansion. Add shrinkage percentage + shrinkage due to mould wall movement (0 - 2 %) for high pressure moulding lines to obtain total feed metal requirement of the casting. Feed metal from the feeder: hot sand feeders = 16 % cold feeders = 10 % Exo/Iso feeders = 33 % at least Feedable casting weight (W)

W=

1 Feeder weight (kg ) 100 3 Shrinkage (%)

4. Determination of feeder neck dimensions

- so that the neck remains open just long enough to satisfy feed metal demand of the casting/casting sections. i ii Top feeder: Feeder neck dimensions are not called for. Whenever possible, breaker cores of adequate design and quality should be used. Side feeder: Necessary dimensions of feeder neck N are determined through modulus calculation in the bar formula or from the diagram in Table 5.
MN = ab 2(a + b)

MC : M N : M F = 1: 1

ST ST : 12 . 100 100

Foseco (FS) Limited, Tamworth, Staffordshire, B78 3TL Tel: +44 (0)1827 289999 Fax: +44 (0)1827 250806 www.foseco.co.uk

Foseco (FS) Limited, Tamworth, Staffordshire, B78 3TL Tel: +44 (0)1827 289999 Fax: +44 (0)1827 250806 www.foseco.co.uk

Table 2

Table 3

FEEDING DISTANCE WITH CARBON STEEL CASTINGS


For the mathematical calculation of the number of feeders required, the feeding distance factors (FD) as shown in Table 2a are to be used in the formula
nF = L (m m ) d F (m m ) + FD T (m m )

Shrinkage of principal casting alloys


Casting alloy Carbon steel Alloyed steel High alloy steel Malleable iron Al AlCu4Ni2Mg AlSi 12 AlSi5Cu2Mg AlSi9Mg AlSi5Cu1 AlSi5Cu2 AlCu4 AlSi10 AlSi7NiMg AlMg5Si AlSi7Cu2Mg AlCu5 AlMg11Si AlZn5Mg Cu (pure) Brass Bronze Al Bronze Sn Bronze Shrinkage % 6.0 9.0 10.0 5.0 8.0 5.3 3.5 4.2 3.4 4.9 5.2 8.8 5.0 4.5 6.7 6.5 6.0 4.7 4.7 4.0 6.5 7.5 4.0 4.5

FD T = 2 FZ
The examples shown below refer to steel with 0.25 % C.

Key to abbreviations: see below. Table 2a

FEEDING DISTANCE FACTORS OF CASTING ALLOYS


Casting alloy Steel (0.25 % C) Steel (0.20 % C) Steel (0.60 % C) Malleable iron Al (99.99 %) Al Cu 4.5 Al Si 7 Al Si 12 Al Si (6 - 13) Cu (pure) Cu Ni (30 % Ni) Brass Al Bronze Ni Al Bronze Sn Bronze Flake graphite iron (GGL) GGL, CE = 3.0 GGL, CE = 3.4 GGL, CE = 3.9 GGL, CE = 4.3 Spheroidal graphite iron (GGG) GGG, CE = 3.6 GGG, CE = 4.2 GGG, CE = 4.3 GGG, CE = 4.4 FD 4.0 5.0 4.5 5.0 10.0 6.0 6.0 10.0 5.0 8.0 2.0 5.0 5.0 2.0 3.0 6.5 7.7 8.8 10.0 6.0 6.5 7.0 9.0

Flake graphite iron and SG iron see diagram Table 4 Conversion scale Degree of saturation SC =

%C 1 4.3 (% Si + % P ) 3

Carbon equivalent CE = % C + 1/3 (% Si + % P) Key to abbreviations dF EZ FD FZ L MF MC MN N nF S ST T V W = Feeder diameter = End zone = Feeding distance factor = Feeder zone = Casting length or mean circumference = Feeder modulus = Casting modulus = Feeder neck modulus = Feeder neck = number of feeders required = Cooling surface area = Shrinkage time = Section thickness = Volume = Feedable casting weight

Foseco (FS) Limited, Tamworth, Staffordshire, B78 3TL Tel: +44 (0)1827 289999 Fax: +44 (0)1827 250806 www.foseco.co.uk

Tabel 4

Foseco (FS) Limited, Tamworth, Staffordshire, B78 3TL Tel: +44 (0)1827 289999 Fax: +44 (0)1827 250806 www.foseco.co.uk

Table 5 Determination of feeder neck as well as any rectangular section if the modulus is known. Alternatively, determination of modulus if rectangular dimensions are known.

Foseco (FS) Limited, Tamworth, Staffordshire, B78 3TL Tel: +44 (0)1827 289999 Fax: +44 (0)1827 250806 www.foseco.co.uk

You might also like