Gating System

Definition: gating systems refer to all those elements which are

connected with the flow of molten metal from the ladle to the mold
cavity.

Another Definition: gating systems refer to all the channels through

which molten metal flows into cavity from outside of mold.
Functions of gating system
1. Enough molten metal reaches the mould cavity.
2. Smallest possible complete mold filling time possible without having to raise metal
temperatures, nor use higher metal heads.
3. Smooth metal flow, without any turbulence to prevent dross formation.
4. Metal flow should be maintained quite to avoid mold erosion.
5. Unwanted material such as slag, dross and other mold material should not be allowed
to enter the mould cavity.
6. Min air aspiration by the liquid metal flow.
7. Gating system is easy to implement and remove after solidification.
8. A proper thermal gradient be maintained to avoid shrinkage of cavities or distortions.
9. Ultimately, the casting yield should be maximized.
Elements of Gating System:
1. Pouring basin (cup)
2. Sprue
3. Sprue base (Well)
4. Runner
5. Runner Extension
6. Riser
7. Ingate
Pouring Basin:
• Acts as a reservoir for the molten metal, from which it moves smoothly into the sprue.
• The pouring basin is also able to stop the slag from entering the mould cavity by means of a
skimmer or skim core .
• The pouring basin may be cut into the cope portion directly or a separate dry sand pouring
basin may be prepared and used.
• It should be full of molten metal during the pouring operation, other­wise a funnel is formed,
air and slag may enter the mould cavity.
Sprue
• A channel through which the molten metal is enters the runners and gates to
reach the mold cavity.
• The molten metal when moving though the sprue gains in velocity, and as a
consequence requires a smaller area of cross-section for the same amount of
molten metal.
• Sprue is tapered to gradually reduce the cross - section and prevent air aspiration
at the low pressure area.
Sprue Well
• A reservoir for metal at the bottom of the sprue, to reduce the
momentum of the molten metal.
• Reduce the molten metal velocity to prevent mold erosion.
• Facilitates the change in the molten metal direction into the runners
in more uniform way.
Runner
• Located horizontally, connects the sprue and ingates.
• normally have trapezoidal in cross - section.
• Usually cope molded , for trapping dross and slags.
• Always full of molten metal during mold filling to avoid entering of
slag the mold cavity.
Runner Extension
• An extended part a little of the runner
further after it encounters the Ingate.
• This extension is provided to trap the
slag in the molten metal.
Gates
• Also called the Ingates.
• Openings through which the molten metal enters the mold cavity.
• The shape and the cross – section are readily to be broken after
solidification of the casting, and complete filling of the mold cavity.
• Depending on application, various types of gates are used, these are:
1. Top Gate
2. Bottom Gate
3. Parting gate
4. Step Gate
1.Top Gate
• Molten metals enters the mold cavity from
the top.
• Favorable temperature gradient towards
the gate.
• Quick mold filling
• High mold erosion.
• Prone to form dross; not recommended
for non ferrous.
• Suitable for ferrous materials, and simple
shapes.
2.Bottom Gate
• It is also called “Horn Gate”
• Molten metals enters the mold cavity from the bottom.
• Unfavorable temperature gradient towards the gate.
• Slow mold filling
• Less mold erosion.
• Suitable for deep molds.
• Difficult to prepare.
3.Parting gate
• Molten metals enters the mold cavity from the parting plane.
• Sometimes, represent a top or bottom gate.
• Ease and economical to prepare.
• For non – ferrous deep molds, less mold erosion, dross formed, and
air entrapment.
4.Step Gate
• Molten metals enters the mold cavity though number of ingates, and
arranged in vertical steps.
• Suitable for heavy and large castings.
• The ingate size is normally increased from the top to bottom.
• The molten metal fill the mold cavity progressively from bottom to
top.
Gating System Design
 Functions of gating system

1. Enough molten metal reaches the mould cavity.

2. Smallest possible complete mold filling time possible without
having to raise metal temperatures, nor use higher metal heads.
3. Smooth metal flow, without any turbulence to prevent dross
formation.
4. Metal flow should be maintained quite to avoid mold erosion.
5. Unwanted material such as slag, dross and other mold material
should not be allowed to enter the mould cavity.
6. Min air aspiration by the liquid metal flow.
7. Gating system is easy to implement and remove after solidification.
8. A proper thermal gradient be maintained to avoid shrinkage of
cavities or distortions.
9. Ultimately, the casting yield should be maximized.
Mold Filling
• The liquid metal flow through the various channels obeys the Bernoulli's equation.
• Bernoulli’s equation:
P v2
h  const .
g 2 g
v  2 gh 1.5 m/s

• Reynold’s number
vD
Re  5 10 4

Injection Molding : Re ~ 10-4
Mold Filling
• Another fluid mechanic law, helps in understanding the gating system
behavior is the law of continuity.
 Continuity Law
Q = A1V1 = A2 V2
Where:
Q = Flow Rate, m3/s
A = Cross – Section Area, m2
V = Flow Velocity, m/s
Pouring Time :
• The time for molten metal for complete filling of the mold cavity.
• Too much pouring time requires much high pouring temperature,
while too short pouring time means turbulent flow and mold
erosion.
 Factors that determine the pouring time:
1. Casting material
2. Casting complexity
3. Casting size
4. Casting section thickness
 Pouring Time calculation:
1. Dieterta: small to medium wall thicknesses for Copper, Aluminum,
and Cast Iron
t = S (sec)
Where:
G: poured metal in Kg
S: coefficient depending on thickness, and metal. From the following table

Wall thickness (mm)

Metal
5-6 7-9 9 - 14 15 – 21 21 - 40 40

Aluminum 1.94 1.98 2.05 2.2 2.3 2.4

Copper 1.15 1.17 1.21 1.26 1.34 1.5
Grey cast iron 1.93 2.14 2.35
steel 1.1 – 1.5
 Pouring Time calculation:
2. Sobolev: medium to large wall thicknesses for Steel, and Cast Iron
t = S1 (sec)
Where: : Average wall thickness of the casting (mm)
G: poured metal in Kg
S1: coefficient depending on thickness, and metal. From the following table
S1
Metal Gate type
Normal temp. High temp.

Bottom & Step Gate 1.3 1.4 – 1.5

Steel Parting Gate 1.4 1.5 – 1.6
Top Gate 1.5 – 1.6 1.6 – 1.8
Cast Iron Doesn’t depend on type 1.8 2
Aluminum Doesn’t depend on type 1.7 3
Brass Doesn’t depend on type 1.9
Bronze Doesn’t depend on type 2 – 2.1
 Choke Area (Ac) :
• Is the main control cross – section area in the
gating system, which meters the metal flow
into the mold cavity for complete mold filling
within the calculated pouring time.
• Choke Area Location:
1. Sprue Bottom → Un-Pressurized
Gating
2. Gate → Pressurized Gating
Choke Area Calculation:
 Ac = (Cm2)
 Where:
G: Metal weight (Kg)
Friction coefficient
: Density (Kg/Cm2)
t : Pouring time (sec)
g : Gravitational acceleration (cm/s 2 )
H : Effective sprue height (Cm)
Effective sprue height (H) :
• Top Gate:
H=h

• Bottom Gate:
H = h – (c/2)

• Parting Gate:
H = h – (p2/2c)
Gating Ratio :
• Proportion of gating system cross – section areas, Sprue area : Runner area :
ingate area; As : Ar : Ag.
• Depending on Choke Area Location:
1. Pressurized Gating System:
As : Ar : Achoke (gate)
Example: steel
A sprue : A runner : A choke (gate) = 1.4 : 1.2 :1

2. Un-Pressurized Gating System:

Achoke (sprue) : Ar : Agate
Example: Brass
Table represents practical values of
gating ratios:
As : A r : A g
1. Sprue :
• Sprue bottom diameter (ds) is calculated from the
gating ratio.
• Sprue top diameter (dt) can be calculated from
continuity equation, such that:

At.Vt = As.Vs
At = As.(Vs/Vt)
At = As.(hs/ht)1/2
At = As.(htotal/hbasin)1/2
 2. Pouring Basin:
• It should be deep enough (at least 2.5 time the sprue
entrance diameter) to reduce turbulence and
momentum of the molten metal.
• Entrance to the sprue at least 25 mm radius for smooth
flow of the molten metal.
 2. Pouring Basin:
• It should be kept full of molten metal to avoid vortex.
• Delay screen (melts during pouring), or strainer core may
be used for quick filling of the basin by molten metal.
 3. Sprue Base well:
• It reduces the molten metal velocity, and mold erosion.
• It has a surface area of 5 times the sprue choke area, and a height
equal to the runner height.
• For narrow and deep runners:
dwell = 2.5 Wrunner 2 runner system
dwell = 2 Wrunner 1 runner system
 4. Runner:
• Circular cross –section is preferable.
• Trapezoidal cross –section runner is employed for
reducing turbulence.
• Square or rectangle runner with a width as twice as that
of the depth my be used for foundry practice.
• Design Considerations:
1. Avoid sharp corners.
2. Avoid sudden change in cross – section area.
3. Runner is preferable to be cope molded.
4. In case of multiple ingate, the runner cross – section
should be reduced after each ingate for equal metal flow.
 5. Ingate:
• Gates are preferable to be drag molded
• Rectangular cross –section runner is usually employed, having a
width to depth ration of 4.
• Gates should not be to high to ensure its complete filling with
molten metal during pouring.
 SUMMARY OF GATING SYSTEM
DESIGN STEPS:
1. Select a suitable flask dimensions for casting.

2. Calculate the mass of casting; Wc in Kg.

Wc = Density gm [g/cm3] x Volume Vc [cm3]

3. Calculate the mass of liquid metal needed (Gross weight); G in Kg; include gating and riser.
G = 1.3 Wc

4. Calculate the pouring time; t in sec.

t=S

5. Select the ingate type; top, bottom or parting gate to get values for P, C and H.
 SUMMARY OF GATING SYSTEM
6.
DESIGN STEPS:
Select the type of gating system; pressurized, or non - pressurized.

7. Assign a proper gating ratio; As : Ar : Ag.

8. Calculate the choke area (Ac, or An).

Ac =

9. Find the pouring basin dimensions; from tables.

10.Find the sprue and sprue well dimensions; from tables.

11.Find the runner dimensions; from tables.

12.Find the ingate dimensions; from tables.

SUMMARY OF GATING SYSTEM DESIGN STEPS:
SUMMARY OF GATING SYSTEM DESIGN STEPS:
 Problem on gating system design

.
 solution

t=S (sec)

G = 1.3 Wc G = 1.3 * 20 = 26 kg

t = 1.5 = 7.65 (sec)

Since the casting is simple we can use top gate

In top Gate H = h =250 mm = 25 cm

Ac = = = 3.93(Cm2)
 solution
Since the casting is steel; We use pressurized gating system

As: Ar: Achoke (gate)

Achoke (Agate)= 3.93(Cm2)

Assume:

A sprue: A runner: A choke (gate) = 1.2: 1.2 :1

In top gate there is no runner, then:

A sprue : A choke (gate) = 1.2 : 1

Then A sprue = 1.2 * A choke (gate) = 1.2* 3.93 = 4.7 (Cm2)

 Solution
sprue Dimension

From table 3 (sprue dimensions) using A sprue= 4.7 (Cm2)

From row no. 4

• D1= 2.5 cm (25 mm), D2= 2.8 cm (28 mm) and h = 250 mm
 Solution
Pouring basin dimensions
The pouring rate = = = 3.4
From table 1 using the pouring rate of 3.4 (1.8 to 3.6) We can get the volume and
dimensions of pouring basin
From row no. 2
The volume of pouring basin = 0.6 liter , and it’s dimensions H= 6 mm , A=15.2 mm,
B= 9 mm
 Solution

ingate dimensions

By using Agate = 3.93(Cm2)

From row no. 8

A = 2 cm (20mm)

B = 0.8 cm (8 mm)

C = 2.8 cm (28 mm)