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Effect of Bottom Gating Filling System Design on the Initial Stage of Mold Filling: A Parametric Study

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Abstract

While the filling stage has the least time during the metal casting process, its influence on the casting quality can be remarkable. In gravity casting, the design and dimensions of the filling system determine the filling rate, metal velocity, and the possibility of surface turbulence, where the reliability of casting is mainly impressed by these parameters. In this study, finding an appropriate filling system for a hollow cylinder is examined by investigating the effect of the ingate size, shape, and geometry on the flow characteristics of the molten metal. Simulations are performed investigating the initial filling stages and their repercussions. Three different bottom-gating filling systems are proposed with rectangular, fan, and ring ingate shapes. To compare the filling pattern, metal velocity, and air entrainment of three different filling systems, ProCAST, a CFD simulation software, is used. Results indicated that fan ingate shape successfully introduced less turbulent flow than rectangular ingate shape, causing a reduction in air entrainment. Moreover, results showed that using ring ingate, with sufficient total ingate cross section and taking advantage of the uphill metal flow, can reduce metal velocity entering the cavity as well as eliminate air entrainment.

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Funding

No funding was received for conducting this study.

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Authors and Affiliations

  1. School of Metallurgy and Material Engineering, Iran University of Science and Technology, Narmak, Tehran, 16846-13114, Iran

    Amir Moradi & Mehdi Divandari

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  1. Amir Moradi
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  2. Mehdi Divandari
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Correspondence to Amir Moradi.

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Appendix 1: Simulation Validation (This Part was Added by the Editor’s Recommendation)

Appendix 1: Simulation Validation (This Part was Added by the Editor’s Recommendation)

This model does not have experimental validation. However, the authors had done some validation on the simulation software (ProCAST) before the current model. The Sirrell and Campbell13 benchmark test and Renukananda and Ravi45 multi-gate test were used for fluid flow validation. Figure

Figure 16
figure 16

(a) Sketch of Sirrell and Campbell benchmark test,13 (b) multi-gate system of Renukananda and Ravi.45

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16a, b shows the benchmark test and multi-gate system sketch in the validation.

Figures 17 and 18 represent the simulation result of these two tests. As is apparent in Figures 17 and 18, simulation results showed a similar pattern for mold filling in both benchmark and multi-gate system tests.

Figure 17
figure 17

Real-time X-ray unit for comparing the progressive filling of the mold13—simulation results of the filling of the mold.

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Figure 18
figure 18

(a) Total volume of flow,45 (b) simulation results of total volume flow.

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Moradi, A., Divandari, M. Effect of Bottom Gating Filling System Design on the Initial Stage of Mold Filling: A Parametric Study. Inter Metalcast 17, 2716–2730 (2023). https://doi.org/10.1007/s40962-022-00937-z

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