Experimental investigation of flow

parameters with the effect of design of multi

gating system for casting industries
Cite as: AIP Conference Proceedings 2128, 030005 (2019); https://doi.org/10.1063/1.5117948
Published Online: 23 July 2019

I. Rajkumar, N. Rajini, and P. Vasanth

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AIP Conference Proceedings 2128, 030005 (2019); https://doi.org/10.1063/1.5117948 2128, 030005

© 2019 Author(s).
 Experimental investigation of flow parameters with the
effect of design of multi gating system for casting industries
I.Rajkumar1,a) , N.Rajini2 , P.Vasanth3
1
Assistant Professor, Kalasalinagm Academy of Research and Education, Krishnankoil, Virudhunagar,
Tamil Nadu.
2
Professor, Kalasalinagm Academy of Research and Education, Krishnankoil, Virudhunagar, Tamil Nadu
3
student, Kalasalinagm Academy of Research and Education, Krishnankoil, Virudhunagar, TamilNadu.

.a)Corresponding author email: irajkumarilango@gmail.com

Abstract. Casting is a traditional manufacturing process used for the production of many engineering components
especially in the field of transport industries. For achieving quality casting components, the effective design of the gating
system is standing front. This work aims to address the two different types of gating system namely End Sprue Parallel
Connection (ESPC) and Center Sprue Parallel Connection (CSPC) through experimental investigations. The parameters
like velocity and discharge were analyzed with the source of water medium. Since, the results obtained from this work
can be applicable for any other metal which is having the similar kinematic viscosity of water. Data were recorded by
closing different gates in different time. The uniform flow of material was achieved throughout the cavity due to the
equidistant arrangement. Further, the higher or equal discharge was found in the case of CSPC gating design almost in all
the cases and this two comparative results was very use full for develop optimum runner and gate findings in multi cavity
system.

INTRODUCTION
The process of converting the molten metal into the metal product depending upon the cavity is known as a metal
casting process. This process is considered as the near-shaping process as this does not require more post-processing
steps instead; it creates the component with desired geometry, and it is shown in the Fig.1. It is one of the traditional
methods which is processed for the manufacturing of metal parts. In olden days, casting processes were used to
assist the Smith for art and jewellery makings. But, its usages have now been extended to the various automobile
parts, domestic and industrial parts production. Though the phenomena involved in the casting processes are easy, it
involves huge mathematical calculations, empirical relations and general Fluid mechanics equations.
The processes of melting the metals, cavity formation, gate, riser, pouring the molten metal and its
solidifications, and finishing processes are to be controlled. The investigation of changing the gate arrangement from
the farthest end with pencil, horn gates was done under the researches of Johnson and Baker[1], The distance
between the two gates was studied by Berger and Locke. [2], they suggested that the ratio of the molten metal flow
depends upon the dimensionless ratio and also added that the flow ratio is independent of gate distances. Johnson et
al. [3], Grube and Eastwood [4] and Webster [5] also have obtained the results in their processes as the flow ratios
are completely independent of the distance between the gates (the length of the runner between the gates) . Failure
occurring in any one of these processes will cause the entire casting product to fail. The varying processes involved
in the casting made it difficult to follow them with the utmost care. Every process should yield the correct response
to make the entire process, a successful one.

International Conference on Materials, Manufacturing and Machining 2019

AIP Conf. Proc. 2128, 030005-1–030005-10; https://doi.org/10.1063/1.5117948
Published by AIP Publishing. 978-0-7354-1870-7/$30.00

030005-1
 FIGURE 1. Components in a typical gating system

The mould filling is the most important process in the casting process. As this involves the complex
characteristic flow, which varies with different material According to the system developed by Morales et al. [6] the
kinematic viscosity of the water is nearly equal to that of aluminium and copper. So, the flow of water is considered
instead of Aluminum, which behaves more or less nearly to the water. F.J.Bradley [7] studied a gating system
methodology to find the control volume hydraulic-based model processed for nonlinear optimisation. Dumaille [8]
undergone a study to compare the results of the gating system with water modelling experiment and simulation and
obtained a correlation of flow. Also, according to the researchers Richins and Wetmore [9], the velocity profile of
the aluminium in a closed duct behaves like that of the water in a turbulent manner. Rabinovich [10] found this in a
true case of cast iron. Also, the flow of molten metal in the basin was studied by Wallace[11]. Thus the flow
depends upon the location, dimension and the distance between the gate arrangements; there are further
considerations that are taken to design the gate to have the high efficiency. The flow of the fluid which is
characterised by the viscosity, surface tension and density of the metal fluid. These points are considered to avoid
the various casting defects and to increase the quality of the product. The defects are usually caused due to the
disturbance occurred during the metal flow. To increase the insight of the cast more systematically and
scientifically, the concerns are taken from the design which decides the best place to assign the gate formation in the
casting process. Though the various misalignments cause the disturbance in the quality of the cast product, the huge
effect depends upon the cavity filling and the flow of the molten metal.
Renukanandha et al. [12] studied the metal flow through the horizontal multi-gating system with the arrangement
of four gates with end sprue arrangement. In this arrangement, the metal reached the farthest gate with speed twice
that of the gate to the nearest one, and it is measured to be 50% more flow than that of the nearer sprue. Ruddle [13]
studied the frictional and head losses in different chambers and determined the method for finding the relative flow
between various gates which is the best way to determine the distance between the various gates. According to the
researcher Kermanpur et al.[14], who have conducted his research with the arrangement of end sprue with the gating
in series axis shown the equal area cross-section and the runner cross section. He had concluded that, the pipe
system works functionally better with four gating than the three gating system. This model was studied by Halappa
et al[15] in his another paper developed the better system for further arrangement. The system developed here
shown the figure with parallel arrangement of the end sprue with four gating system are experimented and tabulated.
As the flow of molten metal into the cavity, which decides the efficiency depends upon the gate formation.
Various researches are going on to increase the performance of gate formation. By re-assembling the arrangement of
gates in casting, its distribution of metal inside the cavity and the velocity of the molten metal are uniform
throughout the product. Most of the small scale industries go for a mass production, they are facing lot of struggle to
develop optimum runner gate finding. This study was purely related to mass production application previous
researches did some experimental study but comparatively this parallel connection experiments producing equal and
optimum results. This parallel connection runner system is very useful for small scale industries.

030005-2
 GEOMETRIC MODEL
The experimental set-ups taken for two set of readings are shown in the Fig.2. The various experiments with
different gates closed at a time are considered with these set-ups of End Sprue Parallel Connection (ESPC) and
Center Sprue Parallel Connection(CSPC) arrangements. The place where the molten metal come into direct contact
is known as pouring basin

1 4

3
2

4
1
3
2

FIGURE 2. Water mold setup designed by using Solid works software (A) ESPC and (B)CSPC
(all dimensions are in mm)

The passage through which the metal passes to reach the gate is known as sprue. The sprue here considered is in
the form of convergent to increase / equaling the velocity. The molten metal reaches the gates through the runner.

EXPERIMENTAL STUDIES
The experimental set-up for analyzing the flow of water in the multi-gating system is shown in the Fig.3. This
set-up consist of the Pouring basin with hole in the bottom for the movement of water of about 22, tapered sprue of
circular cross-section, uniform runner and rectangular shaped gates (18x15) as the outlet of water. The entire set-up

030005-3
is made from the acrylic sheet and pasted to form the set-up, which is checked for the leakage of water from the set-
up.

FIGURE 3. Experimental consideration for ESPC

FIGURE 4. Experimental consideration for CSPC

Depending upon the arrangement of gates, the two experimental set-up is obtained. The first set-up consist of the
arrangement of sprue from the pouring basin in one side with two gates arranged on both the side of the sprue in the
parallel manner. There exist the uniform distance between both the gates to the sprue. The second set-up consist of
the sprue arrangement in the center with parallel gate on both the side in farthest position from the sprue as shown in
the Fig.4.

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 TABLE 1. Results Obtained with ESPC

Volume through gates (cm3)

Expt. Number Time (sec)
Gate 1 Gate 2 Gate 3 Gate 4

1 50 52 148 150 2.21

2 83 123 Closed 194 2.56

3 87 Closed 101 212 2.35

4 94 98 208 Closed 2.94

5 Closed 93 107 200 3.54

6 Closed 110 Closed 290 4.4

7 111 Closed Closed 289 4.54

8 Closed 123 Closed 277 4.7

9 Closed 101 299 Closed 5.2

10 400 Closed Closed Closed 5.3

11 Closed Closed Closed 400 5.45

Water is pumped into the pouring basin to maintain the uniform head throughout the testing. Each set-up with
different eleven readings is taken by closing or opening the individual gates. The water coming out of the gate is
collected with a jar of the uniform cross-section to measure the quantity of the liquid. The experiment is conducted
for several times, and the readings are considered on an average basis. The observations and readings of the first
experiment are tabulated as Table1. The eleven readings in the first experiment are taken from the concept of closing
a gate with rest as open. The next experiment also followed the same procedure and tabulated in Table.2. The
various experiments are obtained by closing one of the gates, two gates and three gates to obtain data on the flow
through each gate. This data is considered to understand the flow of water through various with a certain amount of
distance between them and to obtain the compared data on the time it takes to reach each gate.

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 TABLE 2. Results obtained from CSPC

Volume through gates (cm3)

Expt. Number Time (sec)
Gate 1 Gate 2 Gate 3 Gate 4

1 95 92 97 93 2.2

2 134 132 Closed 134 2.3

3 135 Closed 131 134 2.31

4 132 136 132 Closed 4

5 Closed 134 134 132 3.1

6 Closed 198 Closed 202 3.4

7 197 Closed Closed 203 3.38

8 Closed 204 Closed 196 3.33

9 Closed 201 199 Closed 3.4

10 400 Closed Closed Closed 3.3

11 Closed Closed Closed 400 3

RESULTS AND DISCUSSIONS

As obtained from the Table. 1, the first reading shows that all the valves are opened. At the same time, the data
obtained from the first two gates are nearly the same as they are arranged directly opposite to each other. This is also
the same in the end sprue arrangement, the gate 3 and gate 4 also have their value nearly the same. It is also obtained
from the Table.1 first reading, that there exists the lesser variation in the time to reach the last two gates. Because
the last two gates are not as far as it is in the set-up provided by Renukanandhal et al [12]., there exist the uniform
flow throughout all the gates. From the observations, considering the further readings with an arrangement of
closing any one of the gates in the experiments 2, 3,4 and 5, the water attains the last gate at the earliest time
compared to the previous experiment when all the gates are open. This increase in volume flow through the second
two gates are obtained to be thrice the volume in the first two gates near to the sprue as obtained due to the increase
in velocity of the liquid.
From the Table. 1, the experiment No.5 shows that the first closed gate increases the velocity of the flow and
thus the volume obtained is maximum compared to all the other experiments. From the experiment number 6, the
two gates are closed. The flow is increased in the remaining two gates and the time to reach the last gate is more
compared to the time taken in the previous experiments. As the inlet amount of water has to be out to the remaining
gates, the water takes time to reach the last two gate when the first two gates is closed. The volume is also increased
though it attains the approximately same volume in the first two gates and the rest of the gates as they are connected
in parallel with the same distances from the sprue respectively.
The experiments numbered as 10 and 11 consider the flow of the water by closing the three gates, and hence they
show the results that there exists the same volumetric flow in both the cases. But the time to reach the first valve and
the time to reach the last valve is near which indicates that due to the close condition in all the remaining gates, there

030005-6
exist the increase in the velocity as i) the length of the runner to reach the last gates is small which is the main
responsible for the small variation in seconds, ii) the velocity is increased in due to the closed gate condition in all
the rest of the gates.
The Table. 3 is also obtained from the centre sprue arrangement as shown in Fig. 4. The data obtained are similar
to the procedure followed in the end sprue arrangement. The data obtained from the first experiment is showing that
all the gates have the uniform volumetric flow with the time to reach their gates vary in small amount. This shows in
the result that neglecting the frictional flow, the material is not spreading uniformly throughout the cavity. But there
exist the uniform flow in the previous set-up of end sprue arrangement. Also, in the previous case, the volumetric
flow changes in a large amount and hence this is not present in this case of centre sprue arrangement where, in this
case, the distance between the sprue and the gates of two sides are same. Also, the distribution of the water to every
gate is also the same and hence, this assures the uniform supply of the water throughout the cavity.

TABLE 3. Comparative discharges of ESPC and CSPC

Discharge through gates in ESPC Discharge through gates in CSPC setup

setup (cm3/s) (cm3/s)
Expt.
Number
G1 G2 G3 G4 G1 G2 G3 G4

1 22.62 23.53 66.97 67.87 43.18 41.82 44.09 42.27

2 32.42 48.05 Closed 75.78 58.26 57.39 Closed 58.26

3 37.02 Closed 42.98 90.21 58.44 Closed 56.71 58.01

4 31.97 33.33 70.75 Closed 33.00 34.00 33.00 Closed

5 Closed 26.27 30.23 56.50 Closed 43.23 43.23 42.58

6 Closed 25.00 Closed 65.91 Closed 58.24 Closed 59.41

7 24.45 Closed Closed 63.66 58.28 Closed Closed 60.06

8 Closed 26.17 Closed 58.94 Closed 61.26 Closed 58.86

9 Closed 19.42 57.50 Closed Closed 59.12 58.53 Closed

10 75.47 Closed Closed Closed 121.21 Closed Closed Closed

11 Closed Closed Closed 73.39 Closed Closed Closed 133.33

The Table. 3 shows the readings of the discharge from the various experimental set-up of making the water to pass
through the four gates, closing the two gates and three gates as per the series followed in the previous Table. 1, 2.
The discharge of the end sprue and the centre sprue in the parallel connections are compared in this table.

030005-7
 ESPC Mould setup

100
90
80
Discharge cm3/s

70
60
50
40
30 Experiment 1
20 Experiment 2
10 Experiment 1
0
G1 G2 G3 G4
Gate location mm

FIGURE 5. Discharge through gate end spure arrangement (ESPC)

This table is enough to understand the flow of the water that is passing through the gates in the first experiment
has its discharge same throughout the entire gate in the centre sprue as compared to the end sprue set-up. The further
data obtained on the discharge by closing one of the gates resulted in the value of increased discharge on the parallel
gate with a small amount of variation in rest of the gates in experiment number 2 and 4. On the further readings of
closing the gates 1 and 2, resulted in increased discharge in the gates 3 and 4. The observation of first three
experiment results shows (Fig.5) that the discharge is the highest in the gate farthest to the spure, and the lowest
nearest in the from the spure. The next setup first three results show in Fig.6, it will give lowest discharge level but
almost equal in all gates, so comparatively better casting quality gives to use of this kind of mould setup.

030005-8
 CSPC Mould setup

60

50
Discharge cm3/s

40

30

20
Experiment 3
10 Experiment 2
Experiment 1
0
G1 G2 G3 G4
Gate location mm

FIGURE 6. Discharge through gate centre spure arrangement (CSPC)

CONCLUSION
The ultimate aim of develop this experimental evaluation was producing the optimum runner finding and
reducing the metal and time wastage of small scale industries. In the case of four parallel gate system, equal gate
area and throughout the runner cross section also equal area and the various distance of each two gate to spure.
Previous published case was series connection gate location but runner cross section and spure location was same.
Comparatively the velocity variation of each two cases gives differ. Obviously proved this relation between metal
casting quality and velocity variation, the gate velocity major part of the casting quality, when the velocity was
maintain equal in all gate and metal entry of all gates, it gives the casting quality was improving approximately 20 to
30% increased. The using tapered runner and gate to increase the velocity level so it gives comparatively better
casting quality. From the observation of 11 experiments we can identify that the center spure parallel connection has
even and smooth flow comparing to others.

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