Investigation of the stability of melt flow in gating systems

Melt flow in four different gating systems designed for production of brake discs was analysed experimentally and by numerical modelling. In the experiments moulds were fitted with glass fronts and melt flow was recorded on video. The video recordings were compared with modelling of melt flow in the gating systems. Particular emphasis was on analysing local pressure and formation of pressure waves in the gating system. It was possible to compare melt flow patterns in experiments directly to modelled flow patterns. Generally there was good agreement between flow patterns and filling times. However description of free liquid surfaces proved to be incorrect in the numerical model. Modelled pressure fields served to explain how specific parts of the gating systems cause instability and are a good tool to describe the quality of a gating system. The results shows clearly that sharp changes in the geometry of the gating system causes pressure waves to form that eventually lead to defective castings. It is clear that sharp corners and dead ends in gating systems should be avoided, and that more stream lined, organic designs based on fluid dynamic principles will are necessary to design gating systems for production of high quality castings.