Learning nugget: Filling and feeding systems

SUMMARY:

Industry demands the production of low-cost components, which, in the case of castings, entails a series of challenges and demands, such as high productivity. The availability of machines capable of mass-producing sand molds at high speeds means that filling these molds with liquid metal cannot be a limiting factor in manufacturing. Therefore, the proper design of filling systems, which optimizes filling times without increasing the speed at which the liquid metal enters the mold, is essential for maintaining manufacturing speeds.

Likewise, system performance—the ratio of the weight of the parts produced in a mold to the total weight of the system—is also a key factor for competitiveness. The goal must be to increase this performance, either by increasing the number of parts per mold or reducing the volume of the filling and feeding systems. Understanding the metal solidification processes inside the part will minimize the need for liquid metal fill to avoid shrinkage defects by adjusting the size and number of feeder elements.

Simulation tools make it possible to validate previously calculated systems, verifying their correct sizing and minimizing the possibility of part shrinkage defects. This reduces the number of tests required when industrializing new references and significantly reduces industrialization costs.

INDEX:

1. INTRODUCTION

2. FILLING SYSTEMS

2.1- Elements of a Filling System
2.2- Types of Runners
2.3- Types of System
2.4- Equations
2.5- Examples

3. FEEDING SYSTEMS

3.1- Basic Principles
3.2- Module Concept
3.3- Riser Design
3.4- Coolers

(*) This training module, dedicated to the filling and feeding systems phase, is part of the “Introduction to Iron Casting” training series, which consists of 13 short videos lasting between 15 and 40 minutes.