In this thesis, we compared different gating systems by altering the shape of the well under the sprue bottom in a sand mould. Four different well designs were used to observe their influence on the molten metal flow through the gating system. The experimental results were compared with numerical simulations to evaluate the impact of each geometry on flow dynamics.
The experimental part involved creating 3D models using SolidWorks. After 3D printing, eight sand moulds were prepared (two for each design) to ensure better reproducibility and result accuracy. This was followed by the casting of an aluminium alloy, during which each casting process was recorded. Based on these recordings, numerical simulations were created in ProCast and compared with one another.
The objective of the thesis was to determine which well design is most suitable for casting in sand moulds, with the aim of minimizing casting defects such as vortex formation, surface turbulence, and erosion of the sand mould. We found that a deeper well significantly reduces surface turbulence caused by the molten metal impacting the mould base. The use of runner choke at the transition into the runner also contributed to smoother flow, but in this study, the runner was not fully filled in such cases, preventing us from confirming their effectiveness. However, the implementation of a deeper well proved to be the most effective measure, as it reduced the risk of sand erosion and shortened the flow path of the molten metal to the casting cavity.
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