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Metal Casting Technologies : June 2006
37 METAL Casting Technologies June 2006 mould efficiently. Calculations are based on both Bernoulli's Theorem and the Law of Continuity. All components of the gating system are calculated, including sprue, runners, gates, etc. Sample screens from various points in the gating calculation are shown on the bottom of page opposite. If bottom pour ladles are used, filling becomes more complex, as the pour rate will vary continuously as the metal is discharged from the ladle. As the metal level in the ladle decreases, pouring rate will also decrease. The system can calculate a proper nozzle size for a given ladle geometry and metal amount, to insure that calculated pouring times predicted by the system will be achieved on the shop floor. This data is also fed into the CFD analysis to perform a variable rate mould filling simulation. Modeling the Gating and Risering System Gating and feeder calculations, as outlined above, will normally take only a few minutes to perform. The output is a