It is possible to distinguish potential savings between gains related to the melting process and the casting process, respectively. For the melting process, weight savings from a reduced runner result in savings in the consumption of gas and energy consumed in the melting furnace as well as reducing the effect of melting losses on the unit weight. In addition to the melting process, the corresponding reduction in ingot shipments yields an improved annual return on logistics and inventory costs, as well as on the transfer of molten metal to holding furnaces.
Using MAGMASOFT®, Kırpart investigated five different runner and gate designs for the part in question. In each design stage, especially the results from filling and the liquid fraction distribution during solidification were examined. The results are shown here are for both the original design and the final layout. The simulation studies confirmed that the casting quality could be maintained with runner designs having a smaller volume.
When looking at the runner cross-sections in the final design, it was observed that the velocity of the liquid metal increases proportionally on the way from the biscuit to the gate, and that the melt enters the cavity at an optimum speed. As can be seen, the velocity results show an increased velocity profile along the runner in comparison to the initial design.