A riser, also known as a feeder, is a reservoir built into a metal casting mold to prevent cavities due to shrinkage. If the passage linking the riser to the casting solidifies before the casting, the flow of molten metal to the casting will be. Caines method caines equation where x freezing ratio y riser volume casting volume a, b and c constant freezing ratio 57. To maximize the volume to area ratio, the area of the riser should be minimized. International journal of engineering research and general science volume 2, issue 1, january 2014. Abstract casting design which includes the gating and riser system design has a direct influence on the quality of cast components. Gating system design free download as powerpoint presentation. However, computation in shape factor method is less tedious and quicker than caines method. The design method does not celebrate or perpetuate the design rockstar concept. Amog is able to analyse and design a range of riser systems including. Top risers are advantageous because they take up less space in the flask. Tech student, department of mechanical engineering, gd rcet, bhilai chhattisgarh 2 professor, principal ic, department of mechanical engineering, gd rcet, bhilai chhattisgarh abstract the gating and riser system design plays. Design and analysis of steel catenary riser systems for deep. The proposed optimization framework is applied to the gating and riser design of a sand casting.
It is based on assumption that the cooling rate is linearly proportional to the ratio of the surface. Finding of optimized riser size from riser dimensions as per modulus method l w t sf riser dim. Design and analysis of steel catenary riser systems for deep waters dimensjonering og analyse av kjedelinjestigeror i stal the marine riser is an important part in the oil and gas industry. The student will gain an understanding of standard products used in these systems and the design and selection of such components. Method caines method modulus method novel research method shrinkage volume consideration. Method caines method modulus method novel research method shrinkage volume consideration method equations.
Riser is a reservoir in the mould that serves as a source of liquid metal for the casting to compensate for shrinkage during solidification, also riser neck is provided to slow down the liquid metal into the mould cavity and helps in easy removal of riser from the casting after solidification. Some architects design by solving problems while others rely on intuition. This work presents the implementation of genetic algorithms in the optimization design of deepwater steel catenary risers scrs with discrete design variables. In this research has been calculated the riser geometry by different methods for a. Feeder was designed by modulus method and caines method of feeder design. Design of tapered riser using basic hydraulic principles. Optimal riser design for metal castings springerlink. A key element in producing quality castings is the proper design and sizing of the gating and riser systems.
The design should provide a minimum volume of gating and riser system but warranting the quality of the casting. Gating system design casting metalworking metals free. Riser design caines method compatibility mode free download as pdf file. International journal of engineering research and general.
Ye1 1lancaster university, lancaster, united kingdom abstract currently, there are approximately 3,400 deepwater wells in the gulf of mexico gom having depths greater than 150 meters, and a. The riser casting junction should be designed to minimize riser removal costs. The design method does kindly break the news that design business requires a lot of patience and not a lot of ego. Being a staunch believer that design is not about being artsy or a vehicle for selfexpression and is, instead, an objective, rational, laborious process based on listening to a client and translating that into a tangible, accessible solution, i found the design method the exact kind of prescription the design industry needs. Optimization design of deepwater steel catenary risers. Design consideration in castings good quality at lowest possible cost.
The optimal design of a casting rigging system is considered. Attention to common requirements changes in design to simplify casting example location of parting plane can affect. Optimal riser design in sand casting process using genetic algorithm manikanda prasath k. Proper placement of the risers on castings changes the way in which both the casting and risers solidify such that the riser is the last to solidify. Modulus method caines method it is used to check the adequacy of the riser size for a steel casting. Riser design manufacturing technology the gate academy. Design and analysis of steel catenary riser systems for.
A thorough study of the analysis of riser systems will include global riser analysis methods, strength capacity calculations and fatigue life estimation. Risers help to feed liquid metal into the last portion of the casting. Optimum riser design the role of the methods engineer in designing risers can be stated simply as making sure that risers will provide the feed metal. The gates themselves may be made to serve as risers fig. Failure will lead to major loss and severe consequences. Objectives riser design and placement 6 7 riser functions allows the air to escape from the mould as the molten metal is poured it creates pressure. The design method does not promote a fast track to senior design roles or prestigious design awards. Rejection analysis and quality control of castings at inducto cast written by chintan desai, kishan garala, keval doshi published on 20200124. Apr 21, 2015 riserdesign cainesmethod freezingratiox. Integrity and reliability of such structure is very important.
Modulus method is a further simplification over the shape factor method, since a number of suitable graphs are available for modulus calculation. Riser design casting metalworking metals avaliacao. A similar equation for the contact area of riser has also been given. The volume to surface area ratio of the cylindrical riser was found to be 0. This research involves modelling composite riser to investigate the riser installation behaviour. Methods of riser design following are the methods for riser design.
If the riser is located on the casting then it is known as a top riser, but if it is located next to the casting it is known as a side riser. Design b a large diameter pour cavity in the center of the mold that acts as the main riser. Another type of riser design based on the salm concept is the single anchor leg storage or sals fig. Most metals are less dense as a liquid than as a solid so castings shrink upon cooling, which can leave a void at the last point to solidify. Structural design of production risers and offshore. We found that the appropriate diameter for the cylindrical riser is 3. Benjamin blankenbehler october 22, 2015 october 19, 2016 0. The modulus method provides the best method for obtai ning that initial guess. Caines method of riser design i he formula used tor riser design in this method is where a tv where a exposed surface area rtl for blind riser itt for open riser v volume 0. Unit iii gating and risering rajiv gandhi college of. Design a a center pour sprue with four risers feeding into the hub and fork sections. Two riser designs were considered for the snubber arm. Constant for caines method values of constants are given in table. Every designer needs to understand the steps toward creation.
Modulus method wiodawar has recommended a method of riser calculation in which. Some study on determination of riser sizes for aluminium. For deepwater developments, riser system requirements become a significant factor in the cost of the overall oil field investment. Methods of riser design in casting process youtube. Riser design caines method compatibility mode pdf document. International journal of engineering research and general science volume 2, issue 1, january 2014 issn 20912730 95. Optimal riser design in sand casting process using genetic. From this graph riser volume can be calculated in the same manner as caines method.
Following formulae were used for finding the dimensions of casting. Jun 18, 2017 methods of riser design in casting process. Design of 3d junctions in castings, american foundry society, 2008. Shrinkage porosity occurs because of the incr ease in density from the liquid to solid state of metals. In this approach, we combine finiteelement analysis of the solidification heattransfer process with design sensitivity analysis and. Feeder design has been carried out using three different methods such as caines method, 3. Erics book will hurtle you down the path of mastery, first. Optimization of riser neck for aluminium casting by. The function of a riser is to suppl y addition molten metal to a casting to ensure a shrinkage porosity free casting. Foundries, which have computers will probably find it more useful to employ these graphs to computerise their riser calculation.
Dublin, ohio, usa mississauga, ontario, canada toll free usa only. Condition4 shape of the riser, it should be selected for least surface area for a given volume. To be effective a riser must solidify after the casting and contain sufficient metal to feed the casting or portion of a casting. Pdf design of gating and riser system for grate bar casting. Metal casting 1 featurescomponents of a sand mould pouring basin or pouring. To prevent loose sand and drops from entering the mould cavity and to allow the metal to fall in a small stream, a largesized pouring basin may be fixed on top of the spruecum riser fig. Design of gating and riser system for grate bar casting. Pdf optimal riser design in sand casting process with. Optimal riser design in sand casting process with evolutionary topology optimization article pdf available in structural and multidisciplinary optimization 382. Composite riser experience and design guidance presented in this report captures the latest state of the art advances and experience in the academia as well as in industry for the design and manufacturing of production risers with continuous fiber reinforced polymer matrix composites for deepwater top tension risers. General design rules for riser necks used in iron castings. Participants will work on case studies to develop gating and risers to provide clean, sound and functional castings. Riser design caines method compatibility mode download now. We used chvorinovs rule to get the dimensions of the cylindrical riser.
Rejection analysis and quality control of castings at inducto. In the right amount at the right place at the right time also we must consider the following 1. When designed correctly, a casting thats free of shrinkage will be. Lect 7 metal casting 1 features\components of a sand mould. Optimization design of deepwater steel catenary risers using.
Using the relation we found that the appropriate diameter for the cylindrical riser is 3. A thorough study of the analysis of riser systems will include global riser analysis methods, strength capacity calculations and fatigue. Sals systems are being operated by shell 10 in the castellon field off spain and by esso in the tapis field, offshore malaysia 11. Keeping in mind the various laid out rules for feeder design in the previous section and using caine is method, the design of feeder is as follows. Rejection analysis and quality control of castings at. While modern computer methods make it easier to op timize the riser, an initial guess of the correct geometry is needed. Standard drawing es150, drop inlet spillwap, standard for covered top riser, and to technical release no. In summary, whilst doe methods and the use of computer simulations are no longer new to the manufacturing industry, instances of combining the two for achieving significant increases in productivity during a problem solving.
The optimum neck height was 7 mm for that yield of casting part was maximum. The design of riser was done using caines method 1. Apr 22, 2015 methods of riser design following are the methods for riser design. Apply this thinking everywhere and you might become famous, second. The height of riser was assumed to be 70 mm and the height of riser neck was assumed to be 10 mm. Excessive turbulence results in the aspiration of air and the formation of dross. Connection between riser and casting must stay open. Riser design is very important in metalcasting manufacture. Stfkjcm design of standard covered risers chapter 1. Volume of castingriser module m surface area of casting riser solidification time t k m2, k mold constant surface area includes all surfaces of any shape which transfers heat during solidification of note. The casting geometry is systematically modified to minimize the gate and riser volume, while simultaneously ensuring that no porosity appears in the product. The sals employs integral buoyancy in the rigid arm to provide the tension in the riser. Introduction two major considerations in the casting design are the quality of the final product and the yield of the casting.
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