Total Mass of Metal Poured in Mould from Casting Yield Calculator

Formula:

\[ W_m = \frac{W_a}{Y} \]

Total Mass of Metal Poured in Mould (kg):

1. What is Total Mass of Metal Poured in Mould from Casting Yield?

Definition: This calculator determines the total mass of metal required to be poured into a mould to achieve a casting of specified mass, accounting for yield losses.

Purpose: It helps foundry engineers and metal casters estimate the amount of metal needed to account for system yield inefficiencies.

2. How Does the Calculator Work?

The calculator uses the formula:

\[ W_m = \frac{W_a}{Y} \]

Where:

\( W_m \) — Total mass of metal poured in mould (kg)
\( W_a \) — Actual mass of casting (kg)
\( Y \) — Casting yield (decimal, typically 0.6-0.9 or 60-90%)

Explanation: The actual casting mass is divided by the yield percentage (as decimal) to determine the total metal mass needed to account for system losses.

3. Importance of This Calculation

Details: Accurate calculation ensures proper metal inventory management, minimizes waste, and helps in cost estimation for casting projects.

4. Using the Calculator

Tips: Enter the actual casting mass in kg and casting yield as a decimal (e.g., 85% = 0.85). Yield typically varies ±5% from standard values.

5. Frequently Asked Questions (FAQ)

Q1: What is casting yield?
A: Casting yield is the ratio of usable casting mass to the total metal poured, accounting for losses in runners, risers, and scrap.

Q2: What's a typical casting yield value?
A: Most casting processes have yields between 60-90% (0.6-0.9), depending on the method and design.

Q3: Why is there a ±5% variation?
A: Yield can vary due to process conditions, metal composition, and mould design, so a margin is included.

Q4: How do I improve casting yield?
A: Optimize gating systems, reduce riser sizes, and improve mould design to minimize metal waste.

Q5: Does this include melting losses?
A: No, this calculation only accounts for mould system losses. Additional metal may be needed for melting losses.