Numerical Process Modelling and Simulation of Campbell Running Systems Designs

  • Chengcheng Lyu
  • Michail Papanikolaou
  • Mark JollyEmail author
Conference paper
Part of the The Minerals, Metals & Materials Series book series (MMMS)


In the 1980s, John Campbell developed a new casting process from his research in the industry over a number of years. The Cosworth process was for delivering very high-quality aluminium components for the automotive industry. The process was very capital-intensive and not very flexible for smaller companies delivering lower volumes of product. However, the principles behind the process have been taken and used to develop a range of different so-called running systems to help improve the quality of castings. Some of these designs have been published in ‘Castings Handbook’ [1] authored by Campbell. This paper presents the results of an MSc project during which a number of the proposed designs from Campbell’s Mini Casting Handbook [2] for certain features in running systems have been modelled using a validated CFD software.


Gravity sand casting Running system design Numerical simulation Vortex gate Trident gate Bubble trap Multiple-in-gate Air entrainment Gate velocity 


  1. 1.
    Campbell J (2015) Complete casting handbook, 2nd edn. Butterworth-Heinemann, OxfordGoogle Scholar
  2. 2.
    Campbell J (2017) Mini casting handbook. Aspect Design, MalvernGoogle Scholar
  3. 3.
    Campbell J (2004) Castings practice: the ten rules of casting. Butterworth-Heinemann, OxfordGoogle Scholar
  4. 4.
    Jolly M (2005) Prof John Campbell’s ten rules for making reliable castings. J Mater 57(5):19–28Google Scholar
  5. 5.
    Nafisi S, Mosleh B, Kazazie GR, Boutorabi MA Reviewing aluminum gating systems. Modern Casting, pp. 35–39 (2010)Google Scholar
  6. 6.
    Ingle PD, Narkhede BE (2018) A literature survey of methods to study and analyze the gating system design for its effect on casting quality. Materials Today 5(2):5421–5429Google Scholar
  7. 7.
    Miller RA, Lu SC, Rebello AB (1997) Simple visualization techniques for die casting part and die design. Final report, US Department of Energy, Office of Scientific and Technical InformationGoogle Scholar
  8. 8.
    Kheirabi A, Baghani A, Bahmani A, Tamizifar M, Davami P, Shabani MO, Mazahery A (2015) Understanding the occurrence of the surface turbulence in a nonpressurized bottom gating system: numerical simulation of the melt flow pattern. In: Proceedings of the institution of mechanical engineers: part l: journal of materials: design and applications, vol. 232, no. 3, pp. 230–241, 17 December 2015Google Scholar
  9. 9.
    Campbell J (2015) Sixty years of casting research. Metall Mater Trans (A) 46(11):4848–4853CrossRefGoogle Scholar
  10. 10.
    Campbell J (2012) Stop pouring, start casting. Int J Metalcast 6(3):7–18CrossRefGoogle Scholar
  11. 11.
    Hsu YF, Lin HJ (2011) Foam filters used in gravity casting. Metall Mater Trans B 42(6):1110–1117Google Scholar
  12. 12.
    Jolly MR (2003) Chapter 18: Castings. In: Milne I, Ritchie RO, Karihaloo B (eds) Comprehensive structural integrity, vol 1. Elsevier, Oxford, pp 377–466CrossRefGoogle Scholar
  13. 13.
    Nimbulkar SL, Dalu RS (2016) Design optimization of gating and feeding system through simulation technique for sand casting of wear plate. Perspect Sci 8:39–42CrossRefGoogle Scholar
  14. 14.
    Esparza C, Guerrero M, Rios-Mercado R (2006) Optimal design of gating systems by gradient search methods. Comput Mater Sci 36(4):457–467CrossRefGoogle Scholar
  15. 15.
    Hu BH, Tong KK, Niu XP, Pinwill I (2000) Design and optimisation of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation. J Mater Process Technol 105(1–2):128–133Google Scholar
  16. 16.
    Fu MW, Yong MS (2009) Simulation-enabled casting product defect prediction in die casting process. Int J Prod Res 47(18):5203–5216CrossRefGoogle Scholar
  17. 17.
    Jolly MR, Gebelin J-C (2003) Experimentation and numerical modeling of metal flow through filters. In: Tenth international conference on modelling of casting welding and advanced solidification processes X (MCWASPX), Sandestin, FA, USA, 2003Google Scholar

Copyright information

© The Minerals, Metals & Materials Society 2019

Authors and Affiliations

  • Chengcheng Lyu
    • 1
  • Michail Papanikolaou
    • 1
  • Mark Jolly
    • 1
    Email author
  1. 1.Manufacturing DepartmentCranfield UniversityCranfieldUK

Personalised recommendations