1

]/DIE CASTING DIES

STEP 1:INJECTION PRESSURE (M):- For Al-----280 to 700 bar
DIE OPENING FORCE (T) = M X A
Where, M = Injection pressure,
A = Projected area of casting including overflow, runner
Biscuit/sprue.
LOCKING FORCE = 1.15 1.2 Tm ( find the tonnage of press)
TOTAL PROJECTED AREA = projected area of cavity + 20% of projected area for runner,
.
overflow, gate, Biscuit/sprue
Now the aim is to select proper plunger diameter to exert required injection pressure.
The plunger is forced to move by hydraulic cylinder piston arrangement. By changing hydraulic
pressure, injection force can be changed.
INJECTION FORCE (F) = ( P)/4

Where, D = dia of piston in mm.

2

P = oil pressure in kg/mm

Same force is exerted by metal plunger in shot cylinder on material.
To find dia of metal plunger d
2

F = ( M)/4
d=

M = required metal pressure in N/mm

4F
M

STEP 3 :Determine superheat loss in ladle using homograph.

Temperature drop in ladle Td1 = 10
STEP 4 :Determine superheat loss in shot cylinder using homograph.
STEP 5 :Determine the volume of metal through gate B.
B = volume of casting + volume of overflow.
STEP 6:Determine the optimum fill time t ( using homograph) or from table.t= ------------sec
t= ------------sec
STEP 7:Determine the fill rate Q

Q=

B
t

2
STEP 8:Smallest t in casting in inch

Smallest t in casting in mm

0.03
0.762
0.05 0.06
1.27 1.525
0.075 0.09
1.905 2.286
0.1 0.110
2.54 2.794
0.125 0.15
2.858 3.81
0.185 0.2
4.65 5.08
0.25
6.35
Use lower value for warmer dies & hot metal .
Use higher value for colder dies & cooler metal .

Gate velocity
vg(m/sec)
46 55
43 52
40 49
37 46
34 43
31 40
28 - 35

STEP 9:Estimate gate area Ag

Ag =

Q
Vg

STEP10:Using table find gate thickness.

Thickness of wall in mm
Gate hg
Very thin wall parts
Al in mm Zn in mm
0.75 1.5
0.5 0.8
0.5 0.6
1.5 2.5
0.8 1.25
0.6 0.85
2.5 4
1.25 1.6
0.85 1.35
4-6
1.6 - 2
1.35 1.65
hg is not less 0.4 mm & not greater than half of the wall thickness where gate is located
STEP11:Calculate length of gate. Gate length depends on available portion die parting line.
Ag = lg x hg

lg =

Ag
hg

in mm

STEP 12:Determine runner area Ar

Ar = 1.25 1.6 Ag

Ar = - - - - - - - - - - - mm2

gradually runner area should be changed to gate area & abrupt change in cross section
should be avoided. Causes sudden increase in metal velocity causing turbulance & air
entrapment in metal stream showing blow hole & porosity defests.
For long runner round cross section for minimum heat loss.
For short runner rectangular cross section for maximizing heat transfer.
Width to depth ratio of 1.6 1.8 is used .

Draft angle 10

Wr
= 16
. 18
.
dr

3
runner area = runner width x runner depth
= Wr x dr

= Wr x

Wr
1.7

STEP13:Determine runner velocity

Ag x Vg = Ar x Vr

Vr =

where , Wr = width of runner

dr = depth of runner ,
Ar = runner area.

where,
Vg = velocity of gate
Ag = gate area
Vr = velocity of runner

Ag
x Vg
Ar

Ar
= 125
. 16
.
Ag
Vr =

--------------mm/sec

STEP 14 :Determine superheat loss in ladle using homograph.

Temperature drop in ladle Td1 = 10
STEP 15 :Determine superheat loss in shot cylinder using homograph.
STEP 16:Determine superheat loss in runner using homograph.

= - - -- F / c

dr
STEP 17:Gate temperature Tg
Tg = Tm Td1 Tsl Tdr.
This value is given in table.
STEP18:Determine ratio W/A

W
Weight of casting & overflows
=
A
Surface area of casting & overflows
alternative to find fill time is from T , T &
9

STEP 19:Metal piston velocity Vp

Vp =

Q
Q
=
Ap
d 2
4

in mm

W
from homograph
A