Gating Manual

Gating Manual
NORTH AMERICAN DIE CASTING ASSOCIATION
Publication # 512
Although great care has been taken to provide accurate and current information, neither the
author(s) nor the publisher, nor anyone else associated with this publication, shall be liable for
any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. The
material contained herein is not intended to provide specific advice or recommendations for any
specific situation. Any opinions expressed by the author(s) are not necessarily those of NADCA.
Trademark notice: Product or corporate names may be trademarks or registered trademarks and
are used only for identification and explanation without intent to infringe nor endorse the product
or corporation.
2006 by North American Die Casting Association, Arlington Heights, Illinois. All Rights Reserved.
Neither this book nor any parts may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopying, microfilming, and recording, or by any
information storage and retrieval system, without permission in writing from the publisher.
Gating Manual
Table of contents
STEP 1 - Determine the Casting Quality Requirements 9
STEP 2 - Determine the Flow Pattern AND Location of the Ingates AND Outgates 15
STEP 3 - Determine the Segment Volumes, Cavity Fill Time, and Cavity Metal Flow Rate27
STEP 4 - Match the Process to the Flow Rate 35
STEP 5 - Determine the Ingate Parameters and Check for Atomized Flow37
STEP 6 - Do a PQ2 analysis if desired 45
STEP 7 - Design the Fan and Tangential Runners 53
STEP 8 - Design the OverFLows and Vents 75
STEP 9 - Simulation 81
Gating MAnual
introduction
The die casting die is the heart of the die casting process. Good gating design is essential for
making good parts and leads the way to successful die casting. Conversely, poor gating design
makes poor parts and contributes to the struggles in lowering scrap and meeting operational
objectives. This manual describes what the engineer needs to know to develop a successful die
casting gate design. The nal gating design includes a complete set of information and drawings
that the tool designer or toolmaker will use to construct the gating system in the die. There is a
lot of thought and calculations that go into developing gating designs. The best designs come from
die casting experience, NADCA gating formulas, and the guidelines presented in this text. Gating
design takes engineering effort and time. However, the time invested yields higher quality castings
and shop oor productivity.
This text is intended for the process engineer, the tooling engineer, the die designer, the
toolmaker, the production supervisor or whoever has input into the gate design. The more people
in the organization who are on the same page for gating theory and practice, the better for a
plants success. Much of the information will concern cold chamber aluminum machines, since this
comprises most of the worlds die casting activity. However, the gating techniques presented in
this text apply to the zinc and magnesium alloys as well.
Gating design is interactive with the process. Choices made in selecting the process factors will
inuence the gate design. Tradeoffs are made in the developing the gating system to t the plants
processes. The analysis is done many times until the best and hopefully most robust design is
achieved that works with the process factors chosen.
For example, selecting a gate area cannot be done properly without knowing the expected shot
speed and plunger size; and this cannot be determined without knowing the desired ll time; and
the ll time cannot be determined without knowing the quality requirements for the part and the
machine capabilities. Changing one of these factors can affect the others.
The gating design effort includes selection of the ow pattern, the geometry and location
of the ingates, runners, overows, and vents. It also includes the development of the process
parameters. If all is done right, then rst shot success is expected with the process parameters
very close to those calculated in the gating analysis.
Other factors not considered in the gate design calculations are also important for casting
quality. For example, if the die runs too hot or too cold due to spray conditions, cycle time, water
ow, hot oil temperature, etc., or the process runs with an inconsistent cycle time, then the
best gate design in the world may not work. Even though these factors affect the casting quality,
sometimes the gate design is considered at fault when defects occur. Thus, a gate design that has
the right shape, that is in the right location, and has a good ow pattern, may not generate the
expected quality if one or more of the other process factors are out of control. Changing the gate
design is not always the answer to the problem, though some shops change the gate design as a
way to solve almost all kinds of problems. For the designer, this means that the whole process
needs to be examined before developing a gate design, and that the best results are obtained
when the designer knows and makes allowances for the operational practices of the shop where
the die is to be run.
Gating Manual
The calculations presented have been used for some time. The formulas and guidelines are
based on empirical data and the results are successful especially when compared to the lets try
this technique.
It is tempting to short cut some of the methods presented, especially when they take more time
and effort than past practice. However, these techniques have been proven to be effective and
are always better if done carefully and completely. Every effort should be made to obtain missing
information such as a good denition of the casting quality requirements or machine performance
information and to do the gate design as a thorough engineering project. This approach may cost
more initially, but will always prove to be substantially cheaper in the long run when all costs are
considered. Seat of the pants or trial and error strategies are expensive and may never achieve
scrap and operational efciency goals.
Small improvements in quality are critical in todays market. Older methods may achieve a 5 to
10% scrap rate, and may have been more than adequate for yesterdays market. However, todays
market is a lot tougher with slimmer margins and has little room for operational error in order to
make a prot. Old methods wont cut it any more and better gating designs are needed to survive
and succeed in todays market.
Some believe that we cannot reach the very low levels of scrap without a lot of expensive trial
and error die development costs. However, those companies that track the real costs of die
development that comes from welding and re-cutting a gate or runner, will realize that the up
front engineering costs of doing a proper gate design are a real bargain.
The rst gate design should also be the permanent or last design. Although this goal isnt
achieved 100%, it will be the case in the great majority of designs if the NADCA formulas and
guidelines are followed given that good equipment, good process control, and robust dies are also
in place.
Gating MAnual
The Steps to a Good Gate Design

The following steps are used to develop a proper gate design:
1.
Determine the casting quality requirements. Good gating designs start with knowledge of
the customer requirements.
2.
Determine the intended ow pattern and the ingate and the outgate locations. Visualize
the ow of the metal through the die. Segment the casting and determine the desired ow
angles.
3.
Determine segment volumes, the cavity ll time, and metal ow rate for each segment and
for the entire casting.
4.
Dene the process constraints of the machine(s) intended to run the part fast shot
velocity, plunger sizes, and casting pressures. What are the plunger tip, pressure, fast shot
velocity alternatives? Can the intended machine deliver the desired ow rate and pressure?
5.
For each casting segment determine the ow rate, the ingate velocity, the apparent ingate
area, the ow angle, the actual ingate area, and the ingate length and thickness. Check for
atomized ow. Check the results for the entire casting against the process limits. Redo the
analysis until satised.
6.
If desired do a PQ2 gating analysis.
7.
Design the runner system to support the ingate(s) working back to the biscuit of sprue.
8.
Design the vent and overow system.
9.
If desired turn the design over to the simulation software to ne tune the design. The
simulator may show ow patterns, hot and cold areas, and porous areas that were not
visualized in Step 2.
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Gating MAnual
Gating Manual
Step 1 Determine the Casting

Quality Requirements
Quality speciFIcations
The designer needs to understand the customers casting quality specications and how the
part functions in the application. How good does the nish have to be plating quality, no cold
ow, or some cold ow? How important is porosity leak test, some porosity in certain areas,
or no porosity requirement? What makes the part work in the application? What are the critical
characteristics on the print?
To develop a good gate design, it is important that the casting specications be dened as
completely as possible. In many cases the customer is not an expert in die casting and looks to
the die caster for guidance. Ideally, the die caster and customer make a joint effort to optimize
the design and quality specications for the casting. A Design FMEA is useful in this endeavor
and should be done for every casting. After doing a Design FMEA changes are frequently made to
make the casting design better and all parties are on the same page for what is required to make
the casting work in the application. Old methods such as dumping the design over the transom
forces the die caster to make assumptions that can lead to sub-optimized gating designs resulting
in sub-optimized production with high scrap rates, misunderstandings, etc.
Sometimes quality specications that are critical to the die caster seem insignicant to the
customer. For example, an upgrade in the requirements for surface nish or porosity may change
the machine needed, and will likely cause a change in the gating design. If this is discovered after
the die is built and many irrevocable decisions have been made, any changes will be expensive for
everyone concerned. It is incumbent for the die caster to ask the right questions.
There are two major defect problem areas in die casting -surface nish and porosity. Some
considerations for the designer about quality requirements in these areas are listed below:
Surface FInish
Surface quality is always a concern and need to be considered in all gate designs. However,
the surface nish requirements can vary widely. There is a big difference in gating development
between a chrome plated decorative zinc casting and a functional aluminum part.
Since surface nish is subjective, the NADCA Product Standards checklist C-8-2-06 is valuable in
helping to develop a more specic standard for any given part. A copy of the checklist is shown on
the next page.
Gating MAnual

Casting Surface Finishing Specifications

To be used in consultation with your caster (Use in combination with Checklist C- 8 -1)*
Checklist for Finished Die, SSM and Squeeze Casting Part Purchasing
This Finishing Checklist provides a convenient method for assuring that important factors
involved in the surface nishing of cast parts are evaluated and clearly communicated between
the purchaser and the caster.
This checklist is for use in consultation with your die caster prior to estimating production
costs. Use in combination with the Finishing Checklist C-8-2. Also review Checklists
T-2-1A and T-2-1B, for Die Casting Die Specification, in Section 2.
It should be used as a supplement to the essential dimensional and alloy specications detailed
on part prints submitted for quotation, since the listed factors directly affect the basis on which
the casting quotation is made. The checklist may be reproduced for this purpose. Your caster will
clarify any item requiring explanation.
This checklist provides a numbering system in which the lowest numbered description for each
requirement can be met at the lowest production cost, as follows:
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Gating Manual

* The specication provisions and procedures listed in Section 7, Quality Assurance, should also be
addressed.
Publisher grants permission to reproduce this checklist as part of a casting Request for Quotation or
Production Specification .
Gating MAnual
11

There will be four gating design factors that affect the surface nish ow pattern, cavity ll
time, ingate velocity, and overow size. These factors and their effects on surface nish will be
discussed later in the manual. The intent here is to help the designer plan for surface quality
requirements and to learn as much as possible about the nish required.
There will be some judgmental values to be established later for ll time, which is discussed in
the next section, but the following will give some guidance.
Surface Finish
Quality requirements
Guidance for selections

used during ll time
calculation
General considerations in
ow pattern design
Average (some minor cold ow

permissable)
Middle to high end values of ll

time
Some minor lines and swirls are no

problem
Good (no cold ow visible)
Middle values of ll time
Minimum swirls, minimum ow

lines
Excellent (painting or plating

grade nish)
Shortest possible ll time
No swirls, no ow lines, even in

small areas
The decisions made later when establishing the cavity ll time will determine the machine
capabilities needed, but the choice at this point is about how good is good, or what are the
required surface quality levels.
The intent of reviewing the surface quality issues at this time is resolve questions that must be
referred to the part designer. Changing the nish quality requirements later may involve changing
machines or doing a different die design, so these issues need to be resolved early.
Internal quality or porosity considerations

The porosity concerns need to be dened so the gate design can be developed accordingly. The
two types of porosity that will cause the most concern are shrink porosity and gas porosity.
Shrink porosity occurs because cast metals shrink when they go from the liquid state to the solid
state. Since the metal freezes to the die steel rst, the spaces left over at the end of solidication
will be inside the casting and is called shrink porosity. They will be located at the last point to
solidify in the hottest and thickest areas in the casting. The only way to feed more material into
these spaces and reduce them is to shrink feed more metal during solidication. This is usually
done with high pressure applied at the end of the shot. If the ingate is too thin and freezes
prematurely, then the shrink porosity is left in the part.
Shrink porosity can be exposed during machining. It can also cause sinks, leak test failures, and
cracks. The gating system should allow delivery of metal under high pressure at the right location
with high pressure to address the shrink porosity issues.
Gas porosity comes from trapped air, steam, or volatized lubricant. Hydrogen gas porosity can
be a problem in aluminum die casting, but the gas content from the other sources is often so large
that hydrogen gas is a very small percentage of the total.
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Gating Manual

Gas porosity is often a concern for machined areas, or it may show up as blisters in other areas.
With gas porosity the gate design issues include developing a ow pattern that doesnt produce
swirls or backlls and developing the proper venting and or vacuum system.
So denition of part quality requirements needs to be understood early as these requirements
affect the gating design strategy and decision making process.
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13
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Gating Manual
Step 2 Determine the Flow

Pattern and Location of the
Ingates and Outgates
General considerations
All gating designs start with a grand plan for the metal ow through the die. Where is the most
logical and available place for the metal to come in? Where is the most logical and available place
for the air to escape? What obstacles to the metal ow will be encountered inside the cavity?
What pattern is best to satisfy the quality requirements? Visualizing the ow pattern is a critical
step in the gating design process. When the ow pattern is dened, then the ingates and outgates
can be located provide the desired pattern.
In visualizing the metal ow:
1.
Use as much of the parting line as possible deliver metal to where it is needed and to
spread the heat out,
2.
Take the shortest distance across the cavity, and
3.
Minimize diverging and converging ow paths.
Part of visualizing the metal ow paths is also visualizing the components that will feed the
metal. Here are illustrations of the ow coming off a curve sided fan and tangential runner.
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15
Step 2 Determine the Flow Pattern and

Location of the Ingates and Outgates
The metal ow angle is shown in this gure.
A long rectangular part can be gated with a fan and two tangential runners.
Filling a corner can be done with a fan and possibly two tangential runners. Round parts present
difculties in getting the pattern right to prevent backlling at the far end of the casting. The
ingates need to vary in depth.
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The overall metal ow plan can be drawn on the preliminary die design print.
Of primary importance to the envisioned ow pattern are the quality issues. Flow needs to
be directed to areas that need the best surface nish or to a location where there are porosity
requirements. Thus, any area that has special quality requirements should receive direct ow and
should be close to the gate if possible.
The gate location should be such that there is as much unobstructed metal ow distance
the area of concern. The metal loses a lot of energy when the ow impacts directly on a wall.
Adjusting the parting line or moving the gate so the ow can avoid direct impact is worth the
effort.
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In setting the ow pattern, the engineer should review the location of areas expected to be last
to ll. These locations are always suspect for possible porosity and poor surface nish. In placing
the part in the die, the last points to ll should be located where it is possible to place vents
and overows. Determining the location of the last points to ll is an important part of the ow
pattern decision, and it is one of the major uses of simulation software.
Using cavity segments to develop FLow patterns and gate

locations
The denition of the ow pattern and the gate locations includes dividing the casting up into
segments. While the segmented ow plan is visualized, fan and tangential runner components
that feed the ingates with ow angles are also visualized. Segmenting the casting insures critical
areas and difcult to ll areas are addressed and that segment ows are balanced with the runner
components in mind. Best results are usually obtained by keeping the number of segments to a
minimum typically 2 to 4. Each segment should have an ingate, and the design should be such
that the ow from one gate lls just that segment.
Segments should be chosen by the following guidelines:

Quality issues. If a section of a casting has a different quality requirement than the rest of the
casting, then consider making it a segment. For example, if a section has a very high quality
surface nish requirement as compared to the rest of the casting, then it should be chosen as a
segment.
Natural ow paths. Look for ribs or thicker sections that will provide a natural path for metal
ow. Also, look for obstacles that will force the metal to divert. Evaluate the conditions in the
natural metal ow paths. If the casting has an open area that divides the ow, rst look at each
side of the divided ow to see if there are different geometries for the two ow paths. For
example, if the wall thickness on one side was double the wall thickness on the other side, then
each side probably should be a separate segment.
Casting shape. Segments should be used where two areas have substantially different wall
thickness. Different segments are also appropriate if the ow distance is substantially different
from one segment to another. Consider the path of the metal as it is reected from wall to wall to
develop the ow distance.
Any portion of the casting with features that are considered hard to ll, especially if these
features are located at the end of the casting with the furthest ow distance, can be made into a
separate segment.
In general, segments should be different from each other or fed by a particular runner. Different
wall thickness, different ow length, different quality requirements, or different geometry, or
different runner are typical reasons for selecting segments.
Essentially, segments will divide the casting and are treated in the gating analysis as separate
castings. Each segment will have an ingate, and will be sized in direct proportion to the volume
that it feeds relative to the other segments.
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The gate areas should be such that each segment will have the same ll time and the concept of
simultaneous ll is achieved. If the segments were engineered to ll with different times, then one
segments ow will spill over into another segment causing swirls and backlls leading to poor ll
and porosity.
A simple way to keep track of segment gate areas is to develop a table like the following:
Segment
Volume of Segment
Volume as a Percent
Gate Area for each

Segment
#1
0.2
20%
0.07
#2
0.3
30%
0.105
#3
0.5
50%
0.175
Total
1.00
100%
0.35
The fraction of the total volume of each segment is multiplied times the total casting ingate
area to get the segment ingate area. The principal is to balance segment gate ow areas to
segment volumes. This same principle is used when doing the gating for a multi-cavity die.
The reason for dividing the casting into segments can be seen in the following example:
On the left side is a casting with two equal gates. The casting is divided into two segments, with
the large segment on the left being twice as large as the segment on the right. With equal ow,
the right segment lls quicker, and after it is nished lling, the metal will ow as shown with the
red arrow along the back side of the casting into the other segment, which will tend to be an area
of cold ow and poor ll problems.
On the right is the same casting, but the gate areas have been adjusted to match the segment
volumes.
Gating MAnual
19

Since segment A is twice as large as segment B, the gate for A is made twice as large as the
gate for B, consequently the two segments nish lling at the same time, and cross ow between
segments is minimized.
This concept of having the same ll time for all segments or proportioning gate ow areas to
segment casting volumes is fundamental to good gate design. The same concept applies when
designing gates for different cavities in the same die, where the design goal is to have each cavity
nish lling at the same time. In this case, the gates for different cavities in the same die are
sized in proportion to the cavity volumes.
Experience will help to logically segment the casting. However, even for complex shapes, the
number of segments is usually kept to 2, 3 or 4.
Flow pattern guidelines

Some general rules and guidelines for setting the ow pattern would be as
follows:
1.
Distribute the ow. The ow pattern should always be distributed and not focused into
small jets with a few small narrow gates. These small jet gates are good for some kinds of
porosity control, but unless the goal is to focus ow in a small area for porosity control, it
is much better to use a distributed ow pattern.
A distributed ow spreads out the ingate, which results in a wider and thinner gate. The
heat is also distributed over a large area allowing for better temperature control
and longer die life. Thin gates will not erode or burn out if the gate velocities
are within NADCA guidelines. The minimum thickness in aluminum is about typically
about .040, although it can be less if the metal is cleaned and ltered close to where it is
ladled. Zinc gates are typically about .015 to .020, although they can be thinner as with
minature zinc. Magnesium can be the same as zinc, but should start at about .02 to .04.
Fan and tangential runners should be used to distribute the ow from the main runners.
Chisel runners produce a solid jet stream that cause swirls, trapped gas and poor ll. Wide
ingates will also trap some gas, but the distributed ow pattern will also break up and
distribute the trapped gas and the metal for better ll.
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2.
Direct the ow towards the critical quality areas. This is true whether the problem is
porosity or surface nish.
Surface nish. If one of the quality issues is a good surface nish, then direct ow from
the ingate to the ares requiring good surface. The gate should be located as close to these
areas as possible, and the ow should be as unobstructed as possible.
If there is a choice about parting line location, it is important for the best nish if the ow
is directed into the area of concern, as shown below.
Atomized ow is best for a good nish. If the metal slows down, the ow will drop out of
the atonized ow range, and the nish will become less than optimal. The ow distance
for good nish can be up to 7. However, this distance depends upon the obstructions
encountered, the metal temperature, the die temperature, the gate velocity, and the
casting wall thickness. Incoming metal will not maintain good speed through more than
about 2 or 3 reections.
Metal velocities higher than normal will provide better nishes, however, with aluminum a
high metal velocity can cause premature gate erosion and solder. High metal velocities with
zinc and magnesium can cause some soldering. Gate velocities should be kept at the high
end of the range for the best nish but not exceed the high limit of NADCA guidelines.
Porosity issues. For shrink porosity, the ow also needs to be directed right at the problem
area. In this case, the gate should be thicker to delay ingate freezing allowing more time
for shrink feeding to occur.
The gate to runner ratio should also be large so there is more local heat. Runners with a
45 ramp to the gate can be used to maintain heat keeping the ingate from freezing too
soon. While this approach keeps the gate area hot, it also tends to reduce die life around
the ingate.
A gate thickness of about .080 (2 mm) should be considered a mimimum for porosity
control, and a thicker gate should be considered if it can be trimmed. A gate thickness
of.125 in (3.2 mm) can usually be trimmed, and even thicker gates are possible with
properly built trim dies or by sawing.
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A gate intended to feed shrink porosity should be located as close to the problem area as
possible. A small but thick gate can be fed by a larger than normal runner in a location
away from the main gate. The sole purpose of this kind of gate is to feed an area of
possible shrink porosity, and it should not be counted on to improve surface nish.
Always try and ow the metal across the shortest path from ingate to outgate. The metal loses
heat and drops in temperature as it traverses the cavity. Taking the shortest path minimizes
thermal differences between the near and far sides of the ow, and also allows for the best
control of the ll pattern within the cavity. The ow direction should be the short direction across
the casting unless there are other ow restrictions or reasons for not doing so. This means that the
rst thought is to orient the casting so the gating would be on the long side.
The exceptions will be if there are natural impediments to ow in the short direction. For the
shape below, where the internal squares represent cut outs in the casting, the metal ow would
need to come from the end, the long way, instead of the short way across the casting, which
would normally be preferable.
3.
Use the natural casting shape to direct the ow. This is an exception to the rule about
owing the short way. If, for example, the casting above had ns along the top that
extended the long way, then the natural ow path is with the ns and the ow should be
the long way instead of the short way.
Be alert for natural ow paths, and try to use them. Watch for thick sections that will
guide the metal, for example, and try to design a ow path that will utilize this natural
ow path.
4.
It is important to keep casting wall thickness uniform, especially for large at surfaces,
when a good surface nish is required.
Sometimes part designers will specify a large thin section, but put a rather large tolerance
on it. For example, the wall section of a large at piece may be .080 +/- .010. It is a
lot easier to make the casting at .088 thickness than at .072 thickness. If there are ribs
or bosses on a wall sections, then the NADCA guidelines for wall thickness and radii are
important for metal ow purposes. Working with the tool maker to take advantage of print
tolerances can help with lling the die and robustness of the casting process.
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5.
Follow the NADCA Product Specication Standards for Die Castings for draft and radius.
These standards allow the casting to release from the die minimizing distortion. However,
sometimes adequate radii make the difference between whether a casting has a ow
pattern that works or not. The difference between having a radius and a sharp corner could
be the difference between an acceptable casting and scrap. Having radii that conform to
NADCA design recommendations also helps with die life.
Therefore, the minimum radius specied in the NADCA specications should be followed
for good ow pattern development. Larger radii are especially valuable at the point where
metal is expected to ow into bosses or ns. However, a word of caution if radii are too
large, cracks can occur due to shrink porosity at the base of the rib or vertical wall.
6.
The high velocities in die casting mean the metal ow characteristics are dominated by
momentum. This has a number of implications. For example, when considering the ow
into a n or boss on the top of a at section, the metal will normally shoot past the boss,
go the end of the casting, and then backll and start to ll into the boss as as shown below
left.
The n gets some ow early during casting ll, but may not really ll until the whole
casting is pressurizing towards the end of ll. This makes it difcult to ll these features.
Sometimes it is necessary to change the geometry. For example, some die casters add a
deection boss to the casting to get the metal to deect as shown below. Adding radii on
the bottom of the n or boss helps, but may not solve the entire problem as shown below
right. When this is a problem, adding vacuum can be an effective solution because the
trapped gas in the n or boss resists the metal ow from coming in.
7.
Try to avoid gating directly on a vertical wall or on a core. The ow will eventually heat
check or erode the die steel creating an undercut and cause ejection problems. However, if
ow is required at this location, then the lesser of two evils is to gate on these features as
the priority is to get the ow pattern right.
The reection from a wall will tend to go sideways and around the casting unless the metal
impinges at close to a 90 angle. Thus, only that portion of the ow that is perpendicular
to the wall will tend to go up the wall. If the objective is to get the metal to go up the
wall, then the gate must be carefully designed so most of the metal ow impinges on the
wall at a 90 angle. Another approach is to turn the metal in the runner and ingate to ow
metal with the wall. However, this strategy requires face milling as a secondary operation.
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23

8.
Avoid mixing the metal ows between segments. The ow angles from adjacent segments
should be coincident where they meet. Diverging metal ows from adjacent segments
create weak ll areas resulting in poor ll and porosity. Converging metal ows from
adjacent segments cause hot areas resulting in thermal control problems.
9.
If possible, the ow should not impact on a gasket groove. Gasket grooves generally have a
tight tolerance, and can be easily eroded.
10. Casting areas behind a core or an opening in the casting where the metal ow will be split
can be a problem. These areas are candidates for poor ll and porosity. If this is a concern,
then the ow needs to come from two directions, as noted in the following sketch. This
approach could be used for a plated zinc casting that needs a perfect nish, or for an
aluminum casting with a large hole that gets machined where there can be no porosity
exposed by machining.
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Ingate locations
Once the desired ow pattern is established, then ingate locations can be placed with associated
metal ow angles. Note that ow angles cannot be greater than 45 degrees as will be discussed
later.
Except where an effort is made to shrink ll a local area for porosity, ingate thicknesses should
be compatible with wide gates and distributed ow. Gate thickness should not exceed 75% of the
part thickness in order to trim without distortion or breakout. An ingate thickness of 50% of the
part thickness is better for reducing trim distortion and breakout. If simulation is used later, then
there may be some changes in the gate location as a result of information learned in simulation.
Outgate, OverFLow, and Vent Locations

The ideal place for outgates, overows, and vents is where the last of the metal will naturally
ll the die. This is a lot harder to visualize as the metal can get deected inside during cavity
ll. On the other hand, vents have a drawing effect on the metal ow pattern. Perhaps there are
similar castings where the metal ow pattern can be read on cold start up shots and give insight as
to where the ougates, overows, and vents should be for the gating system being designed. Areas
on the far end of the casting with anticipated poor ll and porosity problems will benet with
adjacent outgates and vents.
Gating MAnual
25
26
Gating Manual
Step 3 Determine the Segment

Volumes, Cavity Fill Time, and
Cavity Metal Flow Rate
Segment Volumes
For existing castings, segment volumes can be determined by cutting the casting up with a band
saw, weighing each segment, and calculating the segment volume. The volume of a segment may
be calculated with the following formula.
Volume (in3 ) = Weight (lb)/Density (lb/in3)
Where, densities are:
Aluminum
= .096 lb/in3
Zinc
= .256 lb/in3
Magnesium
= .064 lb/in3
Lead
= .400 lb/in3
For new castings the easiest way to determine segment volumes is to use 3D CAD software to
generate segment volumes. This method is fast and accurate. When many gating design scenarios
are used and the casting is successively resegmented for each scenario, CAD makes the process
fast and efcient. With 3D CAD and a comprehensive spreadsheet that calculates ingates, runners,
outgates, and vents, many gating interations can be done quickly and efciently. By doing many
scenarios a better job of approaching the optimum gating design is done.
A more time consuming method would be to determine the casting volumes with a spreadsheet and
a calculator. This method is slower and not as accurate as 3D CAD and gating design quality will suffer.
Planned overows associated with each segment should be included in segment volumes.
Including overow volume with segment volume is called metal through the gate and yields a
more conservative design. Each segment volume with the planned overows is placed into the
spreadsheet and then summed to get the total casting volume.
Cavity Fill Time

Cavity ll time is the time from when the metal begins to ow into the die until the cavity
is full. Metal ow into a die casting die time is a race against time. As the metal enters the
cavity and hits the die steel, it loses heat and drops in temperature. The metal must reach all
extremities of the cavity before the metal temperature decreases to the point where the metal
no longer ows and meshes with converging streams. If the race is lost, then poor ll and porosity
appear in the casting. When determining the cavity ll time for a new casting whether by formula,
table, or historical data, it is better to normally err on side of a fast ll time. The exception might
be the case of porosity issues and feeding the far side of big cores on thick castings where fast ll
times can actually make the castings worse.
Gating MAnual
27
Step 3 Determine the Segment Volumes, Cavity

Fill Time, and Cavity Metal Flow Rate
The ll time calculated by the methods presented here are considered to be maximum ll
time, and not ideal ll time. The reason for this is because of varying ow distances and metal
deection within specic die casting cavities. General equations and tables cannot address specic
ow distance and obstruction issues. So the ll time calculations by formula should be the upper
limit for any gating design.
An important design consideration is that shorter ll times benet surface nish provided the
gates areas are proportional to segment volumes. A casting requiring a good nish needs a fast ll
time and becomes the dening variable for the rest of the process selections.
Fast ll times can be constrained by the vents. There is a limit as to how fast air can ow
through vents. Sometimes fast ll times obtained by modern machines may require more venting
area than can be installed in a given die. In these cases, chill blocks or a vacuum system need to
be considered. This is discussed in the section on venting.
While ll time is the major factor affecting the surface nish, the factors affecting porosity may
not be strongly affected by ll time. In the case where shrink porosity is the dominant quality
issue, then the ll time need only be fast enough to get a good ll with an average nish. In fact,
a slower cavity ll time may help porosity by allowing more air to escape through the vents and by
lling with a higher per cent solids.
The NADCA formula contains factors the gating designer must assume. Wall thickness, die
temperature, metal temperature, and percent solids come from the designers judgment of what
will actually happen when the casting is in production. Thus, the calculated cavity ll values
become a function of the designers experience and perception of actual oor practices. A good
database from process engineering on the actual process conditions of the shop is valuable when
used in conjunction with NADCAs formula.
Deviations from the formula and recommendations should come from historical data which would
be the best for knowing what works for a particular class of castings. The best ll time values may
come from the process engineer who has run similar parts, and has a data base containing ll time
numbers. When good ll time data is available, these values should supercede the NADCA formula
values.
Feedback is important for any gating designer. The actual casting results for all designs relative
to cavity ll time should be critiqued. What worked? What did not work so well? Improving gating
skills is a journey. Over time gating designers get better at determining cavity ll time values for
any particular operation.
Some castings are tolerant of ll time variations, while some are not. However, gating designers
should give all castings serious thought to a proposed cavity ll time especially if the casting is
plated of leak tested.
J. A. Wallace (Practical Application and the results of metal ow and gating research 1965)
developed the basic NADCA ll time formula. E. A. Herman published the current version in his
book, Gating Die Casting Dies. This basic ll time formula is:
28
Gating Manual

t=K{
Ti - Tf + SZ
Tf - Td
}T
Where:
K = Empirically derived constant related to the die steel
T = Wall thickness of the casting
t = Maximum ll time
Tf = Minimum ow temperature of the metal alloy
Ti = Metal temperature at the ingate
Td = Die surface temperature just before the metal arrives
S = Percent solids at the end of ll
Z = Solids units conversion factor, degrees to %
From observation of the formula, cavity ll time is proportional to:

1.
Casting thickness, T. The thicker the wall, the longer the time can be. The thinner the wall,
the shorter the time must be.
2.
Metal temperature, Tj. The hotter the metal, the longer the time can be. The colder the
metal, the shorter the time must be.
3.
Die temperature, Td. The hotter the die, the longer the time can be. The colder the die,
the shorter the time must be.
4.
Percent solids, S. The higher per cent solids at the end of the ll, the longer the ll time.
The lower the percent solids, the shorter the ll time.
Tf, the minimum ow temperature of the alloy is a constant. K is the constant of proportionality
and is related to the thermal conductivity of the type of die steel used. Note that the NADCA
formula does not address ow distance or obstructions within the cavity to the ow.
Values for the variables in the ll time formula can be taken from the following tables:
Selecting the values used in the formula depends on the judgment of the gating designer. The
following are some guidelines:
(T) Casting wall thickness. The following methods are used in calculating this value:
Thinnest wall section found anywhere on the casting. This method is conservative, and will
yield shorter ll times than may be required. Using the thinnest wall section in NADCAs
formula decreases cavity ll time and will increase machine power requirements. A very
fast ll time may require a fast shot velocity that is beyond the machines upper limit.
Gating MAnual
29

Average casting wall thickness. If the casting wall thickness is fairly uniform, and there are
no specic surface quality issues, then the average wall thickness can be used. However,
for typical castings with unequal wall thickness, the time may be too slow resulting in poor
ll in the thin areas or in areas at the far end of the ow.
Average thinnest wall thickness. This is the method recommended. Most castings have
unequal wall thicknesses. Using the thinnest part wall section that can be found on the
casting would place unrealistic burdens on the die casting machine for ow rates and would
not be necessary to make the casting. If the casting thickness is uneven, then calculate an
average thickness of the thinner wall sections.
(Tf). Minimum ow temperature of the alloy. This value is found in the charts.
(Ti ) Temperature of the metal at the gate. On cold chamber machines there is a metal
temperature drop between the holding furnace and the ingate. The drop for aluminum can
be as little as 25F (14C) or as much as 70F (39C) depending on the amount of metal
pored, the ladle traverse time, the type of ladle cup, the pour rate, the shot delay time,
the sleeve and die temperatures, the slow shot velocity and length, and the length and
geometry of the runners.
The following temperature drop values are suggested for typical operations: Aluminum (cold
chamber) = 50F (28C)
Aluminum (cold chamber) = 50F (28C)
Zinc (hot chamber) = 30F (17C)
Magnesium (cold chamber) = 80F (44C)
5.
(Td ). The temperature of the die surface just before the metal arrives. This is an
another difficult estimate. In addition, die temperature varies across the cavity. At any
one area the die temperature before close is a fun on of cycle me,die spray,coolant flow
rate,etc.The process engineers data again would be helpful for similar parts or for general
plant conditions in coming up with this number. lacking data it is suggested that the
designer use 500oF (260oC) for aluminum and magnesium and 400oF (204oC) for zinc.
6.
(S) The percent solids at the end of fill. This value represents the solidified portion of
metal at the end of the flow path at the time when the cavity is full. The higher this factor,
the worse the surface finish. However,a higher value of S helps shrink porosity as there is
less metal to shrink in changing state from liquid to solid. A higher S value yields a longer
cavity fill time with the other factors held constant. If S is set at 50%, then theoretically
50% of the metal at the end of fill will be solid, andwill have completed its density change
yielding less shrink porosity.
30
Gating Manual

Alloy
Empirical Constant, K
H-13/H-21
sec/mm
sec/in
P-20
sec/mm
sec/in
Tungsten
sec/mm
sec/in
Mg
0.0252
0.640
0.0124
0.311
AI
360,380,384
0.0346
0.866
0.0124
0.311
Al390
0.0346
0.866
0.0124
0.311
Zn 12,27
0.0312
0.799
0.0346
0.866
0.0124
0.311
Zn 3,5,7
0.0312
0.799
0.0346
0.866
0.0124
0.311
Fe
0.0346
0.866
0.0124
0.311
Cu 60/40
0.0346
0.866
0.0124
0.311
Cu 85-5-5-5
0.0346
0.866
0.0124
0.311
0.0173
0.433
Pb
0.0156
0.39
Alloy
Metal Injection Temp

Ti
c
Min. Flow Temp. Die Cavity Temp.

Tf
Td
Solids Factor
Z
C/%
F/%
Mg
650
1200
510
1050
340
650
3.7
6.6
AI 360,
380, 384
650
1200
570
1060
340
650
4.8
8.6
Al390
720
1325
595
1100
355
675
5.9
10.6
Zn 12,27
565
1050
445
835
260
500
3.2
5.7
Zn 3,5,7
405
760
382
720
230
450
2.5
4.5
Fe
1540
2800
1370
2500
980
1800
10.8
Cu 60/40
955
1750
900
1650
510
950
4.7
8.4
Cu 85-55-5
1035
1900
930
1710
515
960
4.7
8.4
Pb
315
600
280
540
120
250
2.1
3.8
The table below shows some recommended values for S. Note also that S is entered in the
formula as a whole percent, with no decimal point.
Suggested Percent Solids S (use lower values for good nish)

Wall thickness (inches)
Al
Mg
Zn
.01-.03
5%
10%
5-15%
.03-.05
5-25%
5-15%
10-20%
.05-.08
15-35%
10-25%
15-30%
.08-.125
20-50%
20-35%
20-35%
For typical aluminum castings with a commercial nish, the values for S will be between about
20 and 50. A percentage below 20 is needed only for the very thin wall castings, while a percentage
Gating MAnual
31

for S of about 20 to 35 will work for typical castings with a wall thickness over about .125 inches
and up. The lower value would be used for a better nish, or for a longer metal ow path.
One factor not included in the ll time formula is the metal ow distance. This is the distance
of the path the metal takes to reach the last point to ll, or the end of travel for the segment or
casting area of concern. The path includes deections and angle ow paths, and is not necessarily
the shortest distance.
While the ability to ow through long distances is mostly determined by the average wall thickness
along the ow path, some other factors that affect the ability of the metal to ow long distances are:
the die temperature, the metal temperature, and the gate velocity at the start of the ow.
An empirical guide for evaluating ow distance and wall thickness is to divide the ow distance
by the average wall thickness along the ow path. This is a rough guideline as it assumes the die
temperature, the metal temperature, and the ingate velocity are within typical operating ranges.
For aluminum, if this number is below about 150, then the ow distance should not be a big factor.
If the number is between 150 and 300, then there will be increasing difculty in making the part
and the ll time needs to be kept short in order to make the part. If the number is over 300, it
could be very difcult to make the part even with a short ll time. Note that these numbers are
approximate and are intended to help the designer be aware of potential problems with a long
ow distance in choosing the cavity ll time.
For some thin wall parts, the short ll time requirements will force some high metal velocities.
The following example shows how to use the ow distance number and to make adjustments.
An aluminum pan used in a bread-making machine has a .080 inch wall with a ow distance
of 23 inches. The metal is directed up one side and down the other. The die runs cold (400F or
204C) because of the thin wall, low metal volume, and no hot oil. The normally selected values
for calculating ll time for a wall thickness of about .080 and an S of about 15% would calculate
a ll time of .026 seconds. The ow distance number is 287, which indicates that this is a difcult
part that should have a minimum ll time. This could be done by reducing S to the minimum
of 5%, which would give a ll time .017 seconds. This ll time is conrmed by historical data,
which suggests a ll time of less than .020 seconds is needed, so a ll a maximum ll time of
.017 seconds is used. The change in ll time is only .009 seconds. However, the percent ll time
decrease of 38% is signicant.
A spreadsheet can be used to calculate the ll time formula. NADCA provides a cavity ll time
spread sheet in the Gating class.
32
Gating Manual

For the process engineer, there will be some discrepancy between the calculated value of ll
time and the value taken from a typical monitoring system. The ll time value taken from a
monitoring system includes the plungers deceleration time, while the calculated ll time from the
formula is a theoretical value that assumes that the plunger speed stays constant throughout ll.
Usually the surface nish is determined in the rst part of the ll when the plunger speed is
high. This is the speed that is important for a good nish, and this is the plunger speed needed to
meet the ll time calculated from the theoretical maximum ll time calculations.
The compaction of the metal in the cavity is done while the plunger slows down, and this portion
primarily affects the internal porosity rather than the surface nish. Thus, for practical purposes,
the plunger speed during the rst part of cavity ll should match the cavity ll calculations.
If a partial ll under slow speed conditions is being used as a way to reduce porosity for thick
walled castings, then ll time is difcult to measure. It may also be difcult to get a good surface
nish because of the long time lapse during the prell conditions.
The ll time calculation from the formula can be accurate if care is used in selecting the values.
Experience with feedback from casting oor data will improve the results. This calculation should
be done for every gate design effort.
The following table is useful for picking a cavity ll time. The table is based on the cavity ll
time formula. If in doubt about a ll time to use, use the chart value and reduce it by 25%.
Average Wall
Thickness (Inches)
Zinc 3,5,7
Fill Times in Seconds

Aluminum
Magnesium
0.01 - 0.03
<.015 - <.020
0.04 - 0.05
0.02 - 0.026
0.0173 - 0.0417
0.0132 - 0.0209
0.06 - 0.08
0.0245 - 0.0529
0.0296 - 0.0845
0.0221 - 0.0413
0.09 - 0.125
0.0468 - 0.085
0.0553 - 0.1458
0.0366 - 0.0707
0.13 - 0.15
0.075 - 0.125
0.0956 - 0.2082
0.0579 - 0.0997
Gating MAnual
33
Flow Rates
Given the segment volumes and cavity ll time, the ow rate for each segment and for the
entire casting can be calculated.
Qi = Vi / t
Where,
Qi = ow rate of a segment (in3/sec)
Vi = volume of a segment volume (in3)
t = cavity ll time (sec), and
Q = ( Qi) = ow rate for the entire casting (in /sec)
This data is entered into the gating spreadsheet.
34
Gating Manual
Step 4 Match the Process to

the Flow Rate.
Process factors and limits

For the die casting machine(s) intended to cast the part there are parameter choices. The
casting pressure and fast shot velocity limit can be changed by changing the accumulator pressure.
The fast shot velocity can be changed with the shot valve. There are ranges of plunger tip
diameters available that yield varying metal pressures and ow rates. What accumulator pressure,
and sleeve/plunger tip diameter should be used to satisfy the ow rate calculated in Step 3 (cavity
ll time) and to address the pressure issue from Step 1 (quality requirement). A way to choose
plunger tip diameters is make a spreadsheet showing the options.
Required Flow Rate = xxx in3/sec,
Desired metal pressure = x.x tons/in2
Accumulator pressure = xxx lb/in3
Plunger
(in)
Plunger Area
(in2)
Required Fast Shot Velocity

(in/sec)
Final Metal Pressure

(tons/in2)
x.xx
xx.x
xxx
x.x
x.xx
xx.x
xxx
x.x
x.xx
xx.x
xxx
x.x
x.xx
xx.x
xxx
x.x
To do the spreadsheet the relationship between the accumulator pressure and the metal
pressure needs to be known. This information can be obtained from the machines manual for the
intended die casting machine. Once the chart is constructed choices can be made. A die casting
machine has a normal range and maximum limit for the fast shot velocity. This information comes
from process engineering.
100 in/sec, then 80% or 80 in/sec should be used in the gating analysis. The gives some wiggle
room if more fast shot is needed to make the part than the gating analysis indicates. The other
factor to look at is nal metal pressure. For normal aluminum castings 4 tons/in2 intensied
pressure is used. If porosity is a quality issue or leak testing is required, then 5 tons/in2 nal metal
pressure should be used.
The rst question to ask when reviewing the spreadsheet is can the machine deliver the ow
rate required. If the machine can not deliver the ow rate, then another machine needs to be
found or the cavity ll time in Step 3 needs to be increased.
Gating MAnual
35
Step 4 Match the Process to

the Flow Rate.
Assuming the machine can deliver the ow rate, then select a plunger diameter that gives a
good t for fast shot velocity and nal metal pressure. Other issues to consider in making this
analysis are:
Can the die casting machine hold the metal at the proposed nal metal pressure? What will be
the tonnage on each tie bar with the proposed die design and casting pressure? If the machine
cant hold the metal, then surface nish and porosity quality standards will be difcult to meet
regardless of the quality of the gating system.
Can the accumulator pressure be lowered and still have sufcient fast shot velocity? Casting the
part with the least amount of pressure and fast shot velocity allows the die cast machine to run
more smoothly with less mechanical stress and strain. This is a cost savings opportunity for die
casters who normally set the injection and die close pressures to the maximum regardless of the
part being cast.
In choosing a plunger tip diameter, what will the per cent ll of the sleeve be. The greater the
per cent ll, the less air needs to be vented and the lower the probability for trapped residual
air at the end of the shot. In addition, a higher percent sleeve ll conserves heat with less metal
temperature drop from the furnace to the ingate.
These process decisions may appear to be complicated. However, if the gating designer knows
the capabilities of the intended machine(s) and gives some thought to the tradeoffs of casting
pressure, fast shot velocity, and sleeve per cent ll, then intelligent choices are made and the
gating system is engineered to work for the intended machine. The objective at this point is to
know that the die casting machine can deliver the casting ow rate calculated in Step 3 and metal
pressure in the cast of porosity from Step 1 without undo stress to the machine.
If the machine cant deliver the desired ow rate and metal pressure, then the cavity ll time
has to increase or a more powerful machine used.
36
Gating Manual
Step 5 Determine the Ingate

Parameters and Check for
Atomized Flow.
The next step in the gating analysis is to continue setting up a spreadsheet by segments with
ow rate (Q), ingate velocity (Vg), apparent ingate area (Aag), ow angle (Af), actual ingate area
(Ag), ingate length (Lg), ingate thickness (Tg), and atomization factor (J).
Segment
Flow Rate
(in3/sec)
Ingate Velocity Apparent Ingate

(in/sec)
Area (in2)
Flow angle
(deg)
Ingate Area
(in2)
xxx
xxx
x.xx
xx
x.xx
xxx
xxx
x.xx
xx
x.xx
xxx
xxx
x.xx
xx
x.xx
Totals
xxx
Segment
x.xx
Flow Rate
(in3/sec)
Ingate Velocity
(in/sec)
Ratio Length/
Thickness
Atomization
Factor
x.xxx
x.xxx
xx
xxxx
x.xxx
x.xxx
xx
xxxx
x.xxx
x.xxx
xx
xxxx
Segment Flow Rate

These numbers come from Step 3.
Ingate Velocity
The gating designer chooses an ingate velocity for the casting. Normal ranges for ingate
velocities are shown in the following chart. The ingate velocity selected should fall within these
ranges.
Alloy
Normal Ingate Velocity (in/sec)
Aluminum
700 to 1600
Zinc
900 to 2000
Magnesium
1000 to 2000
Gating MAnual
37
Step 5 Determine the Ingate Parameters

and Check for Atomized Flow.
Higher velocities are chosen for thin walled castings that require a good surface nish, where the
travel from the near to the far end of the casting is long, or where the geometry is complicated
and the metal will encounter deections. When using higher velocities more machine power will
be required and die erosion around the ingate will occur sooner.
Lower velocities will require less machine power and die erosion around the ingate will occur
later. Lower ingate velocities are more economical using less power and lower tool maintenance
and replacement costs.
Thus, choosing an ingate velocity has to do with the quality requirements and the geometry of
the casting. Historical gate velocity data would be helpful for the gating designer. Troubles occur
when the chosen ingate velocity is not within the recommended range. The ingate velocity may
be changed for different gating scenarios. Later in the analysis the ingate velocity in combination
with the ingate thickness is tested for atomized ow.
Apparent Ingate Area

The apparent ingate, Aapp, for each segment is calculated.
Aappi = Qi / Vg
Where,
Aappi
= apparent ingate area of a segment (in2)
Qi
= ow rate of a segment volume (in3/sec)
Vg
= ingate velocity (in/sec), and
These numbers are calculated in the spreadsheet.
Flow Angles
The metal ows into each segment at some angle, which is measured from an axis perpendicular
to the parting line and can range from 0 to 45 degrees. Flow angles of an existing casting can be
observed in a cold start up shot. In Step 1 the ow plan was visualized. This plan included specic
ow angles in each segment.
These ow angles are entered into the spreadsheet.
Actual Ingate
The metal velocity at an angle coming off the ingate can be represented as a vector with
magnitude and direction. This ow vector can be broken into two vectors, one normal to the
ingate and one parallel to the ingate. The vector normal to the ingate represents the metal
actually going into the die. The normal vector = Cos() * ow vector and is illustrated as follows:
38
Gating Manual

To arrive at the actual ingate area for each segment we use:

Agi = Aappi / Cos (), and
Ag
= (Agi)
Where,
Agi = actual ingate area of a segment (in2)
Aappi = apparent ingate area of a segment (in2)

= ow angle rate of the segment (deg)
Ag
= total ingate area (in2)
These numbers are calculated in the spread sheet.
Ingate Length & Thickness

The ingate area is the product of the ingate length and the ingate thickness.
Agi = Lgi * Tdi
Where,
Agi
= actual ingate area of a segment (in2)
Lgi
= ingate length of a segment (in)
Tgi
= ingate thickness of the segment (in)
Perhaps the ingate length is known or desired from Step 1. Then Tgi = Agi / Lgi. Perhaps we
have a desired ingate thickness, then Lgi = Agi / Tgi. Perhaps for a particular scenario we have a
compromise between the two.
These numbers are entered and calculated in the spreadsheet.
Gating MAnual
39

Ratio Ingate Length: Thickness

If the ratio of the segment ingate length to the ingate thickness length is less than 10, then the
ingate depth should be corrected.
Lgi / Tgi
> 10
Where,
Lgi
= segment ingate length (in)
Tgi
= segment ingate thickness (in)
This condition does not occur very often. Distributing the ow over a large area of the casting
normally yields length to thickness ratios much higher than 10.
40
Gating Manual

Ingate Velocity
The ingate velocity required in die casting is much different than that required for other casting
processes. In other processes such as permanent mold, the goal is to reduce turbulence to reduce
trapped gas. The cavity is lled slowly and requires a thick wall and gate. Die castings have
relatively thin walls, thin gates, and rapid heat absorption by the die steel.
Cavity ll in die casting dies is fast with a range of 10 to 150 milliseconds. Instead of a solid ow
front as in permanent mold, the die casting process sprays the metal into the die.
In permanent mold the metal ow though a large gate is a solid front with laminar ow. As the
metal velocity through a smaller gate is increased, the metal front breaks up and the ow consists
of course and relatively large particles. This is called the course particle range. In die casting,
course particle range ow produces questionable castings with excessive internal porosity and
poor surface nish. As the metal velocity is increased further, there is a point where atomized
ow off the ingates begins. The course particles are broken up and the stream of metal consists of
ne particles at very high velocities. While this very turbulent ow may appear to be undesirable
for trapped gas, it is the ow produces successful die castings. In die casting, the ingate and the
process are engineered to deliver atomized metal ow to the cavity.
If some metal dribbles through the gate before the fast shot reaches its terminal velocity,
the metal may prematurely freeze at the gate or in the cavity. This will cause cold ow and
laminations. Thus, the metal velocity should be accelerated early enough through the runner
system so that the metal is at its nal velocity before it reaches the gate and the metal is
atomized through the gate.
In some cases, an operational setting will be used such that the cavity is partially lled (usually
about 10% to 15%) with low velocity, and then the metal is accelerated to atomized ow velocities.
This is done to reduce trapped gas porosity. Where this is successful, there is a relatively thick wall
(greater than .160 in., or 4 mm) and thick gate, and the gate is on the bottom of the casting going
into a thicker wall section. This process setting for partial ll under low turbulence conditions can
sometimes generate a reduction in gas porosity. The gate design, however, should be done for the
standard atomized ow conditions even if it is expected that the partial ll process setting will be
used.
Gating MAnual
41

On some castings, it is possible to have a very large gate, and to ll the casting with slow nonturbulent ow. This will not provide high quality surface nish, but when combined with the highpressure capability of the typical die casting machine, it can provide excellent internal quality.
This technique is called squeeze casting, although there can be many different versions of the slow
fast ll methods.
The very long ll times used in some of these methods mean that the wall thickness must be
greater than typical die casting and the surface nish requirements are not as good. The method
also results in very high die temperatures that shorten die life. This technique typically uses metal
pressure from 15,000 to 25,000 lb/in2. With careful use of die coatings, it can be done with the
more common low iron alloys such as the 356 or 357 alloys. The non-turbulent ll and very low
gas porosity results in a casting that can be heat treated or welded with the potential for higher
elongation and some increase in tensile strength after heat treating.
The slow ll techniques are now done often enough that the line between squeeze casting and
regular die casting is somewhat blurred. A combination of very large gates, low velocity ll at the
start and higher velocity for the nal ll will work for some part shapes. However, the gate design
techniques presented here are for conventional die casting and atomized ow.
The calculation of the minimum gate velocity needed to reach the atomized flow region can be
done from the following formula, which was developed from some earlier research.
Vg1.71 * Tg * p > J
Where,
Vg
= the ingate velocity (in/ sec)
Tg
= the ingate thickness (in)
= The density of the metal (lb/in2)
= the atomization factor
Values of J are based on experimental work in copper alloys. E. A Herman calculates J for each
alloy as:
Alloy
J Factor
Magnesium
275
Aluminum
400
Zinc
475
Most proposed gating systems will have a J Factor well above these minimums. Industry practice
uses gate velocities and thickness that yield a minimum J Factor of 750 which is conservative and
is recommended for normal gating analysis. The following table shows the relationship of gate
thic kness and gate velocity if 750 is used in the atomization equation.
42
Gating Manual

Aluminum
Zinc
Gate Thickness
Minimum Velocity
Gate Thickness
Inches
mm
in/sec
m/sec Inches
0.030
0.762
1497
38
0.035
1.016
1368
32
Magnesium
Minimum Velocity
Gate Thickness
Minimum Velocity
mm
in/sec
m/sec
Inches
mm
in/sec
m/sec
0.006
0.152
2312
59
0.012
0.305
3212
82
0.008
0.203
1954
50
0.015
0.381
2819
72
0.040
1.143
1265
30
0.010
0.254
1715
44
0.020
0.508
2382
60
0.045
1.270
1181
28
0.012
0.305
1542
39
0.024
0.610
2141
54
0.050
1.397
1110
27
0.013
0.330
1471
37
0.028
0.711
1957
50
0.055
1.524
1050
25
0.014
0.356
1409
36
0.032
0.813
1810
46
0.060
1.651
998
24
0.015
0.381
1353
34
0.036
0.914
1689
43
0.065
1.778
952
23
0.016
0.406
1303
33
0.040
1.016
1588
40
0.070
1.905
912
22
0.017
0.432
1258
32
0.044
1.118
1502
38
0.075
2.032
876
21
0.018
0.457
1216
31
0.048
1.219
1428
36
0.080
2.159
843
21
0.019
0.483
1178
30
0.052
1.321
1363
35
0.085
2.286
814
20
0.020
0.508
1144
29
0.056
1.422
1305
33
0.090
2.413
787
19
0.021
0.533
1111
28
0.060
1.524
1253
32
0.095
2.540
763
19
0.022
0.559
1082
27
0.064
1.626
1207
31
0.100
2.794
740
18
0.023
0.584
1054
27
0.068
1.727
1165
30
0.110
3.048
700
17
0.024
0.610
1028
26
0.072
1.829
1126
29
0.120
3.302
665
16
0.026
0.660
981
25
0,076
1.930
1091
28
0.130
3.556
635
15
0.028
0.711
939
24
0.080
2.032
1059
27
0.140
3.810
608
15
0.030
0.762
902
23
0.084
2.134
1029
26
0.150
4.064
584
14
0.032
0.813
869
22
0.088
2.235
1002
25
0.160
4.572
562
13
0.034
0.864
838
21
0.092
2.337
976
25
0.180
5.080
525
13
0.036
0.914
811
21
0.096
2.438
952
24
0.200
5.842
494
12
0.040
1.016
762
19
0.100
2.540
930
24
0.230
6.604
455
11
0.045
1.143
712
18
0.150
3.810
733
19
0.260
7.620
423
10
0.050
1.270
669
17
0.200
5.080
620
16
0.300
8.890
389
0.060
1.524
602
15
0.250
6.350
544
14
0.350
10.160
356
0.070
1.778
550
14
0.300
7.620
489
12
0.400
11.430
329
0.080
2.032
508
13
0.400
10.160 413
10
0.450
11.430
307
0.090
2.286
475
12
0.450
11.430 386
10
0.500
12.700
289
0.100
2.540
446
11
0.500
12.700 363
The J factor is calculated in the spreadsheet and compared to the minimum required to
determine if the proposed gate velocity and gate thickness will produce atomized metal. If J is
less than the minimum, then the gate thickness or the gate velocity needs to be increased.
If any number falls out of normal recommended ranges such as an ingate thickness of .023 inch
for aluminum, or a length, which exceeds the available ingate length at the parting line, then
changes need to be made. Perhaps the ow plan, the segmentation, the cavity ll time, or ingate
velocity need to be changed and another scenario generated. Doing many scenarios is normal for
the gating design process until the best compromises are made. When the simulators do a gating
project, scenario after scenario will be run until the design is considered optimized. The same
process occurs when doing unsimulated gating design.
Gating MAnual
43

A special gating case occurs with long castings and small casting volumes such as chrome plated
automotive body side molding. In this case the ingates will calculate to be very thin because of the
long ingate length and small cavity volume. Ingate velocities exceeding the normal ranges would
be needed to atomize the metal. This would demand high machine power and would erode the
ingate die steel if attempted. This remedy for this case is comb gating.
At this point in the gating analysis the ingate width and length have been determined. The
gate velocity is within the normal range. The ow is atomized, and it is known that the intended
machine can deliver the ow with a chosen plunger tip.
44
Gating Manual
Step 6 Do a PQ2 analysis if

desired
The goal of the PQ2 analysis is to match the dies designed gating system to the machines total
hydraulic system. In the analysis P stands for metal pressure and Q stands for metal ow rate.
The molten metal ow rate through an orice such as an ingate is a function of the pressure on
the molten metal - the higher the pressure, the higher the ow rate. However, the relationship
of pressure and ow rate is not linear. The governing equation for uid ow through an orice or
ingate is Bernoulli equation.
Pm = ( / 2 g) * ((Q / (Ag * Cd ) ) 2
Where,
Pm
= metal pressure (lb/in2)
= metal density (lb/in3)
= gravitational constant (in/sec2)
= metal ow rate (in3/sec)
Agapp = apparent area of the ingate (in2)

Cd
= coefcient of discharge
The expression in Bernoullis equation (Q / Ag) is equal to the ingate velocity Vg. So the equation
can also be written as:
Pm = ( / 2 g) * ((Vg / Cd ) )
From observation of the Bernoullis equation:
Metal pressure required is directly proportional to metal density.
Increasing the metal pressure increases the ow rate. Decreasing the metal pressure
decreases the ow rate. The relationship is non-linear.
Increasing the apparent ingate area, Agapp, decreases metal pressure, Pm needed. Decreasing
the ingate area increases the required pressure. The relationship is non-linear.
Increasing the coefcient of discharge, Cd, with a more efcient metal and hydraulic
system decreases the pressure required. Decreasing the coefcient of discharge with
a more inefcient metal and hydraulic system increases the pressure required. The
relationship is non-linear.
Gating MAnual
45
Step 6 Do a PQ2 analysis if desired
Increasing the metal pressure, increases the ingate velocity, Vg. Decreasing the metal
pressure, decreases the ingate velocity required. The relationship is non-linear.
Values used for liquid density are:
Aluminum = .093 lb/in3
Zinc
= .221 lb/in3
Magnesium = .063 lbs/in3

The gravitational constant g is 32.2 ft/sec2, or 386.4 in/sec2
The coefcient of discharge (Cd) is a measure of inefciency of the metal delivery and machine
hydraulic system. It is the ratio of the ow in the actual machine and die to an ideal uid system
that has no friction.
Common values for Cd for die casting applications are:
Cold chamber aluminum = .45 to .5
Cold chamber magnesium = .45 to .5
Hot chamber zinc or mag = .55 to .65
The following graph shows the non-linear relationship between metal pressure and ow.
Special graph paper with a non-linear Q2 scale makes the P and Q2 relationship linear.
46
Gating Manual
The PQ2 gating analysis using graph paper or a computer generated graph is:
1.
Obtain the appropriate PQ2 graph paper for the machine and die to be analyzed.
2.
Determine the accumulator pressure and convert the accumulator pressure to metal
pressure for a selected plunger diameter. Plot the metal pressure on the PQ2 graph paper
on the vertical axis (Q2 = 0).
To nd the metal pressure from the accumulator pressure:
Pm = ((Ph * Ah) (Pr * Ar)) / Ap)
Where,
Pm
= metal pressure (lb/in2)
Ph
= shot cylinder head side pressure (lb/in2)
Ah
= area head side (in2)
Pr
= shot cylinder rod side pressure (ib/in2)
Ar
= area rod side (in2)
Ap
= area plunger (in2)
The values for the head side and rod side areas are in the machine manual. The pressures
can be read from gages on the machine.
Gating MAnual
47
3.
Find out or determine the dry shot fast shot velocity at the accumulator pressure
chosen and plot on the horizontal axis (P = 0). The values for the dry shot speed for
given accumulator pressures can be found in the machine manual or can be determined
experimentally on the oor.
4.
Draw a straight line between the points of Steps 2 and 3. This is called the Machine
Performance Line.
5.
Assume a coefcient of discharge.
6.
Select an ingate velocity. Calculate the metal pressure required to produce this velocity.
Select an ingate area. Calculate the ow rate associated with this ingate area and ingate
velocity (Q = Vg * Ag). Plot this point on the PQ^s graph from the origin. Draw a straight line
though this point. This is called the Die Resistance Line for the selected ingate velocity and
ingate area.
7.
The intersection of the Die Resistance Line and the Machine Performance Line is maximum
operating condition for the parameters selected.
48
Gating Manual
Minimum Gate Velocities for J = 750

Aluminum
Gate
Minimun
Thickness
Velocity
Zinc
Gate
Thickness
Minimun
Velocity
Magnesium
Gate
Minimun
Thickness
Velocity
Inches
mm
in/sec
m/sec
Inches
mm
in/sec
m/sec
Inches
mm
in/sec
m/sec
0.030
0.762
1497
38
0.006
0.152
2312
59
0.012
0.305
3212
82
0.035
0.889
1265
32
0.008
0.203
1954
50
0.015
0.381
2819
72
0.040
1.016
1181
30
0.010
0.254
1715
44
0.020
0.508
2382
60
0.045
1.143
1110
28
0.012
0.305
1542
39
0.024
0.610
2141
54
0.050
1.270
1050
27
0.013
0.330
1471
37
0.028
0.711
1957
50
0.055
1.397
998
25
0.014
0.356
1409
36
0.032
0.813
1810
46
0.060
1.524
952
24
0.015
0.381
1353
34
0.036
0.914
1689
43
0.065
1.651
912
23
0.016
0.406
1303
33
0.040
1.016
1588
40
0.070
1.778
876
22
0.017
0.432
1258
32
0.044
1.118
1502
38
0.075
1.905
843
21
0.018
0.457
1216
31
0.048
1.219
1428
36
0.080
2.032
814
21
0.019
0.483
1178
30
0.052
1.321
1363
35
0.085
2.159
787
20
0.020
0.508
1144
29
0.056
1.422
1305
33
0.090
2.286
763
19
0.021
0.533
1111
28
0.060
1 .524
1253
32
0.095
2.413
740
19
0.022
0.559
1082
27
0.064
1.626
1207
31
0.100
2.540
700
18
0.023
0.584
1054
27
0.068
1.727
1165
30
0.110
2.794
665
17
0.024
0.610
1028
26
0.072
1.829
1126
29
0.120
3.048
635
16
0.026
0.660
981
25
0.076
1.930
1091
28
0.130
3.302
608
15
0.028
0.711
939
24
0.080
2.032
1059
27
0.140
3.556
584
15
0.030
0.762
902
23
0.084
2.134
1029
26
0.150
3.810
562
14
0.032
0.813
869
22
0.088
2.235
1002
25
0.160
4.064
525
13
0.034
0.864
838
21
0.092
2.337
976
25
0.180
4.572
494
13
0.036
0.914
811
21
0.096
2.438
952
24
0.200
5.080
455
12
0.040
1.016
762
19
0.100
2.540
930
24
0.230
5.842
423
11
0.045
1.143
712
18
0.150
3.810
733
19
0.260
6.604
389
10
0.050
1.270
669
17
0.200
5.080
620
16
0.300
7.620
356
0.060
1.524
602
15
0.250
6.350
544
14
0.350
8.890
329
0.070
1.778
550
14
0.300
7.620
489
12
0.400
10.160
307
0.080
2.032
508
13
0.400
10.160
413
10
0.450
11.430
307
0.090
2.286
475
12
0.450
11.430
386
10
0.500
12.700
289
0.100
2.540
446
11
0.500
12.700
363
Gating MAnual
49
PQ2 Notes
1.
Cavity ll time is a function of ow rate. The minimum ow rate for a desired maximum
cavity ll time can be plotted on the PQ2 diagram as a vertical line. Operating conditions
must be to the right of this line.
2.
For an intended ingate thickness, there is a minimum ingate velocity needed to atomize
the metal for an intended ingate thickness. From Bernoullis equation metal pressure can
be calculated from this minimum velocity. This can be drawn as a horizontal line. Operating
conditions must be above this line. The horizontal, vertical, and machine performance lines
create an area that can be called the operational window. The die should operate in this
dened area.
3.
Effects of Parameter Changes

Reducing or increasing the accumulator pressure creates parallel Machine Performance
Lines on the PQ2 graph.
50
Gating Manual
Closing the shot valve has the effect of creating Machine Performance Lines that pivot from
the metal pressure point with zero ow. This data can come from the machines book or be
determined experimentally.
Changing the plunger tip has the effect of changing the slope of the Machine Performance Line.
Smaller plungers yield higher metal pressure and less ow. Larger plungers yield lower metal
pressure and more ow.
Changing the ingate area changes the slope of the Die Resistance Line. Smaller ingate areas yield
more pressure, less ow. Larger ingates areas yield less pressure, more ow.
Gating MAnual
51
From all these options many Machine Performance and Die Resistance Lines can be drawn to
show the operating conditions for a given set of gating parameters. Many scenarios are run. The
objective is to nd a combination of ingate area, ingate velocity, ingate thickness, plunger tip
diameter, and accumulator pressure that create a large central operational window on the PQ2
diagram. NADCA provides software to help with the PQ2 analysis and calculations.
The PQ2 analysis can be run as a check on the conventional gating analysis or vice versa. Note
the coefcient of discharge appears as a squared term in Bernoullis equation which means a small
per cent change in this number results in a signicant per cent metal pressure change all other
factor being equal. The machines performance and other mechanical issues such as the alignment
of the sleeve and plunger change through time. These factors affect the coefcient of discharge.
Selecting a coefcient of discharge on the low side is a conservative approach.
52
Gating Manual
Step 7 Design the Fan and

Tangential Runners
Flow area considerations

The function of the runner is to deliver the metal to the ingate and to generate the desired ow
pattern within the cavity segments. There are three runners used plus the chisel runner that is
sometimes used in dealing with local porosity. The three runners are the straight fan, the curved
fan, and the tangential runner.
The ingate controls the metal ow into the cavity. Therefore, the ingate has the smallest area
in the metal ow path from the biscuit or sprue to the cavity. If this were not true, then some
other feature in the runner system will control the metal ow such as an undersized runner or an
undersized nozzle on a hot chamber machine.
Runner systems should always be designed starting at the ingate and working back to the sprue
or biscuit and in the case of hot chamber machines working back to the gooseneck plunger. At this
point in the analysis the ingate areas and locations are known so the runner design starts at the
gate opening and works backwards to the sprue or biscuit.
The runner area should decrease as the runner transitions into the gate. This not only maintains
the gate as the smallest area in the ow path, but it also forces the metal ow to spread the full
width of the gate and lets the gate do what it was designed to do. Decreasing the runner area
leading up to the ingate also prevents mixing air with the metal in the runner that might show up
in the casting as porosity.
Starting at the gate, the runner will be larger than the gate. The ratio of the runner to gate
area will vary with the design, and will usually range between 1.1:1 and 1.4:1. However, it can be
larger as in the case of small castings where using a ratio of 1.4:1 would result in too much metal
heat loss in the fan or tangential runner system. Thus, if the gate area is 1.00 in2, then the runner
area should be between 1.1 and 1.4 square inches except in small castings.
The ratio is determined by several design factors, and it important to realize that there isnt a
magic number that applies to all circumstances. Some of the factors to consider are:
Aluminum
Typical ratios will be about 1.1 to 1.4. The higher ratios are used where there is a larger ow
angle. A ow angle greater than 35 for a fan gate design will require a ratio of 1.3:1 or greater. A
ow angle of 10 to 35 would be acceptable with a gate to runner ratio of about 1.1:1 to 1.3:1.
Higher ow angles require more restriction to force the metal to conform to the gate shape.
Gating MAnual
53

Tangential Runners
On the other hand, the designer should be cautious about using large ratios for large castings
because the main runner off the biscuit or sprue may up being excessively large. Runners dont get
shipped. Runners only add to the energy and dross loss costs of the plant.
In some plants, it is common to use a steep 45o ramp for the transition from the fan or
tangential runner to the gate. The thought is to keep the metal hot up to the gate to prevent
premature freezing of the ingate. However, freezing at the gate can usually be corrected with
process changes, and this kind of gate design should not be necessary. It can be used in some cases
to help specic porosity spots, but it forces the metal to accelerate in a very short distance and
may not allow the metal to spread to the edges of the gate. If this gate design technique is used,
then it is suggested that the gate to runner ratios will need to be quite high, typically 1.5:1 or
even 2:1.
Zinc
Thinner gates and smaller gates are used in zinc with runners as small as .125 x .125 inches or
even smaller in four slide machines. The smaller runners require a very fast ll time (less than 10
msec) to stay open.
The runner size ratio is often 1.05 to 1.15 times the gate area. These are smaller increases than
those used in aluminum, partly because the area of the sprue or the nozzle feeding the sprue
limits the maximum area of the runner in a hot chamber machine.
When this occurs, most of the available area reduction should be used at the gate, which may
mean that the runner components will be designed with a small area reduction from the sprue
start of the gate. The sprue and nozzle areas need to be reviewed in all hot chamber designs along
with the runner components. Sometimes the nozzle or sprue is smaller than it should be. A good
design solution may be to go to a runner sprue, which will provide less restricted ow and can
support a bigger runner system.
Magnesium
Magnesium runners work well with more speed than other metals. High runner speed is desirable
to keep the heat loss down, which is critical in magnesium where the latent heat and the
specic heat are low. Although using the same strategy as in aluminum is suitable for most dies,
smaller runner sizes and higher velocities can be an advantage. The concept is to keep the runner
velocities high with modest area increases from the ingate to the sprue or biscuit to minimize heat
loss in the runners.
54
Gating Manual

Tangential Runners
Fan Runners
Fan runners can be used to feed the entire casting or to split the metal from a main runner
to two adjacent tangential runners. Fans generate a desirable strong center ll. There are two
types of fans a curved sided fan and a straight sided fan. In order for the fan to have constantly
decreasing area from the main runner to the ingate, a curve sided fans depth will decrease
linearly, and a straight sided fan will have a depth which is curved. If the fan is constructed with
straight sides and a linear depth reduction, then the fan area from the runner to the ingate will
not decrease linearly though the fan. The metal will pull away from the sidewall and generate
a pocket. This pocket will feed a steam of air bubbles into the owing metal and contribute to
casting porosity.
Straight and curve sided fans are shown in the next gures.
Gating MAnual
55

Tangential Runners
An inferior fan gate with straight sides and depth looks like the following.
The at fan shape is simple to make and may appear to do reasonably well, but it will add gas
porosity to the casting.
The advantages of straight sided fans are that the ow angle is known and the runner breaks
clean without a trim die. The disadvantage of a straight fan is it is more difcult to machine into
the die. The fan should be modeled and edmed in.
The advantage of a curve sided fan is that is easier to machine into the die. The disadvantages
of the curve sided fan is the ow angle is not clearly dened and that the fan does not break
cleanly and must be trimmed.
Fan Flow Angles

The ow angle for the straight sided fan is the angle of the sidewall to the centerline. The
straight sided fan design shown earlier has a ow angle of 26, which is measured as shown below.
The curved fan gate has a ow angle measured at a point the distance from the gate to the
runner, as shown below.
56
Gating Manual

Tangential Runners
The maximum ow angle for any fan is 45. The ow off the ends of fans with ow angles
greater than 45 will be negligible.
The edge of a curved fan tends to break out as shown below. If the part is hand degated or
tumbled off, it is recommended that the gate width be reduced approximately as shown with the
red dotted lines to address the break out issue.
Gating MAnual
57

Tangential Runners
The ow angle for fans varies from left to center to right. The average fan ow angle used to
calculate the actual ingate area from the apparent ingate area is:
= ((l + r) / 4) + c
Where,
= average fan ow angle
l = ow angle left side of fan
r = ow angle right side of fan
c = ow angle center of fan
Designing Fan Runners

The procedure for designing a fan is:
1.
Determine the fan width and the fan length. The fan width at Section A is the same width
as the ingate. The fan length is the distance from the end of the fan to the beginning of
the fan, Section I, joining the main runner. The ratio of the fan width to the fan length
determines the fans ow angle at each edge. Increasing the fan length decreases the ow
angle at the fans edges.
2.
Divide the fan into equal sections from beginning to end. A convenient number of sections
to use is 9.
58
Gating Manual

Tangential Runners
3.
Determine the area of the end Section A. This area is equal to or greater than the ingate
area. It is customary to make the area of Section A 10% greater than the ingate area it
feeds. This gives some wiggle room if the ingates need to be increased slightly when the
part is cast without having to reburn the fan to enlarge it.
4.
Determine the area increase from Section A to the beginning of the fan Section I. In the
example the area increases 200%. This percent increase is a judgement call and will vary
with each casting. On one hand the objective is to deliver hot metal to the ingates, and on
the other hand the objective is to minimize the size of the runners to reduce remelt costs.
5.
Determine the area of each section with a linear reduction in area from the beginning of
the fan to end of the fan. If 9 sections are used, then the area of Section E is the average
of Sections A and I. The area of Sections C is the average of sections A and E, etc.
6.
Determine dimensions of the beginning of the fan, Section I. The main runner dimensions
that feeds the fan and the dimensions of Section I are the same.
7.
For a curve sided fan, the fan depth linearly decreases from the beginning to the end.
Determine the depths of each section with a linear reduction from the beginning to the
end. The same method as in Step 5 can be used.
8.
Calculate the average width of each section. This is the section area divided by the section
depth.
9.
Put all the fan data into a chart and draw a sketch showing the plan view and the crosssectional view of the fan. On the cross-sectional view show the relationship of the fan in
the ejector half and the ingate in the cover half overlapping the fan and the land distance.
The straight sided fan is done the same way only the width increases linearly from the fan
beginning to end. The fan depth is calculated from the sectional fan areas and widths and will be
non-linear.
Fan Notes
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Tangential Runners
Curved Sided Fan Data Table

Ingate Width = 5.000, Ingate Thickness = .063, Flow Angle = 40 degrees
Section
Distance
Area
Depth (h)
Avg Width
Base (b)
Top (t)
Side (c)
Side (d)
0.000
0.347
0.069
5.000
5.012
4.988
0.012
0.012
0.750
0.408
0.136
3.009
3.033
2.986
0.024
0.024
1.500
0.470
0.202
2.326
2.362
2.291
0.036
0.036
2.250
0.532
0.268
1.981
2.028
1.934
0.047
0.047
3.000
0.593
0.335
1.773
1.832
1.714
0.059
0.059
3.750
0.655
0.401
1.633
1.704
1.563
0.071
0.071
4.500
0.717
0.467
1.533
1.616
1.451
0.082
0.082
5.250
0.778
0.534
1.458
1.552
1.365
0.094
0.094
6.000
0.840
0.600
1.400
1.506
1.294
0.106
0.106
h = Area / depth
Avg Width = Area / h
b = Avg Width + c
t = Avg Width - c
c = 0.176 * h
d = 0.176 * h
Area Ratio Sections I:A 2.42
1.
The sides of fans have 10o draft. Any section of the fan is actually a trapezoid.
2.
Planned ow with associated ow angles was determined in Step 2. By changing the fan
length relative to the fan width, the ow angle changes. Normally many fan scenarios are
generated to get the ow angle desired and to t the fan to the space available on the die.
It is helpful to have spreadsheets containing generic straight and curve sided fans so that
fan design data can be calculated quickly and accurately.
Either type can be set at an angle to direct the ow towards a problem area. The illustration
below shows how this can be done. The gure below also shows the straight fan gate at left turned
at a 30 angle. The arrows approximate the new ow pattern. This allows the ow to be directed
at a particular problem area.
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Flow patterns for the fan gates

The ow patterns generated by the two different types of fan gates are shown by the following
pictures:
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Tangential Runners
Tangential Runners
Tangential runners run tangent along the side of the cavity. The advantages of tangential runners
are:
the runner is compact and can be kept close to the casting,
the ow direction can be controlled, and
hot metal can be distributed over a relatively long distance.
A disadvantage of tangential runners is that runners will get overly big if small ow angles are
desired.
The tangential runner ow angle is determined by the ratio of ingate area to runner area. At
any point in the tangential runner the ow angle is the arctangent of the gate area divided by the
tangential runner area. For this calculation, the gate area is the total gate area downstream from
the section selected, and the runner area is measured at the section selected.
Because of the ow angle, the metal sees a smaller gate area than that actually cut into the die.
It also means the actual velocity is higher than the apparent ingate velocity.
Actual gate area = Apparent gate area / Cosine (ow angle)
or
Apparent gate area = Actual gate area * Cosine (ow angle)
And,
Actual gate velocity = Apparent gate velocity / cosine (ow angle)
where the Apparent gate velocity is calculated by using the plunger diameter, fast shot velocity,
and measurements of the ingate.
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Tangential Runners
Since the cosine of the ow angle is always less than one, the difference of the Actual and
Apparent ingate velocities can be signicant. Solder and erosion problems can occur due to
unexpected high actual ingate velocities especially with aluminum.
The following table shows the approximate ow angles attainable from the tangential runner.
Note that a very large runner is needed to get the metal with a low ow angle into the casting.
If this is the ow pattern that is needed, then a fan gate may be more appropriate than the
tangential gate.
Examples of
Runner Area Gate Area
Ratio of
Gate/Runner
Flow Angel
Degrees
0.10
0.10
1.00
45.00
0.11
0.10
0.90
41.99
0.13
0.10
0.80
38.66
0.14
0.10
0.70
34.99
0.17
0.10
0.60
30.96
0.20
0.10
0.50
26.57
0.25
0.10
0.40
21.80
0.33
0.10
0.30
16.70
0.50
0.10
0.20
11.31
Practical tangential ow angles vary from 26 to 45. A shock absorber is desirable for
tangential runners. The shock absorber will prevent spitting of metal into the die at the end of
the tangential runner when the runner is lling. This spurt of metal will eventually erode the
runner and the ingate at the end of the runner. The shock absorber allows the tangential runner
to ll and pressurize providing simultaneous ll along the tangential runners length. A proper
designed shock absorber will trap compressed air in the center. Shock absorbers should be feed
tangentially to create a whirlpool ow pattern with air trapped in the center. An ejector pin
should always be placed underneath the shock absorber. If there is no ejector pin under the shock
absorber, then the shock absorber will stick to the die. The diameter of the shock absorber should
be large enough to create the air pocket in the center. The shock absorber diameter should be
approximately the square root of the inlet area to the tangential runner.
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Tangential Runners
The dimensions for the designed tangential runners are provided to the toolmaker of die
designer with the above drawing, a data chart, and a generic tangential runner cross section.
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Tangential Runners
The aspect ratio is the ratio of the average width to the height of the tangential runner. A
typical aspect ratio for tangential runners is 2:1. An aspect ratio of 1:1 would be more compact
conserving heat. An aspect ratio of 3:1 would be more spread out and would dissipate more heat
to the runner die steel.
To calculate the dimensional data for each section:
1.
Calculate the areas for all sections except the last (Section J). The tangential runner area
for any section is the ingate area that it feeds divided by the cosine of the ow angle.
2.
Calculate h, b, d, t, and c for each section except the last (Section J). The formulas for a
2:1 aspect ratio are given in the example.
3.
The tangential runner at section J feeds an ingate of zero. However, it is customary to

make section J at least as thick as the ingate. If a shock absorber is used, it needs to be big
enough to feed the shock.
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Tangential Runners
Tangential runners do not have to be kept parallel to the edge of the casting with tangential
gates. The ramp from the runner to the casting can be extended so this type of gate can feed an
irregular edge. This is shown below.
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Tangential Runners
The ramps from the runner to the casting can be lengthened as needed to t the casting contour.
The ramps are usually sloped about 5 from the runner to the casting (or to the land if one is
used).
A side view of the technique is shown below.
This technique can also be used to direct the ow of a tangential runner. The runner can be
angled to make the ow pattern go in the direction desired.
The picture below shows a gate design where the tangential gate was shaped so as to direct the
ow at particular problem areas. The ow pattern in this case worked well to solve some defect
problems.
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Tangential Runners
If it is desired to have a different angle, it is possible to angle the runner away from the casting
in order to get the ow angle directed better. The gate can be added to the curved sections of
the tangential gate and thus obtain some different ow angles that could not be achieved with a
straight section. This is shown below, where the runner curves were used to direct metal into the
two corners of the casting that could not be reached without using this technique.
This technique is very powerful, especially when a good surface nish is required. This
example was done by computer, but to do it manually, the following procedure will get a close
approximation. First, set the straight section in the middle.
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Tangential Runners
Now do the following steps:

1.
Draw the ow vector as it is desired,
2.
Add a perpendicular to the line approximately in the area the runner is expected to be.
3.
Then add a line at an angle to the line from step 2 of approximately 30. The end of this
line should intersect the edge casting where the initial gate starts. The runner will then be
a curve matching the existing runner that is tangent to this line.
4.
Draw a perpendicular to this line done in step 3, starting where the line from step 3 and
the ow vector intersect.
5.
Draw a vertical line from the starting point of the gate for the initial straight section.
6.
Where the lines from 4 and 5 intersect is the center of the radius forming the outside of
the new runner section.
The 30 is selected as a ow angle that is relatively easy to achieve, this could be any value
with in the range of about 30 to 40. This curve would be the path for the runner that would ow
in the direction of the vector if the runner were sized to provide the ow angle selected when
drawing the tangent line.
Main Runners and Cavity Layout

Main runners carry the metal from the sprue or biscuit to fan and tangential runners. The runner is
usually done in trapezoidal shape, although round runners are used for miniature zinc 4-slide machines.
Round runners should have a straight section added at the parting line to avoid a slight undercut.
The width to depth ratio is called the aspect ratio, and will usually be between 1:1 and 3:1. The
lowest surface area to volume ratio comes when the when the depth is equal to the width, and
this is typically used for most runners. However, in large aluminum dies where the main runner will
get too large to freeze in a reasonable time, the runner depth is kept constant at about .7 inches
and the width is expanded as necessary to get the required area.
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69

Tangential Runners
The most important concept in runner design is that the beginning of ow at the biscuit or sprue
must be the largest area, and that the metal encounters an ever decreasing area as it moves to
the fan and tangential runners. Ultimately, the smallest area in the delivery system is the ingate
area and this area controls the ow and velocity going into the cavity not some other feature of
the runner system.
Another factor to consider is the high velocity and momentum of the metal in the runner system.
Wherever the metal encounters sharp corners turbulence can be created causing gas entrapment,
which ends up as porosity or blisters. Thus, main runners turns should be smooth and gradual.
Runners dont get shipped. Energy costs keep rising. Excessively large runners slow the cycle
time and increase energy costs. Therefore, the designer is encouraged to design the runner wisely.
Runner design procedure

Runner design should start at the gate and proceed to the sleeve or sprue. The rst step was
covered earlier in the fan and tangential runner design, and should result in the initial runner size
about 1.1 to 1.3 times the gate area. The main runners should be increased in size as the design
proceeds from the fan and tangential runners to the sprue or biscuit. Each turn of transition from
one main runner to two should have an area reduction from entrance to exit. Properly designed
bends need only a small increase, usually 3% to about 5%, depending on the sharpness of the bend.
These small increases depend on having a good runner design, and a smooth model of the runner
system, preferably one that can be machined from a CAD model.
Y junctions should also have an increase in area when going upstream from the branches from
the main runner on the order of 3% to 10%. An increase of 5% for good smooth shapes should be
adequate.
Larger increases are more conservative and more certain to cover errors, however, they often
result in a large main runner that slows the cycle time.
Tree runners are often used for multi cavity work. They are always a problem because the metal
will not arrive at the top and bottom cavities at the same time. Tree runners violate the principle
of simultaneous ll and should be avoided, as the top and bottom cavities will not run the same
creating quality problems. It is far better to use a die layout with cavities equidistant from the
sprue or biscuit.
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Tangential Runners
Six cavity dies are more difcult, and may require some ingenuity, but the effort is well worth it.
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71

Tangential Runners
The design of main runners follows the same pattern as with fan and tangential runners. The
cross sections of all main runners need to be dened for the tool maker or the too designer. The
aspect ratio of main runners is the ratio of the average width to the depth. Typical ratios are 1:1
to 3:1. Here is a spreadsheet example of Main Runner dimensional data. The whole runner system
is drawn on the preliminary die where the main runner sections are identied.
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Tangential Runners
Main Runner Description

Component
Description
1
2
3
4
5
6
7
Tangential
Fan
Fan
Fan
Fan
Fan
Fan
Main Runner:
Aspect Ratio = 2:1
Main Runner
Section
Feeding
Draft = 10o
Area
(in2)
Avg Width h (in) b (in) d (in) t (in) c (in)

(in)
0.237
0.688
0.344
0.748
0.061
0.627
0.061
Any Fan
0.225
0.671
0.335
0.730
0.059
0.612
0.059
1+2
0.485
0.984
0.492
1.071
0.087
0.898
0.087
1+2+3
0.721
1.201
0.600
1.306
0.106
1.095
0.106
0.236
0.687
0.344
0.748
0.060
0.627
0.060
6+7
0.473
0.972
0.486
1.058
0.086
0.887
0.086
All
1.643
1.813
0.906
1.972
0.160
1.653
0.160
(Area Section M = All = K + 2*I + G =1.643 )
Main Runner dimension formulas for an aspect ratio of 2:1

h = (Area / 2).5
b = 2.176 * h
d = 0.176 * h
t
= 1.824 * h
= 0.176 * h
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Gating Manual
Step 8 Design the OverFLows

and Vents
OverFLows and Outgates

Overows collect the initial contaminated metal that traverses the cavity, provide local heat
to the far side of the cavity, and provide a base to help eject the casting off the die. The number
and size of overows is a function of the ow distance through the cavity whereas long distances
will have more overows and the surface nish requirements of the casting whereas good surface
quality will have more overows than a commercial nish. A guide to overow size as a percent of
the adjacent segment can be found in the table below:
Typical Overow Sizes

Thickness of
Segment - in.
(mm)
Cavity Fill Time Overow size as percent of adjacent cavity segment

- sec.
Hardware Quality
Some Cold Shut Allowed - %
Surface Finish - %
0.035 (0.90)
0.012 - 0.021
150
75
0.050 (1.30)
0.017 - 0.029
100
50
0.075 (1.80)
0.026 - 0.044
50
25
0.100 (2.50)
0.035 - 0.059
25
25
0.120 (3.20)
0.042 - 0.071
----
----
NOTE: The values shown are typical values which may change for specic situations.
Overows that connect to vents should be located at the last portion of the segment to ll. If
the overow lls before the segment, then backlling will occur causing poor ll and porosity.
Metal will be drawn to the outgates and overows, so it is better to have many modest overows
than a few large ones for purposes of distributed ow within the casting. Like runners, overows
do not get shipped, so the number and placement of overows should be judicious.
The outgate connects the casting to the overow. The sum total of all the outgate areas should
be approximately one half the total ingate area since the outgates provide the passageway for air
to escape through the vents. For aluminum the minimum outgate thickness should be .040 in. For
magnesium and zinc the minimum thickness is .020 in for conventional die casting. Overows are
normally located on the ejector half with an ejector pin underneath them. Outgates like ingates
are normally located in the cover half.
If possible the design of overows as with vents should be for inefcient metal ow. The concern
is keep the molten metal within the die at the end of the shot. If the die does not hold the metal,
then the packing that occurs at the last instant of ll is diminished causing poor surface nish and
porosity. Inefciency is created when the outgate is offset from the vent forcing the metal to turn
within the overow.
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and Vents
Overow dimensional data along the locations need to be provided to the toolmaker or die
designer on the preliminary die layout. The following is an example of an overow.
Vents
Vents are essential to die casting. Vents let the air out of the die throughout the shot. If this
doesnt happen air and other gasses will be trapped within the cavity with the metal. The trapped
gas will be in the form of smooth round bubbles that form gas porosity. These bubbles can be
anywhere, but will be concentrated in the areas that were the last to ll or at the last points to
solidify. It is difcult in die casting to vent all the air. However, there is a big difference in residual
air and the resultant casting quality between no vents and proper vents. If the die is designed with
insufcient vents, over time the air will nd a way out. The die will ash, and some of the ash
will stick to the die causing inserts to be crushed unevenly into the holder block or the holder
block itself will be crushed around the perimeter of the cavity inserts causing continuous ash or
natural venting. This all can be avoided by designing proper vents.
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Gating Manual

and Vents
The best locations for the vents are the last points to ll. The simulation programs best predict
these points. A program distributed by NADCA called CastView will do a good job of predicting
these last to ll locations.
Air is compressible and reaches a terminal velocity in the vents no matter how much pressure
is applied to the air. The air velocity in the vents assuming the terminal velocity is not reached is
a function of the ingate velocity of the metal and the vent area. The air velocity in the vents is
directly proportional to the ingate metal velocity and inversely proportional to the vent area. A
way to determine the vent area is to calculate the incoming metal ow rate, and set the vent area
so the volume of air that can escape through the vents must do so without exceeding a speed that
is 70% of the speed of sound at standard conditions. To calculate this vent area, the metal ow
rate (Q) is calculated rst, and then it is assumed that the air escaping has the same ow rate.
If the maximum reasonable velocity in the vents is assumed to be about 70% of the speed of sound
or 8000 in/sec (200 m/s), then the approximate minimum area for the vents can be found from:
Minimum Vent Area = Q / 8000
Depending on the choice of variables, this calculation approximates the formula developed by J.
F. Wallace:
AV = (0.00571)(V)/(T)(K)
Where:
AV
= the minimum area of the vent
= the total volume of gas in the system, including runner and shot sleeve
= the cavity ll time
= the percentage of the vent area remaining open during lling
It would be reasonable to assume the air in the shot sleeve is moved out under slow speed
conditions, and so is not a factor during cavity lling. If this is the case, we could let V = cavity
and runner volume only, and assume the percentage of vents remaining open is about 50%; then
the two formulas will be about the same.
Another way to determine the vent area is to divide the ingate area by four or:
Vent Area = Ingate Area / 4
Since the normal range of ingate velocities is less than 2000 in/sec, this formula can also be used.
The problem in designing a venting system with the proper area is nding real estate on the die
to put all the vents in. It is always a good idea to have a plan for the vents before signing off on
the cavity insert sizes. Sometimes the steel is ordered and there isnt enough room to install the
vents. This issue also becomes complicated with slides and other features that make it difcult or
impossible to install the proper venting. If the casting is sensitive to gas porosity, then this should
be a strong warning that there will be some gas porosity in the casting, or that freeze blocks or
vacuum should be considered. On the other hand, if the casting is not machined, and gas porosity
is not an issue, then probably the designer should add as much venting as possible and accept the
remaining porosity. The following is an illustration of a freeze block. The freeze block allows for a
large vent area in a small die area.
Gating MAnual
77

and Vents
Vents need to be cut into the cavity insert steel and polished so the cast metal does not stick
to them. Vent thickness varies from .005 to .020. The air has less resistance owing though vents
that are .020 versus ones that are thinner. It is a good idea to machine a small radius between the
overow and vent to help pull the vent upon ejection. Some vents are designed with steps to help
pull the vent off the die. For example, the vent thickness starts at .020, and then goes to .015,
and nally to .010. However, with stepped vents it is the last thickness that sees the atmosphere
that counts for vent area. Vents need to receive die lube spray. Die lube spray enhances release,
washes fragments of metal off the vents before the next shot, and cools the vent die steel.
Sometimes the problem of insufcient cavity insert preload occurs. If the cavity insert preload
is .002 inch or greater per die half, then the space between both holder blocks when the die is
closed should be sufcient for the air to escape.
Vents should be designed for inefciency. Turns slow the metal down and promote freezing. The
objective is to have the metal stop dead before reaching the holder block. If metal reaches the
holder block then ash and inevitable crushing will occur. The vent length required to stop the
metal before reaching the holder block is a function of vent thickness - the thicker the vent the
further the metal will travel. Experience and judgment are the best guide to estimating the vent
length needed to stop the metal. If the vents are .020 inches thick, then about 4 inches of vent
length will be required to stop the metal. However, this is contingent on metal temperature, die
temperature, ingate velocity, amount of die lube spray on the vents, etc.
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Gating Manual

and Vents
A better system than vents to remove the air is to evacuate it during the shot with a vacuum
system. Vacuum removes the air and also lowers the required shot pressure as the metal wants to
ll the nooks and crannies of the cavity. However, vacuum has problems of its own as it another
thing in the process that can go wrong such as when the vacuum valve lls with metal in the
middle of a production run producing neither vacuum or venting. For gating design purposes, it is
important that the proper effort be applied to nding the last point to ll to locate the vacuum
channels. Many vacuum runners look like the ingate runner system as vacuum is pulled from
multiple locations and fed to main vacuum runner leading to be inefcient with turns and blind
runners.
The vacuum channels need to be large enough with low resistance to handle the airow during
evacuation for the system to work properly. The time available for the vacuum system to work is
less than 1 second. Although the pressure from the incoming metal will push some of the air out,
the vacuum system should have evacuated most of the air before the metal arrives. The vacuum
system suppliers are a good source for vacuum runner design information.
The vacuum valve pulls vacuum throughout the entire shot including fast shot. What triggers
the valve to close is the metal itself reaching the valve. However, the valve is prone to failing as
metal eventually gets into the valve. An alternative to this approach is to pull the vacuum though
a freeze block or freeze blocks. In this case, a slow shot velocity of around 10 in/sec is used and
the vacuum is shut off prior to going into fast shot. The vacuum levels achieved with this method
will not be as good as with valves, but it is simpler and easier to maintain. The freeze block needs
to be sprayed with air and die lube to prevent metal fragments from sticking and building up on
the freeze block.
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79
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Gating Manual
Step 9 Simulation
The use of simulation is certain to become more popular as computers become more
powerful and the capability of the simulation software gets better. Simulation is a useful
engineering tool, and should be used to supplement the engineering work of gating and not to
replace it. In the described gating process in this book there are a lot of assumptions made by the
designer and a lot of thought that is needed for any well designed gating system. Simulation is not
a substitute for the techniques described in this book and should be done after the gating
design is complete Ideally, simulation should be done as early as possible so the results can so the
results can inuence
the part design. Using simulation has several useful and important objectives that can assist
making the gating design better:
1.
What does the simulator say about the ow pattern? Is the ow pattern similar to one
envisioned in Step 2?
2.
Where are the last areas to ll? Are the outgates adjacent to these areas?
3.
Are there areas of trapped gas critical to porosity control? Does the proposed design and
pattern address them?
4.
Does shrink porosity occur in areas critical to porosity control? Does the proposed ingate
location and thickness address them?
5.
Is there strong ow to areas where surface nish matters?
The last areas to ll is the easiest, and probably the most important of the factors located by
the rst simulation run. There may be several pockets of possible trapped gas where the gas has
no escape path, and is surrounded by liquid metal at the end of ll. These locations could have gas
porosity and perhaps poor ll..
A product of the NADCA research efforts is a program called CastView, which is designed to
locate the last point to ll quickly. The program can run in minutes as opposed to the hours
needed by full blown commercial simulation software. It also can be run by anyone, and does not
need a trained simulation operator to use it.
The designer should determine if these last to ll points are at a location where overows and
vents can be relocated or added. If they are in areas where surface nish or porosity matters, then
possibly ow patterns with revised ingate locations can be changed and another simulation done.
If there are areas critical to surface nish requirements, then the area should be checked for
smooth ow conditions, for a very minimum amount of swirls, and particularly for any indication
of early metal ow mixing with late metal ow on the surface.
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81
Step 9 Simulation
If there is an area of concern about gas porosity, then the user should check for swirls or trapped
gas pockets in this area. There should be smooth metal ow through this area, and the pockets
should be in other locations. If the software is capable, this should include examining the internal
ow inside the casting.
The ow simulations may need to be changed and repeated several times for different gating
and process conditions to get the optimum gating situation. This will be similar to the same
trial and error method that used to be done on the die casting machine. However, it is just a lot
cheaper and faster on the computer. The information learned from simulation can be valuable, but
the user needs make sure the results are interpreted properly by someone familiar with die casting
and not just familiar with simulation.
If there is concern about shrink porosity, then an initial thermal analysis should be run. The
thermal analysis will be needed for oil and water cooling channel placement and can predict the
cold areas and the hot areas that may affect surface nish or shrink porosity. Most systems at this
time can not predict the results of applying intensied pressure during solidication as they were
designed for other casting processes not pressure casting. The user should have some experience
in die casting to interpret the results and be somewhat cautious with the simulators results.
Since simulators will predict the cold and the hot locations, this information can be effective in
placing water or hot oil lines. Die lube spray also removes heat but not all systems can account for
the effects of the spray. Many interations of the thermal simulation are done where the cooling
channels are moved, resized, and the coolant changed in order to optimize the design.
Once the gating system and the heating/cooling systems are optimized, then the die design can
be nalized and given to the die designer of tool maker so construction can start.
Computer are getting faster and software is getting cheaper and better. The days are coming
where simulation will be the standard method of verifying and optimizing gating designs.
References
1.
E.A. Herman, J. F. Wallace, Copper Alloy Pressure Die Casting, International Copper
Research Association, 1975
2.
E. A. Herman, Gating Die Casting Dies, Society of Die Casting Engineers, 1979
3.
E. A. Herman, Die Casting Dies, Designing, Society of Die Casting Engineers, 1979
4.
J. A. Wallace, Practical Application and the Results of Metal Flow and Gating Research, ,
1965
5.
Russ Van Rens ,Gating Design, NADCA, 1996
6.
W. Walkington, Seven Steps to Quality Gating Design, NADCA, 2001
7.
Derek Cocks, Fan and Tangent Gate Feed Design System , American Die Casting Institute,
1987
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Gating Manual
Step 9 Simulation
Gating MAnual
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Gating Manual

NORTH AMERICAN DIE CASTING ASSOCIATION

The Steps to a Good Gate Design

If desired do a PQ2 gating analysis.

Design the vent and overow system.

Step 1 Determine the Casting

Step 1 Determine the Casting

Casting Surface Finishing Specifications

Step 1 Determine the Casting

Step 1 Determine the Casting

Guidance for selections

Average (some minor cold ow

Middle to high end values of ll

Some minor lines and swirls are no

Good (no cold ow visible)

Middle values of ll time

Minimum swirls, minimum ow

Excellent (painting or plating

Shortest possible ll time

No swirls, no ow lines, even in

Internal quality or porosity considerations

Step 1 Determine the Casting

Step 2 Determine the Flow

Take the shortest distance across the cavity, and

Minimize diverging and converging ow paths.

Step 2 Determine the Flow Pattern and

The metal ow angle is shown in this gure.

Step 2 Determine the Flow Pattern and

Step 2 Determine the Flow Pattern and

Using cavity segments to develop FLow patterns and gate

Segments should be chosen by the following guidelines:

Step 2 Determine the Flow Pattern and

Gate Area for each

Step 2 Determine the Flow Pattern and

Flow pattern guidelines

Step 2 Determine the Flow Pattern and

Step 2 Determine the Flow Pattern and

Step 2 Determine the Flow Pattern and

Step 2 Determine the Flow Pattern and

Step 2 Determine the Flow Pattern and

Outgate, OverFLow, and Vent Locations

Step 3 Determine the Segment

Cavity Fill Time

Step 3 Determine the Segment Volumes, Cavity

Step 3 Determine the Segment Volumes, Cavity

From observation of the formula, cavity ll time is proportional to:

Step 3 Determine the Segment Volumes, Cavity

Step 3 Determine the Segment Volumes, Cavity

Metal Injection Temp

Min. Flow Temp. Die Cavity Temp.

Suggested Percent Solids S (use lower values for good nish)

Step 3 Determine the Segment Volumes, Cavity

Step 3 Determine the Segment Volumes, Cavity

Fill Times in Seconds

Step 4 Match the Process to

Process factors and limits

Required Fast Shot Velocity

Final Metal Pressure

Step 4 Match the Process to

Step 5 Determine the Ingate

Ingate Velocity Apparent Ingate

Segment Flow Rate

Normal Ingate Velocity (in/sec)

Step 5 Determine the Ingate Parameters