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Die Casting Basics

Die is closed. Metal


is drawn in to tool
(plunger).
Tool injects metal
into cavity.
Cavity continues
to fill. (fractions
of a second)
Metal solidifies
under pressure.
Die is opened.
Casting removed.
Machine recovers to
initial orientation
(cycle starts over)
Properties: Pb-Sb vs. Zn-Al
L35
Pb-Sb Alloy
Zamak 3
Zn-Al Alloy
Density
( g/cm^3) at 21C
11.04 6.6
Solidification
shrinkage ( % )
3.36 1.17
Freezing
range ( C )
252-299 381 - 387
Specific heat capacity
( J/kg/C ) at 20 - 100 C
133.1 418.7
Thermal expansion
( um/m per C at 20-100 C)
27.8 27.4
Thermal conductivity
( cal/cm
2
/cm/ C/sec at 70-140C )
.073 .27
Viscosity (poise) .032 .01
Stage III:
Temperature Monitoring Overview
Nozzle temperature
Nozzle freezing

Die temperature
Thermal expansions

Holding pot temperature
Temperature gradients
Excess superheat

Results:
Injection Pressure
Monitor weight as a
function of pressure

Decreasing Pressure:
Reduces flashing
Decreases machine
errors

Weight variation for
each setting < 1%
*Tolerance (41.24 43.80g)
Pressure Dependency Analysis
Molten metal
leaking
through the
gap is called
flashing.
Assume the upper and lower mold pieces have opposing f aces which are perf ectly smooth, but
with a gap of thickness 10
3
m .. Consider if a Zn melt is pressurized to 3 10
5
Pa while
atmospheric pressure is 1 10
5
Pa . The viscosity of the Zn is 0.003 Pa s. Determine the steady
state volume flow rate through the mold gap if the circumference of the cylindrical mold is 6 m
and the distance f rom the inside of the mold to the outside of the mold is 0.2 m. Assume laminar
f low. Hint: think about f low between parallel plates.
Upper Mold
Lower Mold
Pressurized
Molten
Metal
Atmospheric
Pressure
Mold gap
VolumeFlowRat e
2
3
AP
L q
o
3
W
Solution : The volume f low rate is given by the average velocity multiplied by the cross section of
f low, which is the same as the velocity prof ile integrated over the gap thickness multiplied by the
width of the gap, W
VolumeFlowRat e
2
3
AP
L q
o
3
W
where o is the half thickness of the gap and W is the width (circumf erence in this case)
o 0.510
3
m := AP 2 10
5
Pa := q 0.003Pa s := W 6 m := L 0.2m :=
VolumeFlowRat e
2
3
AP
L q
o
3
W :=
VolumeFlowRat e 0.167
m
3
s
=
Upper Mold
Lower Mold
Pressurized
Molten Metal
Atmospheric
Pressure
Mold gap
L(t1) L(t2) L(t3) L(t4)
The above problem is concerned with steady state f low of molten metal through the mold gap.
Of greater interest is the time required for the molten alloy to reach the outside of the mold
af ter it is f irst injected into the mold. We can estimate that time by letting L be the distance
between the melt and the tip of the f low through the mold gap and assuming that the rate of
change of the of L is the average rate of f low between parallel plates. Note that this is an
approximate solution to this problem.
AverageFlowRat e
1
2 o
o
o
y
AP
2 L t ( ) q
o
2
y
2

( )
(
(
(
]
d

(
(
(
(

t
L t ( )
d
d
Af ter integration with respect to y
t
L t ( )
d
d
AP
3 L t ( ) q
o
2

Solving the diff erential equation by integration


0
L
L L t t ( ) ( )
(
(
]
d
AP
3 q
o
2

0
t
t 1
(
(
]
d
1
2
L
2

AP
3 q
o
2
t
The approximation that the
liquid:air interface velocity is
equal to the average velocity
of the steady stae profile was
introduced by E. W.
Washburn, Physical Review,
vol. 17, pp. 213-283, 1921.

1
2
L
2

AP
3 q
o
2
t
The solutions f or L f rom the Mathcad symbolic solver ('symbolics' on
the tool bar, then variable and then solve) are
1
3 q
6
1
2
q AP t
( )
1
2
o
1
3 q
6
1
2
q AP t
( )
1
2
o

(
(
(
(
(
(
(

Picking the positive one


L
1
3 q
6
1
2
q AP t
( )
1
2
o
t 0 0.001 , 0.01 .. :=
L t ( )
1
3 q
6
1
2
q AP t
( )
1
2
o :=
0 0.005 0.01
0
0.2
0.4
L t ( )
t
m
s
Looks like it will take about 0.005 seconds f or the molten metal to begin f lashing through
the mold wall gap given the parameters def ined above.

Air Fluid
Further discussion of the planar interface
approximation.
Flow profile is disturbed at the fluid air interface
Average velocity must be equal for incompressible fluid
Represent the surface tensions of a multi-phase junction as vectors drawn parallel to the respective surfaces
The surface energies for the for the solid/liquid, the solid/vapor and the liquid/vapor interfaces are sl, sv, lv
sl
sv
lv

The contact angle is a measure
of the magnitude of the solid
liquid interface energy compared
to the solid vapor and liquid
vapor energies.
Complications regarding the shape of the moving solid vapor interface.
Meniscus Formation
Youngs Equation
Represent the surface tensions of a multi-phase junction as vectors drawn parallel to the respective surfaces
The surface energies for the for the solid/liquid, the solid/vapor and the liquid/vapor interfaces are sl, sv, lv.
The vectors representing these surface energies must balance at the three phase triple junction. This equation
representing this balance is known as Youngs equation
sl
sv
lv

lv sl sv u ) cos( + =
sl
sv
lv

sl
sv
lv

Large sl, non-wetting
Large
Large sv, wetting
small
Liquid Vapor
Liquid
Vapor
Interface shapes for wetting and non-wetting contact angles

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