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Die Casting Calculation Guide

The document provides guidelines for calculating key parameters for die casting processes. It includes formulas to calculate the shot weight, gate velocity, fill rate, gate and runner dimensions, locking force, plunger diameter, die filling time, gate thickness, and the number of ejector pins required. Tables are also included that provide specific injection pressures, gate velocity ranges, metal and die temperatures, and gate thickness recommendations based on the alloy and wall thickness.

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54K views4 pages

Die Casting Calculation Guide

The document provides guidelines for calculating key parameters for die casting processes. It includes formulas to calculate the shot weight, gate velocity, fill rate, gate and runner dimensions, locking force, plunger diameter, die filling time, gate thickness, and the number of ejector pins required. Tables are also included that provide specific injection pressures, gate velocity ranges, metal and die temperatures, and gate thickness recommendations based on the alloy and wall thickness.

Uploaded by

prabhakarnttf
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd
  • Die Casting Calculations
  • Injection Parameters
  • Tables and Measurements
  • Ejection System

DIE CASTING CALCULATIONS

1. Wt of casting (gms)

2. Density(gms/cc): based on alloy used for casting. Al- 2.6 to 2.7; Zn- 7.8; Cu-9;

Mg- 1.7

3. Projected Area Casting : Surface Area (cm2)

4. Volume of Casting cm 3 : (Wt of Comp) / Density

5. Shot Weight = Wt of Casting + (Wt of Runner + Overflow) + Wt of Biscuits

Wt of Runner + Overflow – 10% of Wt of Casting

Wt of Biscuits – 20% of Wt of Casting

6. Gate Velocity (Vg) in m/sec (Refer Table 2)

7. Gate Thickness – Hg (mm) , Hg = n/3 – n/4 , n – thickness of casting

8. Volume of metal through gate : P (cm3)

. P = vol of casting + vol of overflow (10% of vol of casting)

9. Fill Rate (Q) cm3/sec

. Q = (P x 1000) / t ; t – fill time in milli sec’s

10. Gate area (Ag) (cm2)

. Ag = (Q) / (100 x Vg)

11. Gate Length – Lg (mm)

. Lg = ( Ag x 100 ) / Hg

12. Runner Area – Ar (cm2)

. Ar = 1.25 Ag – 1.6 Ag

13. 13 Runner Depth – D (mm)

D = (Ar / 1.6)(1/2) - (Ar / 2)(1/2)


14. Runner Width (W = 2D) (mm)

15. Locking Force – F (Metric Tonnes)

. F = ( A X P) / 1000

i. A – Projected Area (cm2)

ii. P – Specific injection pressure ( kg / cm2)

16. Machine Specification:- Select Machine based on the locking force.

17. Effective Plunger Stroke (cms) :– Maximum plunger stroke – 20/25 mm for

biscuits

18. Plunger Diameter – d (cm)

. Shot wt = Plunger Area x Eff. Plunger Stroke x 0.75 x 2.5 (gm)

. Shot wt = [ (Π X d2 ) / 4 ]x Eff. Plunger Stroke Plunger x 0.75 x 2.5 (gm)

. 4 x Shot wt = (Π X d2 ) x Eff. Plunger Stroke x 0.75 x 2.5 (gm)

. d2 = ( 4 x shot wt) / (Π X Eff. Plunger Stroke x 0.75 x 2.5)

. d= √ [ ( 4 x shot wt) / (Π X Eff. Plunger Stroke x 0.75 x 2.5) ]


TABLE I Specific Injection Pressure

Zn Al or Mg
Decorative Parts 100 – 200 200 – 400
Engineering Parts 200 – 300 400 – 600
Pressure Tight Parts 250 – 400 800 – 1000

TABLE II Gate Velocity Ranges

Thinnest Wall Thickness (mm) Gate Velocity Range (m/sec)


0 – 0.762 46 – 55
1.27 – 1.525 43 – 52
1.905 – 2.286 40 – 49
2.54 – 2.794 37 – 46
3.175 – 3.87 34 – 43
4.572 – 5.08 31 – 40
3.75 - Above 28 – 35
Use lower values for warmer dies and hot metals
Use higher values for colder dies and colder metals

TABLE III METAL & DIE TEMPERATURE

Alloy Metal Temperature Die Temperature


Zn Alloy 393 C (740 F) 393 C (740 F)
Mg Alloy 657 C (1215 F) 332 C (630 F)
Al Alloy 657 C (1215 F) 332 C (630 F)

Die Filling Time

For Zn, Al, Mg Alloys

Average Wall Thickness (mm) Max Die Filling Time (milli sec)
1 10 – 30
1.5 10 – 35
1.8 20 – 40
2.0 30 – 60
2.5 40 – 90
3 50 – 100
4 50 – 120
For higher values – fill time – 7ms for every 0.5mm wall thickness

For Brass

Average Wall Thickness (mm) Max Die Filling Time (milli sec)
1.5 20 – 25
1.75 25 – 30
2 25 – 35
2.5 30 – 40
3 35 – 45
4 40 – 50

Highest value apply for Al


Medium value apply for Zn
Lowest value apply for Mg

TABLE IV Gate Thickness

Wall Thickness (mm) Gate Thickness (mm)


Al Mg
0.75 – 1.5 0.5 – 0.8 0.5 – 0.6
1.5 – 2.5 0.8 – 1.25 0.6 – 0.85
2.5 – 4 1.25 – 1.6 0.85 – 1.35
Ejection System

Assuming ejecting area to be 4% of the area of the casting

Total Ejecting area = Projected area of Component X 4%

Area of selected Ejector Pin Diameter = A

Area of Ejector Pin = ( Π X A2 ) / 4

No of Ejector Pins Required = Total Ejection Area / Area of Ejection Pin

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