Die Casting Die Design Calculations

1) Tonnage
2) Tangential Force for Side Core
3) Plunger Diameter
4) Filling Time
5) Plunger Velocity
6) Gate and Runner Calculation
7) Ejection Force calculation
8) Die Cooling

Tonnage:

Locking force required = (AxP)/1000 Ton

A = Projected area of casting including runner and over flows in cm2

P = Cavity pressure (400-600 Kg/cm2 For Al and 200-300 Kg/cm2 for Zn alloys)

Tangential Force for Side Core:

Fc = tan A x P)
1000

A = Core Slide projected area in cm2

P = Cavity pressure (400 - 600 for Al, 200 - 300 for Zinc)
= Lock wedge angle

Plunger Diameter:

Plunger Diameter D= 4(Vc+Vr)

h

Vc = Volume of casting in cm3

Vr = Volume of runner in cm3
h = Sleeve length in cm (Sleeve length to be taken from m/c detail and Tool design)

Calculated plunger dia. is minimum value. Select the next size from m/c detail.
Filling Time:

Optimum Filling time To = C x (Tg-Tliq.) x W)

(Tg-Td) x Ac)

Tg = Metal temperature at gate - 640oC for Al. and 400oC for Zn.
T liq. = Liquidus temperature of alloy -580oC for Al. and 390oC for Zn.
Td = Average temperature of Die cavity -250oC for Al. and 180oC for Zn.
W = Weight of casting in gm
Ac = Area of casting in cm2
C = Constant -0.59 for Al and 0.28 for Zn

The optimum filling time 'To' to be considered only if it lies in between the recommended
range mentioned below.
Other wise take 0.04sec.

Average wall Thickness Cavity Filling time in sec.

1.5 0.01 - 0.03

1.8 0.02 - 0.04

2.0 0.02 - 0.06

2.3 0.03 - 0.07

2.5 0.04 - 0.09

3.0 0.05 - 0.10

3.8 0.05 - 0.12

5.0 0.06 - 0.20

6.4 0.08 - 0.30

Plunger Velocity:

V= (4Q)/ d2

d = Plunger Diameter in cm
Q = Cavity filling rate in cm3/sec
= Volume of Casting / Cavity Filling Time
Gate and Runner Calculation:

Method 1 (For Straight runners)

Gate area Agt = G .

(Y x To x W)

G = Wt. Of casting in gm. including

over flows and runner
Y = Density of alloy in gm/cm3
To = Optimum Filling time in Sec.
W = Gate velocity in cm/sec
(Refer Chart)

Runner Cross section area = 3 x Agt

Min. Wall Thickness any Gate Velocity ranges for Gate Velocity ranges for
where in the casting. Aluminum in cm/sec. Zinc in cm/sec.
0.76 4870 4000 - 5500
1.27 - 1.52 4700 - 4570 4300 - 5200
1.90 - 2.29 4420 - 4320 4000 - 4900
2.54 - 2.80 4260 - 4170 3700 - 4600
2.86 - 3.81 4170 - 3960 3400 - 4300
4.56 - 5.08 3800 - 3650 3100 - 4000
6.3 3350 2800 - 3500

Method 2 (Taper Tangential)

Runner Cross sectional area A = Q/Rv

Rv = Runner Velocity which varries in the

cross section as shown in the fig.

Rv at section A = 3000 cm/sec

Rv at section B = 4000 cm/sec
Rv at section C = 5000 cm/sec

Q Discharge = V/T
V = Volume of the casting in cm3
T = filling time in sec.
Ejection force:

Ef = (St x E x A x
ds2 _ ds2 x y
2t 4t

St = Thermal contraction of alloy across the circumference

Co-efficient of thermal expansion X Temperature difference between softening point
and ejection temperature X circumference of moulding surface (ds)
0.000024 X 450 X ds
E = Elastic modulus of alloy
688775.510 Kgf/cm2
A = Total contact area between alloy and ejection die faces in cm2
Coefficient of friction between alloy and steel
0.45
ds = Circumference of moulding surface in ejection die in cm
t = Thickness of moulding in cm
y = Poisson's ratio of alloy
0.34

Die Cooling:

Heat to be extracted from the die per hour

Qa = (M (Cp x (T1-T2))+L) Cal/hr.

M = Wt. Of alloy injected in to the die per hour

Cp = Specific heat capacity of alloy
0.219738 cal/gmoC.for Al. & 0.090761 cal/gmoC. for Zn.
T1 = Injection temperature of alloy oC
T2 = Die temperature in oC
L = Specific latent heat of fusion of alloy
88.888cal/gm for Al. & 23.888 cal/gm for Zn.
Weight of water to be circulated through the die per hour
Mw = Qa/(k x (T3-T4))

Qa = Heat to be extracted from the die

k = Constant to allow for heat transfer efficiency
T3 = Outlet temperature of water oC
T4 = Inlet temperature of water in oC

k = 0.64 for cooling holes made in core and cavity plates

0.50 for cooling holes made in back plates
0.10 for cooling using embedded copper pipes

Prefill stroke :-

Pst = (tst x D /4) + Vr Vl

(D/4)
Where,
Tst = Total available stroke (mm)
D = Short plunger diameter (mm)
Vr = Volume of runner system (mm)
Vl = Volume of ladled metal (mm)