DIE CASTING

DIE DESIGN
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Q1.How to Calculate machine tonnage require for HPDC Die
Casting Part?
Ans:-To Calculate machine tonnage for HPDC die casting part we
need to following three steps:
1. Die clamping force
2. Fill ratio (30-40%)
3. Mold size
DIE CLAMPING FORCE
Q. What is die clamping force?
Ans:-Die clamping force is the force applied to a
mold by clamping unit of HPDC die casting Clamping Unit
machine. The clamping force must be grater then
the separating force.
Which applied by the injection of molten metal
into the mold.
The clamping force >Separating Force
Q. How to calculate the Separating force(Opening Force)?
Ans:-Opening force is the force acting on the cavity to make the
die expand during the production of die casting part. The opening
force can be calculated by the following formula:
F=PXA
F:Opening Force
P:Speicific Injection Pressure
A: Total Projected Area
Q. Specific Injection Pressure?
Ans:-Molten metal is ladled through the shot Shot Hole
hole into the cold chamber and the shot
plunger pushes the metal into the die. The
pressure applied by plunger to push the
metal into the die is specific Injection Pressure.
Injection pressure use for Different Type of Casting:
1.For Standard Casting =600 kg/cm2
2.For Technical Casting=600-800 kg/cm2
3.For Pressure Testing Casting=800 kg/cm2
Q. Projected Area?
Ans:-Projected area is two dimensional area measurement of a three
dimensional object by projecting it’s shape on plane.
Total projected area=Casting Projected area + Slide Projected area +
Runner projected area + Overflow projected area

1 2
Example
✓Casting projected area=56000 mm2
✓Overflow + Runner Projected Area=22400 mm2(40% of total
casting projected area)
✓Slide Projected area=Projected area must be selected in the plane
that is normal to be direction of core travel x tanø
Angel of wedge = Angle of Finger cam angle + 2̊̊
Force FY= F X TanФ
Ф= Angel of wedge lock

wedge lock
Example:
✓ Slide Core 1 Projected Area=Area normal to direction of
travel x tanФ
=5000xTan20̊̊
=5000x0.36
=1800 mm2
✓ Slide Core 2 Projected Area=4500xTan20̊̊=1620mm2
So,
Total Projected Area=56000+22400+1800+1620mm2
=81820 mm2
Q. Separating force(Opening Force)?
Ans: (For Technical Casting=600-800 kg/cm2)
(800 Kg/cm2 =8kg/mm2)
Opening Force =Specific Pressure x Total Projected Area
=8 Kg/mm2 X 81820 mm2
=654560 kg/mm2(1 TON =1000Kg)
=654.56 T
Die clamping force
Ans The clamping force must be grater then the separating force.
Locking force require =FX1.2
=654.56X1.2
=785.472 Tons
We select the 900T machine
FILL RATIO
Q2.What is fill ratio, how it is important for selecting machine
tonnage?
Ans:- It is the percent of molten metal in the cold chamber compared
to the total volume of the cold chamber. Another way of saying it
would be the percentage of metal compared to the percentage of air
in the cold chamber
For example 50% full (of metal) = 50% air remaining
the percentage of fill is important because it is used to calculate the
optimum slow shot velocity. This can have a quality impact on the
casting.
Fill ratio (30-40%) is good for Automobile Die Casting Component
quality.
How to get fill ratio?
Fill Ratio =Shot Wt.
Sleeve Mass
Q How to get Shot Weight?
Ans: Shot Weight is Complete weight of shot in which casting , overflow,
runner, biscuit are included.
So,
Shot Weight= Casting Wt. + Overflow Wt. + Runner Wt. + Biscuit
For Example
Weight of the component = 2600 grams
Overflow Wt. + Runner Wt.=1040 grams (40% of Component Wt.)
Biscuit Wt. =𝜋𝒓2 ℎ
For Getting Biscuit Wt. we need to know what is plunger ø we are using.
For getting Plunger ø we need to follow Die Casting Machine manufacturers
catalogue.
ZDC-900TPSA
900T Die Casting Machine
Features
Locking force: 900Ton
Die height: 400-950mm
Tie bar distance: 930x930mm
Max. weight of shot: 9.2kgf
Max. casting area: 1276~916cm2
Horsepower required: 70KVA

Plunger
Tip
Diameter

Biscuit HT

We Select Med One Plunger Tip Diameter ø90

Biscuit Wt.
𝐷
Ans: Biscuit Wt. =Volume (𝜋𝑟 2 ℎ) X density 𝑟=
2
h=Biscuit HT
For Example is Normal Condition we consider biscuit thickens is 20mm
So , h=20mm
r=45mm
Density=2.75cm^3
Volume=127170mm^3
Biscuit Wt.=349717.5/1000g (1cm^3=1000mm^3)
=349.71g
Shot Weight= Casting Wt. + (Overflow Wt. + Runner Wt. )+ Biscuit
=2600+1040+349.71
=3989.71g
Q How to get Sleeve Mass?
Ans: Sleeve Mass=Plunger Area X Active Sleeve Length X Density
Plunger Diameter= ø90mm Plunger Tip Portrusion

Plunger Area = 𝜋𝑟 2
=6361.72mm^2

Plunger Tip Portrusion=350mm

Plunger Stroke=750mm

Plunger Stroke
Active Sleeve Length=(Plunger Stroke-Plunger Tip Protrusion)
+Sprue Bush-Cone HT
Sprue Bush Length =250.5mm
Diffuser Corn HT=12mm
Plunger Tip Portrusion=350mm
Plunger Stroke=750mm
Active Sleeve Length=
(Plunger Stroke-Plunger Tip Protrusion )+Sprue Bush-Cone HT
=(750-350)+250.5-12
=638.5mm
 Sleeve Volume = Plunger Area X Active Sleeve Length
= 6361.72 X 638.5
= 4061958.22mm^3
Sleeve Mass =(4061958.22x2.7)/1000
=10967.287gm
Fill Ratio % =Shot Wt. X 100
Sleeve Mass
=3989.71 x 100
10967.287
=0.36x100
=36.37 (30-40%)
So, Fill Ratio is 36.37%
MOLD SIZE
HPDC Die Casting Machine Pattern Drawing

Mold Height Clearance

Between Tie
Bar
Ejection St.
Tie Bar Dia
Mold Layout Clearance Between Tie Bar

Tie Bar

Clearance Between Tie Bar

Die Height
Note :
1.Mold and Cylinder Don’t lay to Tie Bar.
2.Mold height must be under between Min and Max die height of
HPDC Machine
What we Learn:
1.How to Calculate machine tonnage require for HPDC Die Casting Part?
2.What is die clamping force?
3.How to calculate the Separating force(Opening Force)?
4.Specific Injection Pressure?
5.Projected Area?
6.How to calculate the Separating force(Opening Force)?
7.What is fill ratio, how it is important for selecting machine tonnage?
8.How to get fill ratio?
9.How to get Shot Weight?
10.How to get Sleeve Mass?
11.Active Sleeve Length?
12.Read HPDC Die Casting Machine Pattern Drawing
13. Mold Layout
Please Comment your question in comment Section
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