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AULUMINIUM PDC
PRESSURE DIE CASTING
1 INTRODUCTION OF DIE CASTING ALLOY
1. ALLUMIUM ALLOY
2. ZINC ALLOY
3. MAGNESIUM ALLOY
4. COPPER ALLOY
a. First class mechanical property in cast connotation (e.g.. Tensile
Strength,Ductility, Hardness.)
b. Dimensional Stability,
c. Good Merchantability
d. Suitable for Pressure tightness,
e. Low melting point,
f. Good Castability (fluidity),
g. Less & even Stirinkage,
h. Less oradition in molten Condition,
I. Corrosive Resistance ,
j. Ability to exellent finishing such as polishing , plating.
2. MECHANICAL & PHYSICAL PROPERTIES OF ALLUMIUM ALLOY HARDNESS

65 BHN TENSILE STRENGTH 22 KG/CM� MELTING POINT 595 � C

SOLIDIFICATION POINT 570 � C SHRINKAGE 0.6 % CASTING TEMPERATURE 640 � C TO 720 � C

SPECIFIC GRAVITY 2.72 Gms/cm�

3. INTRODUCTION TO DIE CASTING PARAMETERS
1. Casting pressure (or) intensifier pressure,
2. Specific casting pressure ( or ) Metal Pressure ,
3. Shot cylinder Pressure on Primary Side
4. Shot cylinder Pressure on Secondary Side
5. Nitrogen ( N2) Pressure ,
6. Pr.Pickuping at end of the die filing
7. First phase ( S1)
8. Casting filling stroke
9. Metal at gate
10. Shot sleeve with 100% metal filling
11. Casting time / Shot time
12. 3 rd phase built-up time
13. Die filling time in 2 ND phase
14. I St phase effective time .
15. 2 ND phase effective time
16. Biscuit tickles
17. Projected area of castings
18. Plunger diameter
19. Shot weight
20. Shot sleeve filling Ratio
21. Metal flow throe. Gate

22. Active length of shot sleeve

23. 1 St phase speed
24. 2 ND phase speed
25. Shot plunger speed
26. Metal velocity at gate
4. PRINICIPLES OF COLD CHAMBER DIE CASTING
Stroke curve Pressure curve 3 rd phase 2 ND phase 1 St phase 1 St PHASE
the metal is slowly brought upped the gate in accordance with shot volume &
produce 1 to 3 seconds.
2 ND PHASE The metal is rapidly injected into the die and filling the cavity in
accordance with
volume and produce 0.01 to 0. 6 seconds. 3 rd PHASE Consolidation of the
fluid metal in the
die under high pressure 400 to 1000 TONS in very shot time 0.01
to 0.2 seconds. According to gate thickness .
5. METAL PRESSURE 1 St PHASE
5 bar 2 ND PHASE 30 to 120 bar 3 rd PHASE 400 to 1000 bar
6. METAL SPEED 1 St PHASE
1 to 5 m/s 2 ND PHASE 20 to 60 m/s 3 rd PHASE 0 TECHNOLOGICAL CALCULATION
7. TRIAL OF NEW DIE S & SETTING OF PROCESS PARAMETERS OF NEW DIES.
1. Shot sleeve Dai
mm 2. Shot sleeve length mm 3. Projected area /

Casting area cm 4. Gate area mm2

5. Shot weight Gms. 6. After gate weight Gms
7. Types of casting a. Standard Parts
b. Technical Parts c. Pressure tight Points
8. CALCULATION UNITS 1. 2 ND Phase limit switch Position / Metal at gate

cm 2
. Filling Ratio % 3. Specific casting pressure bar
4. Shot speed. m/s
5. Injection Pressure bar
6. Die Opening Force Tones
7. Die Locking Force Tones
8. Slow approach mm
9. Metal at gate m/s
10. Metal Velocity at gate m/s
11. Cavity filling time m/s
12 . Specific pressure (in die) m/s
13 . Specific pressure (casting) bar
14. Casting area (or ) projected area cm2
9. HOW TO MAKE PROCESS PARAMETER CHART FOR NEW DIES.
1. Technical calculation to be done for new die.
a. Filling Ratio %

b. Metal at gate m/s

c. Specific Casting Pressure Kg/cm2
d. Injection pressure Kg/cm2
e. Die opening Force Ton.
2. To Check the die is properly pre - heated ( or ) Not.
3. To take practical Fill test of the casting in order to determine slow Phase
length.
4. To check if all over flows & air vents are provided ( or ) Not.
5. To check if all Water Cooling line are provided ( or ) Not.
6. To set slow phase valve & final phase valve minimum at starting of production
.
7. To check die locking Force is less than the die opening Force.
8. To make ok casting First a. By setting proper die solidification time T2
b. By proper valve setting
c. By proper lubrication method
d. To check the over flow and airvents
e. To check the I.D. of shot sleeve
f. To eliminate jamming of piston in sleeve
g. To check matching of spur bush & shot sleeve
h. To check cycle time
I. To check stroke length
j. To record a sample of 50 nose casting to proper Quality.
k. To make a process parameter chart
a. By recording die tempter layout .
b. Water cooling record.
c. Blue matching of die record.
d. Hydraulic circuit of diagram. REMARKS : If with all the above parameters set
flash still exists, then strain gauge measurement to check stern on die
bars is required .
10. PRESSURE DIE CASTING VARIABLES In pressure die casting production process many
variables affect the quilt of casting . If is very important to check and
monitor these variable regularly in production process. in pressure die casting
pressure & temperature is main two variables. TYPES OF VARIABLES 1. PRESSURE
VARIABLE A. Pump pressure B. Nitrogen gas pressure C. Injection
pressure D. Accumulator charging pressure 2. TEMPERATURE VARIABLES A. Die
temperature B. Metal temperature C. Hydraulic oil temperature 3. PROCESS
VARIABLES A. Plunger Speed B. Die Flashing C. Metal Variation Problem
D. Cycle time. 1. PRESSURE VARIABLE A. Pump pressure: Pump pressure should be as
per M/C. Specification. e.g.. For HMT Machine = 150 Kg/cm2
For BULLER Machine = 160 Kg/cm2 REMARKS : Whenever Pump Pressure drops ,

Accumulator Charging Pressure drops , Die locking Pressure drops, Fast Shot
injecting drops, Die Flashing. B. Nitrogen gas pressure: N2 Pressure Should be set
as per Machine Specification. e.g.. For HMT Machine = 110
Kg/cm2 For BULLER Machine = 124 Kg/cm2 In case of HMT
Machine N2gas Pressure is 0.73 % of Pump Pressure. REMARKS :
Whenever N2 gas Pressure drops Accumulator Charging Pressure drops , Second
Phase Speed drops, C. Injection pressure Injection Pressure to be set as per
castings requirement . e.g.. For Standard Part injection pressure low
Pressure tight part injection pressure high REMARKS :
In case internal pressure drops Castings unfailing problems,
Blow holes problems, Shrinkage problems . D. Accumulator charging pressure
Accumulator pressure should be charged upped Pump pressure. e.g.. For
HMT Machine = 150 Kg/cm2 REMARKS : Whenever Accumulator charging
pressure drops , Second Phase Speed ( Fast Shot ) drops
Castings unfailing problems, Blow holes problems, 2. TEMPERATURE VARIABLES A. Die
temperature In Pressure die casting die temperature should be bet range of
180�C to 250�C REMARKS : in case of low die temperature . Affects quality due to
cold defects anon filling, b. cold shut, c. shrinkage, d. flow marks, in case of
high die temperature . Affects quality due to cold defects
a. Flashing, bimetal soldering,
c. crack, d. breaking, e. casting bend. B. METAL TEMPERATURES In pressure die
casting of aluminum alloy metal temperature. Is 640 to 680 e.g.. For thick
casting metal temperature = 640� C ~ 680�C For thin casting metal
temperature = 660�C ~ 680� C REMARKS :
Whenever Metal temperature is low Unveil the casting
cold shut problem Whenever Metal temperature is high

Die flashing Metal soldering on die crack casting bend casting breaking C.
HYDRALLIC OIL TEMPERATURS. Hydraulic oil temperature of pressure die casting
m/c is bet range 30 to 50 whenever metal temperature high, High pressure drops,
Internal pressure drops, oil leakage problem from m/c hydraulic oil seals. Second
phase (fast shot) jerking problem. 3. PROCESS VARIABLES A. Plunger Speed: During
pressure die casting process . Plunger speed to each shot should be variation in
plunger speed affects the quality of casting . RERASONS OF CHANGING PLUNGER SPEED
a. Friction bet, shot sleeve, shot piston. b. Variation of metal pouring temp. c.
Variation of accumulator charging pressure. d. Misalignment of shot end with shot
sleeve. e. Misalignment of shot sleeve & spur bush. B. Die Flashing While
production process die flashing affects quality of casting. To avid die flashing
following reason to be checked. RERASONS OF DIE FLASHING . a. Variation in die rod
reading strain measurement to be done. b. Misalignment of die parting line. c. Core
misalignment. d. High metal temp. e. High plunger speed. f. High injection
pressure. C. Metal Variation Problem Variation of shot weight results variation in
casting quality shot weight toe adjusted . Biscuit thickness
should be bet 20 to 50 mm. 1. Due to less shot weight : Casting unveil
problem,shrinkage problem. 2. Due to more shot weight : 2 ND phase speed not
reader as per requirement . : Riser breaking problem, :
Fixed die side clamping breaking problem, : Melting loss increases. D.
Cycle time.( t sec. ) During production process cycle time of each cycle should be
same variation in cycle time affects quality of casting & production. For
achieving same cycle time automation is veryimportent factor . Automatic machine's
with auto extractor & Auto folder giving same cycle time result low rejection . But
failure in automation result high rejection .Than manual operation machine . Incase
of semiautomatic & manual machine operation 's skill is very important factor for
achievement of good quality & good quantify. Skilled operator's cycle time &
lubrication time is very important with die temperature & metal temperature .
REASON FOR CYCLE BREAKING PROBLEM . 1. Machine tripping problem, 2. Die flashing
problem, 3. Hydraulic core jamming, 4. Casting breaking in die , 5. Runner breaking
.Due to auto ladle metal variation, 6. Flash entering in core slide pockets, 7.
Faulty limit switch of core. 8. Piston jamming in shot sleeve, 9. Low metal level &
low metal emperor, 10. Unskilled operator. For achieving good quality of casting
die should be run continuous without any break. When number of breaks reduces
automatically production increases. 11. QUALITY PROBLEMS OF CASTINGS DURING
PRODUCTION PROCESS TYPES OF PROBLEM 1.CASTING UNFILL, 2. POROSITY, 3. SOLDERING, 4.
CRACKS, 5. BEND, 6. BLISTERS, 7. SHRINKAGE, 8. FLASH, 9. COLD LAPS (OR) FLOW
LINES, 10. INCLUSIONS. 1.CASTING UNFILL CAUSES : a. Plunger speed too slow, b. N2
pressure is tool, c. Excessive lubrication, d. Metal temperature too low, e. Die
temperature too low, f. Venting problems g. inadigualer gating h. Excessive gating.
ACTION. a. Maintain the correct plunger speed . b. N2 pressure to be checked . c.
Add overflows & air vents to unveil area . d. Use corrupt amount & concentration of
lubrication . e. Metal temperature to be checked . f. To check for excessive die
cooling & lubrication . g. Add gating to weak area if problem is changed . h. Black
gate individually one by one & check its requirements . 2. POROSITY, CAUSES : a.
Form of nonfood b. Entrapped air and gases . c. Shrinkage . ACTION. a. Check
suggested action of casting unveil . b. Improve die venting by adding overflows .
c. 1. Add gate to problem area 2. Use hydraulic pressure intensifier . 3.
Put spot rehire in back of problem area . 4. Improve feeding in problem area by
increasing wall thickness ( or ) adding ribs . 3. SOLDERING, CAUSES : 1. Gate
impingement . 2. Excessive plunger speed . 3. Low iron content in alloy . 4. Hot
spots in die . 5. Low metal velocity in dead area of casting . 6. Short comings of
die material . 7. Thick casting sections . 8. Ineffective die lubricant . ACTION.
1. Gates should be located go as to avoid direct impingement on either core ( or )
die surface . 2. If high plunger speed are required to fill casting .Consider more
gates. 3. Increase iron content upped 1.10% may be necessary . 4.a. Make contain
water lines are functioning properly . b. Increase die cooling consider the
addition of spot chiller . 5. Add gates & close the area to proved washing
action on die surface . 6. Substitute molybdenum for H.B.for FEASIBLE
especially core . 7. Core out excess metal . 8. Use silicone containing die
lubrications . DURING PRODUCTION PROCESS 1. Water cooling . 2. Die lubrication .
3. Iron percentage . 4. Plunger speed . Above 4 points to be checked first . 4.
CRACKS, CAUSES : 1. Contraction stresses . 2. Hot spots . 3. Improper ejection . 4.
Off composition metal high iron ACTION. A.1. If creaks are occurring in sharp
coiners increase the fillet radios . 2. Reduce solidification time . 3.
Increase die temperature in problem area by adding overflows & reducing die
cooling . 4. Use alloy which is more ductile . B. 1. Increase die cooling in
critical area 2. Use alloy which is less hot sports . C. 1.Check the ejector
pins broken or Not . 2. Check the ejector rods broken or Not . 3. Check the
rods are equal length . 4. Remove undercut if present . D. Analyze metal boil
if is necessary . 5. BEND, CAUSES : 1. Solidification time is too short . 2.
Ejector force is too high . 3. Undercuts if any . ACTION. 1. Check correct
solidification time . 2. Ejector force & speed to be reduced . 3. Undercuts to be
removed . 6. BLISTERS, CAUSES : 1. Entrapped air (or) gases . 2. Injection pressure
is too high . 3. Injection velocity is too low . 4. Die is too hot . 5.
Insufficient die venting . 6. Metal is too hot . ACTION. 1. Air venting to be
improve . 2. Donut use pressure intensifier . 3. Injection velocity is too
increased . 4. Die temperature to be controlled by cooling . 5. Die air venting to
be added . 6. Metal temperature to be checked . 7. SHRINKAGE, CAUSES : 1. Injection
pressure is too low . 2. Injection velocity is too fast . 3. Die is too cold . 4.
Insufficient die venting ( clogged ) ACTION. 1. Injection pressure to be set . 2.
Injection velocity to be reduced . 3. Die temperature to be maintain above 200�C .
8. FLASH, CAUSES : 1. Injection pressure is too high . 2. Locking force is too
low . 3. Poor die matching . 4. Poor core matching . 5. High temperature of metal .
6. Injection velocity is too high . ACTION. 1. Injection pressure to be checked .
2. Die locking force & pump pressure to be checked . 3. Blue matching to be done
4. Core matching to be done . 5. Metal temperature to be checked . 6. Injection
velocity to be adjusted . 9. COLD LAPS (OR) FLOW LINES, CAUSES : 1. Injection
velocity is too low . 2. Die temperature is too low . 3. Metal temperature is too
low . 4. Excessive die lubrication . ACTION. 1. Injection velocity to be checked .
2. Die temperature to be checked & increased . 3. Metal temperature to be increased
. 4. Die lubrication to be checked . 10. INCLUSIONS. CAUSES : 1. Metal is
contaminated . 2. Die lubrication . 3. Plunger lubrication . ACTION. 1. Analyze
metal . 2. Analyze lubrication . 3. To checked plunger lube - in entering in die
cavity . DIE - SPRAYING TECHNIQUE TYPES OF SPRAYING A. Parting effect , B.
Lubrication , C. Cooling , A. Parting effect , Before the first shot a new die
is always burned with a suitable LPG gas . In this manner a thin axed is foamed
on the surface of the die steel . But this axed is already worm off with the first
shot . Therefore it is necessary to apply a parting agent for production before
every shot. B. Lubrication , Ignored to attain perfect releasing of the casting
's also there must be thin lubrication film on the surface of the die
cavity . Good lubrication is also responsible for correct functioning of the
ejector & core . C. Cooling , Die casting dies have been provided with a poor
water cooling system ( or ) some thin core can only be cooling by spraying only .
DIE - TEMPERATURE , DIE - HEATING AND DIE COOLING With every shot the cooling
amounts of heat energy's feel

Ignored to attain an ideal die temperature heat every has toe dissipated again
as under . 1. Plunger cooling with water , 2. Filling sleeve cooling near spurebush
, 3. Spreader ( diffuser ) cooling , 4. Die cooling , 5. Gate & runner cooling , 6.
Transfer of heat to air , 7. Heat transfer to both platoons , 8. Spraying ,
Above all factors together maintain die temperature constant by extracting heat
energy at every stages .
Low die temperature for
Thick walled casting High die temperature for Thin walled casting . DIE CASTING
ENGINEER DURING PRODUCTION PROCESS FOLLING ITEMS 1. MACHINE PARAMETER'S 2. DIE
PARAMETER'S , 3. AUTO - LADDLES SETTING , 4. HOLDING FURNACS , 5. AUTO -
EXTUCTERS . 6. QUALITY OF CASTING , 7. DIE CASTING MACHINE , 1. MACHINE
PARAMETER'S Before starting production . Process parameter's to be set as
per - Process parameter's 1. Slow phase time & length , 2. Slow phase value , 3.
2 nd phase speed value 4. Injection pressure , 5. Nitrogen pressure , 6.
Accumulater charging pressure , 7. High & low pressure , 8. Tie rod reading /
Die locking , 9. Casting solidification time , 10. Plunger return time , 11.
Ejector returen time , 12. Ejector forward time , 13. Die locking speed , 2. DIE
PARAMETER'S , 1. Lubrication of die checked, 2. Lubrication of piston checked, 3.
Water cooling of die checked, 4. Water cooling of piston checked , 5. Die
temperature checked , 6. Die locking checked, 7. Oil leakage's of core checked, 8.
Oil leakage's of hyd. Connection pipe checked 9. Moving & Fixted clamping checked
10 . Core pull cylinder mounting bracket bolt's to be checked , 11. Die parting
line & core matching to be checked , 12. Ejector rod must be checked, 13. All core
pin's to be checked , 14. Ejector pin's to be checked , 15. Spur bush position to
be checked , 16. Plunger rod & Tip to be checked, 3. AUTO - LADDLES SETTING , 1.
Dipper size & leakage to be checked , 2. Auto ladle timer to be checked, 3. Shot
weight to be checked, 4. Metal variation to be checked , 5. Auto ladle speed to be
checked , 6. Metal swillage while pome pouring to be checked , 7. Senser wire to be
checked, 8. Metal swillage bet the path to be checked , 4. HOLDING FURNACS , 1.
Set temperature & Auctual temperature to be checked , 2. Pilot & Automatic setting
to be checked ( electrically ) , 3. Pilot & Automatic setting of gas & air value to
be checked , 4. Metal level & Metal temperature to be checked , 5. Temperature
control ,Metal & Thermocuple working to be checked , 5. AUTO - EXTUCTERS . 1.
Clamping systems , Spraying unit , Air blow system to be checked , 2. Forward &
Return swing speed to be checked , 3. Senser unit to be checked , 6. QUALITY OF
CASTING , During production die casting engineer's should be watch on quality
of casting required on each machine .Quality to be checked counder . 1. Surface
finish , Surface defecs as coldshot ,Unveil , Lubrication marks , ( or ) Flow marks
. 2. Ejector pin's to be checked whenever pin depression /projection in the
casting came to be required as per QAD'S requirments . 3. Core pin to be checked
whenever core pin broken to be replace ,when core pin bend to be straighen ( or )
replace . 4. Die flashing in core of die flashing metal flash exeist around parting
line of casting . Same to be corrected by blue matching , core matching ,Strain
maesurment matching and die locking . 5. Casting Dimension to be checked as per
QAD'S requrment . 6. Blow holes checked cto be done by cutting casting (or Xrace .
7. Core shifting ,core tilt .core depression , core remains back in casting to be
checked and corrected with the help of die maintance deptrment . 7. DIE CASTING
MACHINE , 1. Oil leakage ,oil temperature , oil level to be checked , 2.
Foundation bolts , shot end vibration to be checked , 3. N2 gas leakage to be
checked , 4. Both pattan water cooling to be checked , 5. Tie bar nuts , Locking
nuts to be checked , 6. Moving patten sliding shoe fitting to be checked , 7.
Machine lubration to be checked , 8. Heat exchanger working to be checked , 9. Tie
bar cleanliness to be checked , 10. Water pump & Cooling tower working to be
checked , 11. Abnormal noise to be checked , 12. Fixed & Moving patten tilting
during locking to be checked , 1.DIE FLASHING PROBLEMS
DIE - PROBLEMS MACHINE - PROBLEMS PROCESS - PROBLEMS 2. CORE JAMMING PROBLEMS
DIE - PROBLEMS PROCESS - PROBLMS 3. DIE NOT FORWARDING PROBLEMS
ELECTRICAL - PROBLEMS PROCESS - PROBLEMS 4. FAST SHOT NOT WORKING /
SPEED DROPPED & JERKING
PROCESS - PROBLEMS MACHINE - PROBLEMS PROCESS - PROBLEMS CAUSE AND EFFECT
DIAGRAM - BLOW HOLES
IMPROPER LOW PUMP SPRAYING PRESSURE POOR
DYCOTE N2 PRESSURE RATIO LOW WRONG S1 SETTING
MACHINE STOPPAGES POOR GATING LOW METAL TEMPERATURE
LOW DIE TEMPERATURE POOR DEGASING AIR VENT ALLOY MIXUP
BLOCK DIE CASTING METROLOGY FONDAMENTALS A. SHOT SPEED The injection time can be
measured by setting two points and the shot speed can be calculated to the
formula Shot speed = Measuring distance ( mm )

injection time ( ms ) shot time stop of shot time Measuring

distance start of shot time pressure Time B. SPECIFIC CASTING PRESSURE The
Hydraulic pressure in the shot cylinder is measured with the measurement .
2 Specific casting pr. = Injection pressure x Shot cylinder dia Plunger dia
Moving die
Fixted die Shot cylinder dia � 130 mm Casting area Plunger tip Dia Plunger Rod
Casting pressurer 2. MEASURING AND CALCULATION 1. Shot speed 2. Specific
casting pressure 3. Injection pressure 4. Die opening force 5. Filling Ratio 6.
Slow approach 7. Cavity filling time 8. Gate velocity 9. Plunger speed 1. SHOT
SPEED
STROKE PRESSURE
Shot time 40 ms Shot time Stop 80% Measuring distance Shot time Start
60% Stroke Pressure TIME EXAMPLE 1. Total plunger stroke
= 400 mm 2. Shot time = 40 m/s 3.
Start of shot time(of 400 mm total stroke) = 60 x 400 = 24000 = 240 mm

100 100 4. Stop of shot time (of 400 mm total stroke) = 80 x 400 = 3200 =
320 mm

100 100 5. Measuring distance = 80% ~ 60 =

20 % ** ( of 400 mm total stroke ) = 20 x 400 = 80 mm

100
SOLUTION Shot speed = Measuring distance m/s
Shot time = 80 / 40 = 2 m/s
= 2 m/s

2. INJECTION PRESSURE Measured with graph - Injection pressure 6 cm Scale =

1 cm = 40 bar SOLUTION Injection pressure = Measured distance x Scale
= 6 x 40 bar = 240 bar

3. SPECIFIC CASTING PRESSURE 2 Specific casting pressure = Injection pressure

x Dia of shot sleeve

Dia of
plunger tip = 240 x 130 / 65
= 240 x 2*2 = 240 x 4
= 960 bar
SPECIFIC CASTING PRESSURE ( BAR ) PARTS ALUM. ZINC. MAGNES. BRASS Standard parts
200 ~ 400 100 ~ 200 200 ~ 400 300 ~ 400 Technical parts 400 ~ 600 200 ~
300 400 ~ 600 400 ~ 500 Pressure tight parts 800 ~ 1000 250 ~ 400 800 ~
1000 800 ~ 1000 4. DIE OPENING FORCE Projected area = 200 cm Specific casting
pr. = 960 bar DIE OPENING FORCE = Die area x Specific casting pressure
= 200 x 960 = 192000 Kn = 192 Tons

5. FILLING RATIO ( % ) One of the main problems in die casting is the

expulsion of air during the extremely shot filling time . Consequently on
horizontal cold chamber machine the highest possibile. Filling ratio will be
between 60 ~ 80 % according to the size of the filling sleeve .

CCV CC N40 FILLING RATIO % = Shot weight / 2.7 740.740741 841.8519

3.14 *r 2 * h 3730.32 3014.4 0.19857298 0.279277 19.8572975 27.92768 Where
= 3.14 r = Radious of plunger tip in mm
h = Storke length in mm Example FILLING RATIO = 550/2.7
X 100
3.14*2.5*2.5*27.5
= 203.70 X 100
539.68 = 0.3774 X 100 = 37.74 %
6. SLOW APPROACH The slow approach represents the first section of the plunger
movement . The plunger moves forward pushing the liquid ahead until reaches the
end of the runner .

Plunger tip dia � 80 mm Filling ratio 40 % Shot volume 60 %

2 3 1 Fig . 1 FILLING RATIO Fig. 2 SLOW APPROACH Where 1. Length of pressure
chamber = 400 mm 2. Cylinder metal length = 160 mm 3. Slow
approach = 240 mm 4. Plunger tip dia
= � 80 mm SOLUTION 1. Plunger area = Length of filling sleeve
Plunger diameter
= 450 / 80 mm = 5 mm
= 50 cm

Shot volume = 800 cm 3

2. Volume of pressure chamber = plunger area x sleeve length

= 50 x 40 = 2000 cm 3

3. Filling ratio = shot volume / volume of pressure chambre x 100

= 800 / 2000 x 100 = 0.4 x 100
= 40 %

4. Cylindrcal metal length = shot volume / plunger area

= 800 / 50 = 16 cm
= 160 mm

5. Slow approach S1 = Length of pressure chamber - Cylindcal metal

length = 400 - 160 mm
= 240 mm

GATING TECHNIQUE 1. Cavity filling a. Free jet flow filling b. Mass filling c.
Combination of free jet flow & mass flow 2. Cavity filling time WALL THICKNESS
( MM) CAVITY FILLING TIME ( ms ) 1.50 0.010 ~ 0.030 1.80 0.020 ~ 0.040.
2.00 0.020 ~ 0.060 2.30 0.030 ~ 0.070 2.50 0.040 ~ 0.090 3.00 0.050 ~ 0.100
3.80 0.050 ~ 0.120 5.00 0.060 ~ 0.200 6.40 0.080 ~ 0.300 3. Gate
velocity ALLOY m/sec ZINC 30 ~ 50 ALUMINIUM 20 ~ 60 MAGNESIUM 40 ~ 90
BRASS 20 ~ 50 4. Gating formulas 1. D = a x b Where
a + b
a = Gate length in mm b = Gate thickness in mm
2. Fa = Va
Where Tg x Wa Fa = Cross section of gate Va = Volume
of metal flow through gate Tg = Casting time ( or ) cavity filling time Wa =
Gate velocity 3. Fa = 0.18 x G Where Fa = Cross section of gate
( mm2) G = Weight of casting (with overflow) SPECIFICATION REMARKS UNITS DC -
60 DC - 120 H 160 D H - 250D H - 400D LOCKING FORCE TONS 60 120 160 250 400
INJECTION FORCE WITH INTENCIFICATION PRESSURE TONS 10 13 20 35 38.5 HYD. EJECTOR
FORCE TONS 4 6 10 15 22 DIE MOUNTING PLATE H X V MM 500 X 500 555 X 600 680 X
690 800 X 850 920 X 980 SPACE BETWEEN DIE TAR MM 320 X 320 380 X 410 430 X 450 500
X 500 920 X 980 TIE BAR DIAMETER MM 60 65 80 100 120 MAX. DIE HEIGHT MM 400 450 600
750 750 MIN. DIE HEIGHT MM 150 150 200 225 200 DIE OPENING STORKS MM 250 375 350
500 600 INJECTION PLUNGER STORKS MM 250 275 300 350 400 EJECTOR STORKS ADJUSTED MM
50 65 80 100 145 FREE CYCLE TIME SEC 3 3.2 3.2 5.5 7 MOTOR CAPACITY
( 18.4 KW ) KW 5.5 11 18.6 22.4 22.4 MACHINE WEIGHT TONS 3.6 4 5 10 12.5 CAPACITY
OF OIL TANK LIT. 300 350 470 550 550 PRODUCTION DATA PLUNGER DIAMETER
MM 40 50 60 70 80 SHOTCAPACITY FOR ALUMINIUM Kg 0.7 1.1 1.6 2.1 2.7 MAX. INJECTION
PRESSURE Kg / cm2 1600 1020 710 520 400 NORMS OF CASTING AREA AT ABOVE INJECTION
FORCE Cm2 100 157 225 308 400 QUALITY SYSTEM IN DIE CASTING
Factor are
1
Degasting of the molten metal , 2 Fluxing of the molten metal , 3 Lubrication
of shot sleeve , 4 Lubrication of die Surface 5 Chamfer Temperature of Furnaces
( � ) 6 Die Casting Machine Pump Pressure , ( Kg/cm� ) 7 Nitrogen Pressure ,
( Kg/cm� ) 8 Accumulator Pressure , ( Kg/cm� )
9
Opening of low speed injection Valve , ( Turns ) 10 Position of high speed
Limit Switch , ( MM )
11
Opening of high speed injection Valve ,( Turns ) 12 Opening of intensifier
Valve , ( Turns ) 13 Die opening time in the timer ( t2 ) 1 . Degasting of
the molten metal , This Process is done by using a degasting agent
namely DEGASOR - 190 in the tablet from Manufactured by M/S . GREAVES ,
FOSECO . 100 Kg of metal 200 gms ( 0.20 % ) tablets for a full pot of
molten metal is used . 2 . Fluxing of the molten metal , This
Process is done by using a Fulexing Powder Called COVERAL - 11 Manufactured
by M/S . GREAVES , FOSECO . 100 Kg of metal 500 gms/ 600 gms ( 0.50 % to
0.6 % ) Powder ( approx ) used for fluxing a full pot of molten metal is used
. 3 . Lubrication of shot sleeve , This Process is done by using
Lubrication oil called LUBIX - 33 Manufactured by M/S . GREAVES , FOSECO .
The lubrication is applied by using a wooden brush covered with bunion
cloth . 4 . Lubrication of die Surface This Process is done by using
Lubrication called DYCOT DR -635 Manufactured by M/S . GREAVES , FOSECO .
This liquid is diluted with water and being used for production. . air is
used through spary gun for sparying the solution on the die surface .
5 . Chamfer Temperature of Furnaces ( � ) The melting point of
Aluminium alloy ADC - 12 is 650� C . To attain this Temperature inside the
Crucible . The Chamber temperature is Fixed as 825 �C � 25�C for Holding
Furnace . 6 . Die Casting Machine Pump Pressure , ( Kg/cm� ) As the
manufacturer of die casting machine recommended 150 Kg / cm � as Max . Pump
Pressure of hydraulic Pump for safer Working condition . We fixed the Pump
Pressure as condition . The tolerance is fixted as 10 Kg/cm� . The max. Pump
150 Kg/cm� . 7 . Nitrogen Pressure , ( Kg/cm� ) The max. Nitrogen
Preassure recommended by the manufacturer is 130 Kg/cm� . But for safe
running conditions we fixed 120 Kg/cm� . 8 . Accumulator Pressure ,
( Kg/cm� ) Since the max. Pump Pressure is set as 150 Kg/cm� the
accumulator Pressure is set as 140 Kg/cm� and tolerance is fixed as 140 Kg/cm� -
10 Kg/cm� . The Variable Parameters are , 9 . Opening of low speed injection
Valve , ( Turns ) This speed is used to inject the molten metal upto
the mouth of the gate area of the die . This Parameter is fixed by experience to
actieve the approximate Plunger velocity 0.1 m/s to 0.3 m/s. 10 . Position of
high speed Limit Switch , ( MM ) The limit switch intiates the
starting time of the high injection the following Calculation S1 = L2 - L1 Where
S1 = Position of limit switch to start high speed injection . L2 = Stroke
length of plunger L1 = Volume of the molten metal into the die area of cross
section of the plunger used .
L1 = 11 . Opening of high speed injection Valve , ( Turns ) This
Parameter control the rate of flow of the molten metal into the die .This Parameter
is achieved from the graph supplied by the manufacturer of the machine relating
plunger velocity and opening of high speed injection valve .

Plunger velocity ( V ) = Where V = Volume of the molten metal injection into

the gate , A = Area of cross section of the plunger , T = Filling time of
the molten metal 12 . Opening of intensifier Valve , ( Turns )
This Parameter ensures the soundness of the casting and porosity of the casting .
The intensifier valve is to be opened upto the required intensifier pressure
achieved . The intensifier pressure is selected from the graph relnting specific
pressure on the die 13 . Die opening time in the timer ( t2 )
This is the time to allow the molten injection into the die to soldifiy . This time
is fixed base. on selling Parameter range for opening time successfully . BASIC
CALCULATION 1. 2 nd PHASE POSITION ( S1 ) =L2 - L1 Where L1 = Shot
weight / chamber length in ( mm ) L2 = Stork length in ( mm ) 2. FILLING RATIO
( % ) = Shot weigth / spec.gravity of allum. X 100
chamber area
3. SPECIFIC CASTING PRESSURE = Injection force / plunger surface ( or )
area p = f / s 4. CASTING AREA
= Locking force / specific pressure cm 2 A = F / P 5.
SPECIFIC PRESSURE ( MAX. ) = Locking force / Casting area
P = F / A Where F = Locking force in tons A = Casting area ( or ) Projected
area in cm2 P = Specific pressure in Kg / cm2 S = Plunger surface ( or ) area
cm 2 6. SHOT CAPACITY = Pl. area x Pl. storke x 75% of filling
ratio x 2.7 7. DIE OPENING FORCE = Casting area x Specific casting
pressure 8. DIE LOCKING FORCE = Die opening force x 1.1 9. SHOT VOLUME
= 3.14 X r2 x h Where r = Radious of plunger tip h = storke length of sleeve
calculation SHOT WEIGHT 310 gms sw CASTING WEIGHT 110 gms cw AFTER GATE WEIGHT 130
gms gw RUNNER WEIGHT 180 gms rw OVER FLOW WEIGHT 20 gms ow STROKE LENGTH 290 mm l2
PLUNGER TIP DIAMETER 40 mm d MACHINE 160 ton t CAVITY 1 nos. GATE AREA 60 sq.mm a
L1 91.41 mm 2nd PHASE POSITION (S2) 198.59 mm FILLING RATIO 31.52 % SPECIFIC
PRESSURE IN DIE KH.HOUSING DATA 1.Shot weight s.w =
310 Gms 2.Casting weight c.w = 110 Gms 3. After gate
weight = 130 Gms 4. Runner weight
= 180 Gms 5. Over flow weight = 20 Gms 6. Plunger
tip size d = 40 mm 7. Storke length
L2 = 290 mm 8. Machine M = 160 Tone 9.
No. Of Cavity = Single 10. Gate (thick&length)
=

11.Specific gravity of alum. a = 2.7 SOLUTION 1. 1st PHASE MOVEMENT

( OR ) 2nd PHASE STARTING (S1) mm S1 = L2 - L1 Where
S1 = L2 - L1 L1 = cm S1 = 29 - 7.14 cm S1 = 210 � 5
cm L1 = L1 = L1 =
L1 = 7.14 cm 2. FILLING RATIO ( % )
F = CCL N14 407.407407 1055.556 F = X100 904.32 3179.25 0.45051244

0.332014 F = X100 45.0512437 F = X100 F = 0.3152 X

100 F = 31.52 % 3. SPECIFIC CASTING PRESSURE ( IN DIE ) Kg/cm�

P = P = Kg/cm� P = Kg/cm� P = 1592

Kg/cm� 4. CASTING AREA ( OR ) PROJECTED AREA ( cm� )

A = cm� A = cm� A = 100.5 cm� ACTUAL CASTING AREA ( cm� )

1.Circle area a = r� cm� a = 3.14 *(2.4)� cm� a = 18.0864 cm� 2.area of
triangle b = 1/2 * b * h b = b = 0.5*27.5*34.5
b = 474.375 4.74375 cm� 3.area of triangle c = 1/2 * b * h c = 0.5*27.5*34.5
b = 474.375 4.74375 cm� 4. Area of Retangle d = l *b d = 27.9*10 d
= 279 d = 2.79 cm� Total area of the casting = a + b + c + d
= 18.08+4.74+4.74+2.79 30.35 cm � 5. SPECIFIC PRESSURE ( MAX ) Kg/cm�

P = P = P = 5271.828666 Kg/cm� 6. Shot capacity S.C = Pl.area *

Pl.storke* 75% of filling ratio* Sp.gravity of alum. S.C = 3.14*2*2*29*0.75*2.7
737.586 Kg / cm � S.C. = 0.737586 Tons 7.DIE OPENING FORCE ( TONS ) D.O.F.
= Projected area (or)casting area x Specific casting pressure ( in die ) D.O.F.
= 30.35 x 1592 D.O.F. = 48317.2 Kg / cm � D.O.F. = 48.3172 Tons
8. DIE LOCKING FORCE ( Tons ) D. L . F . = D.O.F. X 1.1 D. L . F .
= 48.3175 x 1.1 Tons D. L . F . = 53.14892 Tons RESULT : This casting
60 TONS Capacity of the die casting machine to be selected. 9. SHOT VOLUME
( cm � ) S.V. = �*r�*h S.V. = 3.14 x 2 x 2 x 29 S.V. = 364.24 cm � 10. CROSS
SECTION OF GATE ( cm � ) 1. (Required one method )
Where = G = gross weight Fa = Fa = Fa = 0.19 cm � 2. (Required another
method )
Fa = Fa = Fa = 40.7 200 Fa = 0.2 cm � 3. Actual gate area Fa = a x b Fa = 2.4 x
25 mm Fa = 0.06 cm � KH.CENTER BRKT DATA 1.Shot weight
S.W. = 325 Gms 2.Casting weight C.W. = 174 Gms 3. After
gate weight A.F.= 196 Gms 4. Runner weight
= 129 Gms 5. Over flow weight = 22 Gms 6. Plunger tip
size d = 4 cm 2 7. Storke length
L2 = 27.5 cm 8. Machine M = 160 Ton 9.
No. Of Cavity = Double Nos 10. Gate
(thick&length) =
11.Specific gravity of alum. a = 2.7 12 � = 3.14 SOLUTION 1. 1st
PHASE MOVEMENT ( OR ) 2nd PHASE STARTING (S1) mm S1 = L2 - L1 Where
S1 = L2 - L1 L1 = cm S1 = 17.91637179 cm L1
=
325
S1 = 179.1637179 mm 33.912 L1 =
9.583628214
cm 2. FILLING RATIO ( % )
F = X100 F =
320/2.7
X 100

F =
120.3703704
X100 345.4 F = 34.84955714 3. SPECIFIC CASTING PRESSURE ( IN DIE ) Kg/cm�

P = P = Kg/cm� P =
20000
Kg/cm� 12.56 P = 1592.356688 Kg/cm� 4. CASTING AREA ( OR )
PROJECTED AREA ( cm� )

A = cm� A = 160000 cm�

1592.356688
A = 100.48 cm� ACTUAL CASTING AREA ( cm� )
1.Circle area a = r� cm� a = 3.14 *(2.4)� cm� a = 18.0864 cm� 2.area of
triangle b = 1/2 * b * h b = b = 0.5*27.5*34.5
b = 474.375 4.74375 cm� 3.area of triangle c = 1/2 * b * h c = 0.5*27.5*34.5
b = 474.375 4.74375 cm� 4. Area of Retangle d = l *b d = 27.9*10 d
= 279 d = 2.79 cm� Total area of the casting = a + b + c + d
= 18.08+4.74+4.74+2.79 30.35 cm � A = 60.7 cm � 5. SPECIFIC PRESSURE ( MAX ) Kg/cm�

P = P = 160000 Kg/cm�
60.7
P = 2635.914333 Kg/cm� 6. Shot capacity S.C = Pl.area * Pl.storke* 75%
of filling ratio* Sp.gravity of alum. S.C. = 25.434 737.586 Kg / cm � S.C. =
0.737586 Tons 7.DIE OPENING FORCE ( TONS ) D.O.F. = Projected area
(or)casting area x Specific casting pressure ( in die ) D.O.F. = 30.35 x
1592 D.O.F. = 48317.2 Kg / cm � D.O.F. = 48.3172 Tons 8. DIE
LOCKING FORCE ( Tons ) D. L . F . = D.O.F. X 1.1 D. L . F . =
48.3175 x 1.1 Tons D. L . F . = 53.14892 Tons RESULT : This casting 60
TONS Capacity of the die casting machine to be selected. 9. SHOT VOLUME
( cm � ) S.V. = �*r�*h S.V. = 3.14 x 2 x 2 x 29 S.V. = 364.24 cm � 10. CROSS
SECTION OF GATE ( cm � ) 1. (Required one method )
Where = G = gross weight Fa = Fa = Fa = 0.19 cm � 2. (Required another
method )