Gating Manual

NORTH AMERICAN DIE CASTING ASSOCIATION

Publication # 512
 Although great care has been taken to provide accurate and current information,
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aria cnaind hrin i n inndd  prvid pcic advic r rcndain fr an
pcic iain. An pinin xprd b h ahr() ar n ncari h f NADCA.

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ar d n fr idnicain and xpanain ih inn  infrin nr ndr h prdc
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© 2006 b Nrh Arican Di Cain Aciain,

Aciain, Arinn Hih, Iini. A Rih Rrvd.

Nihr hi b nr an par a b rprdcd r ranid in an fr r b an
an, crnic r chanica, incdin phcpin, icrin, and rcrdin, r b an
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 GATING MANUAL
 TABLE OF CONTENTS

STEP 1 - DeteRmINe tHe CAstINg QuAlIty ReQuIRemeNts 9

STEP 2 - DeteRmINe tHe Flow

F low PAtteRN
PAtteRN AND loCA
loCAtIoN
tIoN oF tHe INgA
INgAtes
tes AND outgA
out gAtes
tes 15

STEP 3 - DeteRmINe tHe segmeNt Volumes, CAVIty FIll tIme, AND CAVIty metAl Flow RAte 27

STEP 4 - mAtCH tHe PRoCess to tHe Flow RAte 35

STEP 5 - DeteRmINe tHe INgAte PARAmeteRs AND CHeCk FoR AtomIzeD Flow 37

STEP 6 - Do A PQ 2 ANAl
 ANAlysIs
ysIs IF DesIReD 45

STEP 7 - DesIgN tHe

tH e FAN AND tANgeNtIAl
tANgeNtIAl RuNNeRs
RuN NeRs 53

STEP 8 - DesIgN tHe oVeRFlows AND VeNts 75

STEP 9 - sImulAtIoN 81

GATING MANUAL 
 INTRODUCTION

th di cain di i h har f h di cain prc. gd ain din i nia fr
ain d par and ad h a  ccf di cain. Cnvr, pr ain din
makes poor parts and contributes to the struggles in lowering scrap and meeting operational
operational
objectives. This manual describes what the engineer needs to know to develop a successful die
cain a din. th na ain din incd a cp  f infrain and drain
that the tool designer or toolmaker
toolmaker will use to construct the gating system in the die. There is a
lot of thought and calculations that go into developing gating designs. The best designs come from
di cain xprinc, NADCA ain
ain fra, and h idin prnd in hi x. gain
din a ninrin r and i. Hvr,
Hvr, h i invd id hihr qai cain
and hp flr prdcivi.

thi x i inndd fr h prc ninr, h in ninr, h di dinr, h
toolmaker, the production supervisor or whoever has input into the gate design. The more people
in the organization who are on the same page for gating theory and practice, the better for a
pan’
pan’ cc. mch f h infrain i cncrn cd chabr ain achin, inc hi
cpri  f h rd’ di cain acivi. Hvr, h ain chniq prnd in
hi x app  h inc and ani a a .

gain din i inraciv ih h prc. Chic ad in cin h prc facr i
inflnc h a din. trad ar ad in h dvpin h ain    h pan’
processes. The analysis is done many times until the best and hopefully most robust design is
achieved that works with the process factors chosen.

Fr xap, cin a a ara cann b dn prpr ih nin h xpcd h
pd and pnr i; and hi cann b drind ih nin h dird  i; and
h  i cann b drind ih nin h qai rqirn fr h par and h
achin capabiii. Chanin n f h facr can ac h hr.

th ain din r incd cin f h fl parn, h r and cain
f h ina, rnnr, vrfl, and vn. I a incd h dvpn f h prc
parar. If a i dn rih, hn r h cc i xpcd ih h prc parar
very close to those calculated in the gating analysis.

ohr facr n cnidrd in h a din cacain ar a ipran fr cain
qai.
qai. Fr xap, if h di rn  h r  cd d  pra cndiin, cc i, ar
fl,
fl, h i prar, c., r h prc rn ih an incnin cc i, hn h
b a din in h rd a n r. evn hh h facr ac h cain qai,
qai,
sometimes the gate design is considered at fault when defects occur.
occur. Thus, a gate design that has
h rih hap, ha i in h rih cain, and ha a d fl parn, a n nra h
xpcd qai if n r r f h hr prc facr ar  f cnr. Chanin h a
design is not always the answer to the problem, though some shops change the gate design as a
a  v a a ind f prb. Fr h dinr,
dinr, hi an ha h h prc
nd  b xaind bfr dvpin a a din, and ha h b r ar baind
when the designer knows and makes allowances for the operational practices of the shop where
the die is to be run.

 GATING MANUAL
 The calculations presented have been used for some time. The formulas and guidelines are
based on empirical data and the results are successful especially when compared to the “let’s try
hi” chniq.

I i pin  hr c  f h hd prnd, pcia hn h a r i
and r han pa pracic. Hvr, h chniq hav bn prvn  b civ and
ar aa br if dn carf and cp. evr r hd b ad  bain iin
infrain ch a a d dniin f h cain qai rqirn r achin prfranc
information and to do the gate design as a thorough engineering project. This approach may cost
more initially, but will always prove to be substantially cheaper in the long run when all costs are
cnidrd. sa f h pan r ria and rrr rai ar xpniv and a nvr achiv
crap and praina fcinc a.

sa iprvn in qai ar criica in da’ ar. odr hd a achiv a 5 
10% crap ra, and a hav bn r han adqa fr rda’ ar. Hvr, da’
market is a lot tougher with slimmer margins and has little room for operational error in order to
a a pr. od hd n’ c i an r and br ain din ar ndd  rviv
and succeed in today’s market.

s biv ha  cann rach h vr  v f crap ih a  f xpniv ria
and rrr di dvpn c. Hvr, h cpani ha rac h ra c f di
development that comes from welding and re-cutting a gate or runner, will realize that the up
front engineering costs of doing a proper gate design are a real bargain.

th r a din hd a b h prann r a din. Ahh hi a in’
achivd 100%, i i b h ca in h ra ajri f din if h NADCA fra and
idin ar fd ivn ha d qipn, d prc cnr, and rb di ar a
in place.

GATING MANUAL 
The Steps to a Good Gate Design
The following steps are used to develop a proper gate design:

1. Drin h cain qai rqirn. gd ain din ar ih nd f
h cr rqirn.

2. Drin h inndd fl parn and h ina and h a cain. Viai
h fl f h a hrh h di. sn h cain and drin h dird fl
angles.

3. Drin n v, h cavi  i, and a fl ra fr ach n and
for the entire casting.

4. Dn h prc cnrain f h achin() inndd  rn h par – fa h
vci, pnr i, and cain prr. wha ar h pnr ip, prr, fa h
vci arnaiv? Can h inndd achin divr h dird fl ra and prr?

5. Fr ach cain n drin h fl ra, h ina vci, h apparn ina
ara, h fl an, h aca ina ara, and h ina nh and hicn. Chc fr
aid fl. Chc h r fr h nir cain aain h prc ii. Rd h
anai ni aid.

6. If dird d a PQ 2 gating analysis.

7. Din h rnnr   ppr h ina() rin bac  h bici f pr.

8. Din h vn and vrfl .

9. If dird rn h din vr  h iain far  n n h din. th
iar a h fl parn, h and cd ara, and pr ara ha r n
visualized in Step 2.

 GATING MANUAL
GATING MANUAL 
 1 STEP 1 – DETERMINE THE CASTING
QUALITY REQUIREMENTS

QUALITY SPECIFICATIONS
th dinr nd  ndrand h cr’ cain qai pcicain and h h
par fncin in h appicain. H d d h nih hav  b – pain qai, n cd
fl, r  cd fl? H ipran i pri – a ,  pri in crain ara,
r n pri rqirn? wha a h par r in h appicain? wha ar h criica
characteristics on the print?

t dvp a d a din, i i ipran ha h cain pcicain b dnd a
cp a pib. In an ca h cr i n an xpr in di cain and  
h di car fr idanc. Ida, h di car and cr a a jin r  pii
h din and qai pcicain fr h cain. A Din FmeA i f in hi ndavr
and hd b dn fr vr cain. Afr din a Din FmeA chan ar frqn ad 
a h cain din br and a pari ar n h a pa fr ha i rqird  a
h cain r in h appicain. od hd ch a “dpin h din vr h ran”
forces the die caster to make assumptions that can lead to sub-optimized gating designs resulting
in sub-optimized production with high scrap rates, misunderstandings, etc.

si qai pcicain ha ar criica  h di car  ininican  h
cr. Fr xap, an prad in h rqirn fr rfac nih r pri a chan
h achin ndd, and i i ca a chan in h ain din. If hi i dicvrd afr
h di i bi and an irrvcab dciin hav bn ad, an chan i b xpniv fr
vrn cncrnd. I i incbn fr h di car  a h rih qin.

thr ar  ajr dfc prb ara in di cain -rfac nih and pri. s
cnidrain fr h dinr ab qai rqirn in h ara ar id b:

SURFACE FINISH
srfac qai i aa a cncrn and nd  b cnidrd in a a din. Hvr,
h rfac nih rqirn can var id. thr i a bi dirnc in ain dvpn
between a chrome plated decorative zinc casting and a functional aluminum part.

sinc rfac nih i bjciv, h NADCA Prdc sandard chci C-8-2-06 i vaab in
hpin  dvp a r pcic andard fr an ivn par. A cp f h chci i hn n
h nx pa.

GATING MANUAL 9
 STEP 1 – DETERMINE THE CASTING
QUALITY REQUIREMENTS

CASTING SURFACE FINISHING SPECIFICATIONS

t b d in cnain ih r car (u in cbinain ih Chci C- 8 -1)*

Checklist for Finished Die, SSM and Squeeze Casting Part Purchasing
thi Finihin Chci prvid a cnvnin hd fr arin ha ipran facr
invvd in h rfac nihin f ca par ar vaad and car cnicad bn
the purchaser and the caster.

This checklist is for use in consultation with your die caster prior to estimat- ing production
c. u in cbinain ih h Finihin Chci C-8-2. A rvi Chci

t-2-1A and t-2-1B, fr Di Cain Di spcicain, in scin 2.

I hd b d a a ppn  h nia dinina and a pcicain daid
n par prin bid fr qain, inc h id facr dirc ac h bai n hich
h cain qain i ad. th chci a b rprdcd fr hi prp. yr car i
carif an i rqirin xpanain.

This checklist provides a numbering system in which the lowest numbered description for each
rqirn can b  a h  prdcin c, a f:

 GATING MANUAL
 STEP 1 – DETERMINE THE CASTING
QUALITY REQUIREMENTS

* The specification provisions and procedures listed in Section 7, “Quality Assurance,” should also be
addressed.

Publisher grants permission to reproduce this checklist as part of a casting Request for Quotation or
Production Specification .

GATING MANUAL 
 STEP 1 – DETERMINE THE CASTING
QUALITY REQUIREMENTS

ga pri i fn a cncrn fr achind ara, r i a h p a bir in hr ara.
wih a pri h a din i incd dvpin a fl parn ha dn’ prdc
ir r bac and dvpin h prpr vnin and r vac .

s dniin f par qai rqirn nd  b ndrd ar a h rqirn

ac h ain din ra and dciin ain prc.

GATING MANUAL 
 GATING MANUAL
 STEP 2 – DETERMINE THE FLOW

2 PATTERN AND LOCATION OF THE

INGATES AND OUTGATES

GENERAL CONSIDERATIONS
A ain din ar ih a rand pan fr h a fl hrh h di. whr i h 
ica and avaiab pac fr h a  c in? whr i h  ica and avaiab pac
fr h air  cap? wha bac  h a fl i b ncnrd inid h cavi?
wha parn i b  aif h qai rqirn? Viaiin h fl parn i a criica
p in h ain din prc. whn h fl parn i dnd, hn h ina and a
can be located provide the desired pattern.

In viaiin h a fl:

1. u a ch f h parin in a pib divr a  hr i i ndd and 
spread the heat out,

2. Take the shortest distance across the cavity, and

3. minii divrin and cnvrin fl pah.

Par f viaiin h a fl pah i a viaiin h cpnn ha i fd h
a. Hr ar irain f h fl cin  a crv idd fan and annia rnnr.

GATING MANUAL 
 GATING MANUAL
 STEP 3 – DETERMINE THE SEGMENT

3 VOLUMES, CAVITY FILL TIME, AND

CAVITY METAL FLOW RATE

SEGMENT VOLUMES
Fr xiin cain, n v can b drind b cin h cain p ih a band
saw, weighing each segment, and calculating the segment volume. The volume of a segment may
be calculated with the following formula.

Volume (in3 ) = Weight (lb)/Density (lb/in3)

whr, dnii ar: Ain = .096 b/in3

zinc = .256 b/in3

mani = .064 b/in3

lad = .400 b/in3

Fr n cain h ai a  drin n v i   3D CAD far 
nra n v. thi hd i fa and accra. whn an ain din cnari
ar d and h cain i cciv rnd fr ach cnari, CAD a h prc
fa and fcin. wih 3D CAD and a cprhniv pradh ha caca ina, rnnr,
a, and vn, an ain inrain can b dn qic and fcin. B din an
scenarios a better job of approaching the optimum gating design is done.

A more time consuming method would be to determine the casting volumes with a spreadsheet and
a cacar. thi hd i r and n a accra a 3D CAD and ain din qai i r.

Pannd vrfl aciad ih ach n hd b incdd in n v.
Incdin vrfl v ih n v i cad “a hrh h a” and id a
r cnrvaiv din. each n v ih h pannd vrfl i pacd in h
spreadsheet and then summed to get the total casting volume.

CAVITY FILL TIME

Cavi  i i h i fr hn h a bin  fl in h di ni h cavi
i f. ma fl in a di cain di i i a rac aain i. A h a nr h
cavity and hits the die steel, it loses heat and drops in temperature. The metal must reach all
xrii f h cavi bfr h a prar dcra  h pin hr h a
n nr fl and h ih cnvrin ra. If h rac i , hn pr  and pri
appar in h cain. whn drinin h cavi  i fr a n cain hhr b fra,
ab, r hirica daa, i i br  nra rr n id f a fa  i. th xcpin ih
b h ca f pri i and fdin h far id f bi cr n hic cain hr fa 
times can actually make the castings worse.

GATING MANUAL 
 STEP 3 – DETERMINE THE SEGMENT VOLUMES, CAVITY
FILL TIME, AND CAVITY METAL FLOW RATE

th  i cacad b h hd prnd hr ar cnidrd  b axi 
i, and n ida  i. th ran fr hi i bca f varin fl dianc and a
dflcin ihin pcic di cain cavii. gnra qain and ab cann addr pcic
fl dianc and brcin i. s h  i cacain b fra hd b h ppr
limit for any gating design.

An ipran din cnidrain i ha hrr  i bn rfac nih prvidd h
a ara ar prprina  n v. A cain rqirin a d nih nd a fa 
i and bc h dnin variab fr h r f h prc cin.

Fa  i can b cnraind b h vn. thr i a ii a  h fa air can fl
hrh vn. si fa  i baind b drn achin a rqir r vnin
ara han can b inad in a ivn di. In h ca, chi bc r a vac  nd 
be considered. This is discussed in the section on venting.

whi  i i h ajr facr acin h rfac nih, h facr acin pri a
n b rn acd b  i. In h ca hr hrin pri i h dinan qai
i, hn h  i nd n b fa nh   a d  ih an avra nih. In fac,
a r cavi  i a hp pri b ain r air  cap hrh h vn and b
in ih a hihr pr cn id.

th NADCA fra cnain facr h ain dinr  a. wa hicn, di
temperature, metal temperature, and percent solids come from the designer’s judgment of what
i aca happn hn h cain i in prdcin. th, h cacad cavi  va
bc a fncin f h dinr’ xprinc and prcpin f aca flr pracic. A d
database from process engineering on the actual process conditions of the shop is valuable when
d in cnjncin ih NADCA’ fra.

Dviain fr h fra and rcndain hd c fr hirica daa hich d
b h b fr nin ha r fr a paricar ca f cain. th b  i va a
c fr h prc ninr h ha rn iiar par, and ha a daa ba cnainin  i
nbr. whn d  i daa i avaiab, h va hd prcd h NADCA fra
values.

Fdbac i ipran fr an ain dinr. th aca cain r fr a din raiv
 cavi  i hd b criiqd. wha rd? wha did n r  ? Iprvin ain
i i a jrn. ovr i ain dinr  br a drinin cavi  i va fr
any particular operation.

s cain ar ran f  i variain, hi  ar n. Hvr, ain dinr
hd iv a cain ri hh  a prpd cavi  i pcia if h cain i
plated of leak tested.

J. A. waac (Pracica Appicain and h r f a fl and ain rarch – 1965)
dvpd h baic NADCA  i fra. e. A. Hran pbihd h crrn vrin in hi
b, gain Di Cain Di. thi baic  i fra i:

8 GATING MANUAL
 STEP 4 – MATCH THE PROCESS TO
The Flow RaTe.

Ain h achin can divr h fl ra, hn c a pnr diar ha iv a
d  fr fa h vci and na a prr. ohr i  cnidr in ain hi
analysis are:

Can h di cain achin hd h a a h prpd na a prr? wha i b
h nna n ach i bar ih h prpd di din and cain prr? If h achin
can’ hd h a, hn rfac nih and pri qai andard i b difc  
rard f h qai f h ain .

Can h accar prr b rd and i hav fcin fa h vci? Cain h
part with the least amount of pressure and fast shot velocity allows the die cast machine to run
more smoothly with less mechanical stress and strain. This is a cost savings opportunity for die
car h nra  h injcin and di c prr  h axi rard f h
part being cast.

In chin a pnr ip diar, ha i h pr cn  f h v b. th rar h
pr cn , h  air nd  b vnd and h r h prbabii fr rappd rida
air a h nd f h h. In addiin, a hihr prcn v  cnrv ha ih  a
temperature drop from the furnace to the ingate.

th prc dciin a appar  b cpicad. Hvr, if h ain dinr n
h capabiii f h inndd achin() and iv  hh  h rad f cain
prr, fa h vci, and v pr cn , hn inin chic ar ad and h
gating system is engineered to work for the intended machine. The objective at this point is to
n ha h di cain achin can divr h cain fl ra cacad in sp 3 and a
pressure in the cast of porosity from Step 1 without undo stress to the machine.

If h achin can’ divr h dird fl ra and a prr, hn h cavi  i
has to increase or a more powerful machine used.

 GATING MANUAL
 STEP 5 – DETERMINE THE INGATE

5 PARAMETERS AND CHECK FOR

aToMizeD Flow.

th nx p in h ain anai i  cnin in p a pradh b n ih
fl ra (Q), ina vci (V), apparn ina ara (Aa), fl an (Af), aca ina ara
(A), ina nh (l), ina hicn (t), and aiain facr (J).

Segment F Rt Ingate Velocity Apparent Ingate F  Ingate Area
(in3/sec) (in/sec) Area (in2) (deg) (in2)
x xxx xxx x.xx xx x.xx
x xxx xxx x.xx xx x.xx
x xxx xxx x.xx xx x.xx
Totals xxx x.xx

Segment F Rt Ingate Velocity Ratio Length/ Atomization

(in3/sec) (in/sec) Thickness Factor
x x.xxx x.xxx xx xxxx
x x.xxx x.xxx xx xxxx
x x.xxx x.xxx xx xxxx

SEGMENT FLOW RATE

th nbr c fr sp 3.

INGATE VELOCITY
th ain dinr ch an ina vci fr h cain. Nra ran fr ina
velocities are shown in the following chart. The ingate velocity selected should fall within these
ranges.

Alloy Normal Ingate Velocity (in/sec)

Aluminum 700 to 1600
zinc 900 to 2000
mani 1000 to 2000

GATING MANUAL 
 STEP 5 – DETERMINE THE INGATE PARAMETERS
anD CheCk FoR aToMizeD Flow.

Hihr vcii ar chn fr hin ad cain ha rqir a d rfac nih, hr h
travel from the near to the far end of the casting is long, or where the geometry is complicated
and h a i ncnr dflcin. whn in hihr vcii r achin pr i
b rqird and di rin arnd h ina i ccr nr.

 lr vcii i rqir  achin pr and di rin arnd h ina i ccr
ar. lr ina vcii ar r cnica in  pr and r  ainnanc
and replacement costs.

th, chin an ina vci ha  d ih h qai rqirn and h r f
h cain. Hirica a vci daa d b hpf fr h ain dinr. trb ccr
when the chosen ingate velocity is not within the recommended range. The ingate velocity may
b chand fr dirn ain cnari. lar in h anai h ina vci in cbinain
ih h ina hicn i d fr aid fl.

APPARENT INGATE AREA

The apparent ingate, Aapp, for each segment is calculated.

Aappi = Qi / V

whr,

Aappi = apparn ina ara f a n (in2)

Qi = fl ra f a n v (in3/c)

V = ina vci (in/c), and

These numbers are calculated in the spreadsheet.

FLOW ANGLES
th a fl in ach n a  an, hich i ard fr an axi prpndicar
 h parin in and can ran fr 0  45 dr. F an f an xiin cain can b
brvd in a cd ar p h. In sp 1 h fl pan a viaid. thi pan incdd pcic
fl an in ach n.

th fl an ar nrd in h pradh.

ACTUAL INGATE
th a vci a an an cin  h ina can b rprnd a a vcr ih
anid and dircin. thi fl vcr can b brn in  vcr, n nra  h
ingate and one parallel to the ingate. The vector normal to the ingate represents the metal
aca in in h di. th nra vcr = C(θ) * fl vcr and i irad a f:

8 GATING MANUAL
 STEP 6 – DO A PQ2 ANALYSIS IF DESIRED

3. Find  r drin h dr h fa h vci a h accar prr
chn and p n h hrina axi (P = 0). th va fr h dr h pd fr
given accumulator pressures
pressures can be found in the machine manual or can be determined
xprina n h flr.

4. Dra a raih in bn h pin f Steps 2 and 3. thi i cad h machin
Prfranc lin.

5. A a cfcin f dichar.

6. sc an ina vci. Caca h a prr rqird  prdc hi vci.
sc an ina ara. Caca h fl ra aciad ih hi ina ara and ina
vci (Q = Vg * Ag). P hi pin n h PQ^ raph fr h riin. Dra a raih in
hh hi pin. thi i cad h Di Rianc lin fr h cd ina vci and
ingate area.

7. th inrcin f h Di Rianc

Rianc lin and h machin Prfranc lin i axi
operating condition for the parameters selected.

8 GATING MANUAL
 STEP 6 – DO A PQ2 ANALYSIS IF DESIRED

mini ga Vcii fr J = 750

Aluminum Zinc Magnesium
Gate Minimun Gate Minimun Gate Minimun
Thickness Velocity Thickness Velocity Thickness Velocity
Inch mm in/c /c Inch mm in/c /c Inch mm in/c /c
0.030 0.762 1497 38 0.006 0.152 2312 59 0.012 0.305 3212 82
0.035 0.889 1265 32 0.008 0.203 1954 50 0.015 0.381 2819 72
0.040 1.016 1181 30 0.010 0.254 1715 44 0.020 0.508 2382 60
0.045 1.143 1110 28 0.012 0.305 1542 39 0.024 0.610 2141 54
0.050 1.270 1050 27 0.013 0.330 1471 37 0.028 0.711 1957 50
0.055 1.397 998 25 0.014 0.356 1409 36 0.032 0.813 1810 46
0.060 1.524 952 24 0.015 0.381 1353 34 0.036 0.914 1689 43
0.065 1.651 912 23 0.016 0.406 1303 33 0.040 1.016 1588 40
0.070 1.778 876 22 0.017 0.432 1258 32 0.044 1.118 1502 38
0.075 1.905 843 21 0.018 0.457 1216 31 0.048 1.219 1428 36
0.080 2.032 814 21 0.019 0.483 1178 30 0.052 1.321 1363 35
0.085 2.159 787 20 0.020 0.508 1144 29 0.056 1.422 1305 33
0.090 2.286 763 19 0.021 0.533 1111 28 0.060 1 .524 1253 32
0.095 2.413 740 19 0.022 0.559 1082 27 0.064 1.626 1207 31
0.100 2.540 700 18 0.023 0.584 1054 27 0.068 1.727 1165 30
0.110 2.794 665 17 0.024 0.610 1028 26 0.072 1.829 1126 29
0.120 3.048 635 16 0.026 0.660 981 25 0.076 1.930 1091 28
0.130 3.302 608 15 0.028 0.711 939 24 0.080 2.032 1059 27
0.140 3.556 584 15 0.030 0.762 902 23 0.084 2.134 1029 26
0.150 3.810 562 14 0.032 0.813 869 22 0.088 2.235 1002 25
0.160 4.064 525 13 0.034 0.864 838 21 0.092 2.337 976 25
0.180 4.572 494 13 0.036 0.914 811 21 0.096 2.438 952 24
0.200 5.080 455 12 0.040 1.016 762 19 0.100 2.540 930 24
0.230 5.842 423 11 0.045 1.143 712 18 0.150 3.810 733 19
0.260 6.604 389 10 0.050 1.270 669 17 0.200 5.080 620 16
0.300 7.620 356 9 0.060 1.524 602 15 0.250 6.350 544 14
0.350 8.890 329 8 0.070 1.778 550 14 0.300 7.620 489 12
0.400 10.160 307 8 0.080 2.032 508 13 0.400 10.160 413 10
0.450 11.430 307 8 0.090 2.286 475 12 0.450 11.430 386 10
0.500 12.700 289 7 0.100 2.540 446 11 0.500 12.700 363 9

GATING MANUAL 9
 STEP 6 – DO A PQ2 ANALYSIS IF DESIRED

PQ 2 NOTES
1. Cavi  i i a fncin f fl ra. th ini fl ra fr a dird axi
cavi  i can b pd n h PQ2 diara a a vrica in. oprain cndiin
must be to the right of this line.

2. Fr an inndd ina hicn, hr i a ini ina vci ndd  ai
h a fr an inndd ina hicn. Fr Brni’
Brni’ qain a prr can
b cacad fr hi ini vci. thi can b dran a a hrina in. oprain
conditions must be above this line. The horizontal,
horizontal, vertical, and machine performance
performance lines
create an area that can be called the operational window. The die should operate in this
dnd ara.

3. ec f Parar Chan

Rdcin r incrain h accar prr cra para machin Prfranc
lin n h PQ2 raph.

 GATING MANUAL
 STEP 6 – DO A PQ2 ANALYSIS IF DESIRED

Cin h h vav ha h c f crain machin Pr
Prfranc
franc lin ha piv fr
h a prr pin ih r fl. thi daa can c fr h achin’ b r b
drind xprina.

Chanin h pnr ip ha h c f chanin h p f h machin Prfranc
Prfranc lin.
sar pnr id hihr a prr and  fl. larr pnr id r a
prr and r fl.

Chanin h ina ara chan h p f h Di Rianc
Rianc lin. sar ina ara id
r prr,  fl. larr ina ara id  prr, r fl.

GATING MANUAL 
 STEP 6 – DO A PQ2 ANALYSIS IF DESIRED

Fr a h pin an machin Prfranc and Di Rianc lin can b dran 
h h prain cndiin fr a ivn  f ain parar. man cnari ar rn. th
bjciv i  nd a cbinain f ina ara, ina vci, ina hicn, pnr ip
diar, and accar prr ha cra a ar cnra praina ind n h PQ 2
diara. NADCA prvid far  hp ih h PQ 2 analysis and calculations.

th PQ 2 anai can b rn a a chc n h cnvnina ain anai r vic vra. N
h cfcin f dichar appar a a qard r in Brni’ qain hich an a a
pr cn chan in hi nbr r in a inican pr cn a prr chan a hr
facr bin qa. th achin’ prfranc and hr chanica i ch a h ainn
f h v and pnr chan hrh i. th facr ac h cfcin f dichar.
scin a cfcin f dichar n h  id i a cnrvaiv apprach.

 GATING MANUAL
 7 STEP 7 – DESIGN THE FAN AND
TANGENTIAL RUNNERS

FLOW AREA CONSIDERATIONS

th fncin f h rnnr i  divr h a  h ina and  nra h dird fl
pattern within the cavity segments. There are three runners used plus the chisel runner that is
sometimes used in dealing with local porosity. The three runners are the straight fan, the curved
fan, and the tangential runner.

th ina cnr h a fl in h cavi. thrfr, h ina ha h a ara
in h a fl pah fr h bici r pr  h cavi. If hi r n r, hn 
hr far in h rnnr  i cnr h a fl ch a an ndrid rnnr r an
undersized nozzle on a hot chamber machine.

Rnnr  hd aa b dind arin a h ina and rin bac  h pr
or biscuit and in the case of hot chamber machines working back to the gooseneck plunger. At this
point in the analysis the ingate areas and locations are known so the runner design starts at the
gate opening and works backwards to the sprue or biscuit.

The runner area should decrease as the runner transitions into the gate. This not only maintains
h a a h a ara in h fl pah, b i a frc h a fl  prad h f
idh f h a and  h a d ha i a dind  d. Dcrain h rnnr ara
adin p  h ina a prvn ixin air ih h a in h rnnr ha ih h p
in the casting as porosity.

sarin a h a, h rnnr i b arr han h a. th rai f h rnnr  a
ara i var ih h din, and i a ran bn 1.1:1 and 1.4:1. Hvr, i can b
larger as in the case of small castings where using a ratio of 1.4:1 would result in too much metal
heat loss in the fan or tangential runner system. Thus, if the gate area is 1.00 in 2, then the runner
ara hd b bn 1.1 and 1.4 qar inch xcp in a cain.

The ratio is determined by several design factors, and it important to realize that there isn’t a
aic nbr ha appi  a circanc. s f h facr  cnidr ar:

ALUMINUM
tpica rai i b ab 1.1  1.4. th hihr rai ar d hr hr i a arr fl
an. A fl an rar han 35° fr a fan a din i rqir a rai f 1.3:1 r rar. A
fl an f 10°  35° d b accpab ih a a  rnnr rai f ab 1.1:1  1.3:1.
Hihr fl an rqir r rricin  frc h a  cnfr  h a hap.

GATING MANUAL 
 STEP 7 – DESIGN THE FAN AND
TANGENTIAL RUNNERS

on h hr hand, h dinr hd b cai ab in ar rai fr ar cain
bca h ain rnnr  h bici r pr a p bin xciv ar. Rnnr dn’ 
hippd. Rnnr n add  h nr and dr  c f h pan.

In  pan, i i cn   a p 45o ramp for the transition from the fan or
tangential runner to the gate. The thought is to keep the metal hot up to the gate to prevent
prar frin f h ina. Hvr, frin a h a can a b crrcd ih
prc chan, and hi ind f a din hd n b ncar. I can b d in  ca
 hp pcic pri p, b i frc h a  accra in a vr hr dianc and
a n a h a  prad  h d f h a. If hi a din chniq i d,
hn i i d ha h a  rnnr rai i nd  b qi hih, pica 1.5:1 r
even 2:1.

 ZINC
thinnr a and ar a ar d in inc ih rnnr a a a .125 x .125 inch r
vn ar in fr id achin. th ar rnnr rqir a vr fa  i ( han 10
msec) to stay open.

th rnnr i rai i fn 1.05  1.15 i h a ara. th ar ar incra han
those used in aluminum, partly because the area of the sprue or the nozzle feeding the sprue
ii h axi ara f h rnnr in a h chabr achin.

whn hi ccr,  f h avaiab ara rdcin hd b d a h a, hich a
mean that the runner components will be designed with a small area reduction from the sprue
start of the gate. The sprue and nozzle areas need to be reviewed in all hot chamber designs along
ih h rnnr cpnn. si h n r pr i ar han i hd b. A d
din in a b    a rnnr pr, hich i prvid  rricd fl and can
support a bigger runner system.

MAGNESIUM
mani rnnr r  ih r pd han hr a. Hih rnnr pd i dirab
to keep the heat loss down, which is critical in magnesium where the latent heat and the
pcic ha ar . Ahh in h a ra a in ain i iab fr  di,
smaller runner sizes and higher velocities can be an advantage. The concept is to keep the runner
velocities high with modest area increases from the ingate to the sprue or biscuit to minimize heat
loss in the runners.

 GATING MANUAL
 STEP 7 – DESIGN THE FAN AND
TANGENTIAL RUNNERS

Tangential runners do not have to be kept parallel to the edge of the casting with tangential
a. th rap fr h rnnr  h cain can b xndd  hi p f a can fd an
irregular edge. This is shown below.

 GATING MANUAL
 STEP 7 – DESIGN THE FAN AND
TANGENTIAL RUNNERS

th rap fr h rnnr  h cain can b nhnd a ndd   h cain cnr.
th rap ar a pd ab 5° fr h rnnr  h cain (r  h and if n i
used).

A id vi f h chniq i hn b.

thi chniq can a b d  dirc h fl f a annia rnnr. th rnnr can b
and  a h fl parn  in h dircin dird.

The picture below shows a gate design where the tangential gate was shaped so as to direct the
fl a paricar prb ara. th fl parn in hi ca rd   v  dfc
problems.

GATING MANUAL 
 STEP 7 – DESIGN THE FAN AND
TANGENTIAL RUNNERS

If i i dird  hav a dirn an, i i pib  an h rnnr aa fr h cain
in rdr   h fl an dircd br. th a can b addd  h crvd cin f
h annia a and h bain  dirn fl an ha cd n b achivd ih a
straight section. This is shown below, where the runner curves were used to direct metal into the
 crnr f h cain ha cd n b rachd ih in hi chniq.

thi chniq i vr prf, pcia hn a d rfac nih i rqird. thi
xap a dn b cpr, b  d i ana, h fin prcdr i  a c
apprxiain. Fir,  h raih cin in h idd.

8 GATING MANUAL
 STEP 7 – DESIGN THE FAN AND
TANGENTIAL RUNNERS

Main Runner Description

Component Description
1 Tangential
2 Fan
3 Fan
4 Fan
5 Fan
6 Fan
7 Fan

main Rnnr: Apc Rai = 2:1 Draf = 10

Main Runner Feeding Area Avg Width h (in) b (in) d (in) t (in) c (in)
Section (in2) (in)
e 1 0.237 0.688 0.344 0.748 0.061 0.627 0.061
I An Fan 0.225 0.671 0.335 0.730 0.059 0.612 0.059
F 1+2 0.485 0.984 0.492 1.071 0.087 0.898 0.087
g 1+2+3 0.721 1.201 0.600 1.306 0.106 1.095 0.106
l 7 0.236 0.687 0.344 0.748 0.060 0.627 0.060
k 6+7 0.473 0.972 0.486 1.058 0.086 0.887 0.086
m All 1.643 1.813 0.906 1.972 0.160 1.653 0.160

(Ara scin m = A = k + 2*I + g =1.643 )

main Rnnr dinin fra fr an apc rai f 2:1

h = (Ara / 2).5

b = 2.176 * h

d = 0.176 * h

 = 1.824 * h

c = 0.176 * h

GATING MANUAL 
 GATING MANUAL
 8 STEP 8 – DESIGN THE OVERFLOWS
AND VENTS

OVERFLOWS AND OUTGATES

ovrfl cc h iniia cnainad a ha ravr h cavi, prvid ca ha
 h far id f h cavi, and prvid a ba  hp jc h cain  h di. th nbr
and i f vrfl i a fncin f h fl dianc hrh h cavi hra n dianc
i hav r vrfl and h rfac nih rqirn f h cain hra d rfac
qai i hav r vrfl han a crcia nih. A id  vrfl i a a prcn f
the adjacent segment can be found in the table below:

tpica ovrfl si

Thickness of Cavity Fill Time ovrfl s s prct f djct cvty smt
Smt - . - sc. hrdr Quty Sm Cd Sut ad - %
(mm) Surface Finish - %
0.035 (0.90) 0.012 - 0.021 150 75
0.050 (1.30) 0.017 - 0.029 100 50
0.075 (1.80) 0.026 - 0.044 50 25
0.100 (2.50) 0.035 - 0.059 25 25
0.120 (3.20) 0.042 - 0.071 ---- ----
Note: th va hn ar pica va hich a chan fr pcic iain.

ovrfl ha cnnc  vn hd b cad a h a prin f h n  . If
h vrfl  bfr h n, hn bacin i ccr cain pr  and pri.
ma i b dran  h a and vrfl,  i i br  hav an d vrfl
han a f ar n fr prp f diribd fl ihin h cain. li rnnr, vrfl
d n  hippd,  h nbr and pacn f vrfl hd b jdici.

th a cnnc h cain  h vrfl. th  a f a h a ara hd
b apprxia n haf h a ina ara inc h a prvid h paaa fr air
 cap hrh h vn. Fr ain h ini a hicn hd b .040 in. Fr
ani and inc h ini hicn i .020 in fr cnvnina di cain. ovrfl ar
nra cad n h jcr haf ih an jcr pin ndrnah h. oa i ina
are normally located in the cover half.

If pib h din f vrfl a ih vn hd b fr infcin a fl. th cncrn
i p h n a ihin h di a h nd f h h. If h di d n hd h a,
hn h pacin ha ccr a h a inan f  i diinihd cain pr rfac nih and
pri. Infcinc i crad hn h a i  fr h vn frcin h a  rn
ihin h vrfl.

GATING MANUAL 
 STEP 9 – SIMULATION

If hr i an ara f cncrn ab a pri, hn h r hd chc fr ir r rappd
a pc in hi ara. thr hd b h a fl hrh hi ara, and h pc
hd b in hr cain. If h far i capab, hi hd incd xainin h inrna
fl inid h cain.

th fl iain a nd  b chand and rpad vra i fr dirn ain
and process conditions to get the optimum gating situation. This will be similar to the same
ria and rrr hd ha d  b dn n h di cain achin. Hvr, i i j a 
cheaper and faster on the computer. The information learned from simulation can be valuable, but
the user needs make sure the results are interpreted properly by someone familiar with die casting
and not just familiar with simulation.

If hr i cncrn ab hrin pri, hn an iniia hra anai hd b rn. th
thermal analysis will be needed for oil and water cooling channel placement and can predict the
cd ara and h h ara ha a ac rfac nih r hrin pri. m  a hi
i can n prdic h r f appin innid prr drin idicain a h r
dind fr hr cain prc n prr cain. th r hd hav  xprinc
in die casting to interpret the results and be somewhat cautious with the simulator’s results.

sinc iar i prdic h cd and h h cain, hi infrain can b civ in
pacin ar r h i in. Di b pra a rv ha b n a  can accn fr
h c f h pra. man inrain f h hra iain ar dn hr h cin
channels are moved, resized, and the coolant changed in order to optimize the design.

onc h ain  and h hain/cin  ar piid, hn h di din can
b naid and ivn  h di dinr f  ar  cnrcin can ar.

Cpr ar in far and far i in chapr and br. th da ar cin
where simulation will be the standard method of verifying and optimizing gating designs.

 REFERENCES
1. e.A. Hran, J. F. waac, “Cppr A Prr Di Cain”, Inrnaina Cppr
Rarch Aciain, 1975

2. e. A. Hran, “gain Di Cain Di”, sci f Di Cain eninr, 1979

3. e. A. Hran, “Di Cain Di, Dinin”, sci f Di Cain eninr, 1979

4. J. A. waac, “Pracica Appicain and h R f ma F and gain Rarch”, ,
1965

5. R Van Rn ,“gain Din”, NADCA, 1996

6. w. wainn, “svn sp  Qai gain Din”, NADCA, 2001

7. Dr Cc, “Fan and tann ga Fd Din s” , Arican Di Cain Ini,
1987

8 GATING MANUAL
STEP 9 – SIMULATION

GATING MANUAL 8