⑤ CASTING TECHNOLOGY

・ CASTING THEORY

ﾀﾞﾃｸｾﾝ
08.07.15
TOSHIBA MACHINE Co., Ltd. 渡 辺

2008年7月改訂⑥
DIE CAST ＴＥＣＨＮＩＣＡＬ ＣＥＮＴＥＲ．
Ｐ－1
「PREFACE」
Die cast boast a high productivity besides the products have excellent property of dimension accuracy, thin wall and lightweight, casting surface
etc. Therefore die castings have an important part to play in supplying light metal materials mainly in automobile industries.
To produce die cast products, die cast technology is required: that mold, casting, materials, and melting etc put together. Especially, the issues of
alloy solidification/cooling that are applied to casting generally and physical principle of heat transfer to mold shall be got in die cast technology
basically. As die casting method, molten metal is filled in mold cavity with high-speed and high-pressure by plunger that moves by liquid pressure
cylinder. This is large difference with other casting method mechanically. In face of this mechanical relations as casting theory, it is able to
explain hydraulically. Selection of mechanical requirement (filling requirement) to fill injected molten metal to mold cavity in every corner and the
cross section of sprue that is decided by the mechanical requirement etc are the theoretical idea of casting. Die cast products has various
economical advantages, and at the same time, there are quite a lot of problems as material such as gas hole, shrinkage porosity, shortage of actual
strength by oxide film or broken solidified piece etc.
The recent required quality for die cast products grow increasingly sever. Use vacuum casting method or partial pressurizing casting method in
combination with die casting method to this requirements, and also specific casting method die cast machine is developed to ensure high quality
aluminium castings.
This article is designed to achieve high quality and low cost with full of machine property, and define how to decide injection condition common to
TOSHIBA die cast machines or how to decide gate system for mold design etc. It appreciates to be a help for daily operation.
“Conversion of Unit”
This article is included International System of Units (SI Units) and Non-SI Units. Normally below is applied but below right side is applied for non-
SI units machine.

Type of Value SI Unit Normal Conversion Nom-SI Unit Conversion for This Article
Pressure MPa MPa × 10.2 kgf/cm2（kg/cm2） MPa×10
(Example) 10 10 × 10.2 = 102 102 10×10＝100kgf/cm2
Side of Power kN kN × 0.102 tonf（ton） kN×0.1
(Example) 3500 3500 × 0.102 357 3500×0.1＝350tonf
Ｐ－2
 1. Definition of Die Cast
This is a mass-production casting method that produce castings with high property and smooth skin by pressing molten metal into accurate
mold. It also means the casting products created by this method.

2. Operation of Full Automatic Cycle (Die Cast Machine)

Mold Release Spray → Mold Clamp → Pouring → Injection → Product Cooling

→ Mold Open → Eject → Take Out → Plunger Lubrication

3. Die cast method is one of casting method…
This is a method that change air in mold cavity and molten metal with high speed before molten alloy solidified, and harden with
high pressure.
Mold Data
Die Cast Chip Diameter: 70mm
Wall Thickness: 2.0mm
Product Weight: 430g
Mold Casting Machine Material Project Area: 430cm2
Material: ADC12
Product Shape Casting Condition Alloy Property Molten Metal Temp: 680˚C

Gate System Melting ＨＤＤ (hardware desk drive )

Molten Metal Treatment

4. Die Castings
Good die castings doesn’t have porosities, have clean appearance and high in dimension accuracy.

Casting Condition Casting C/T 28sec

Low Speed Rate High Speed Rate High Speed Range High Speed Low Speed Rate Low Speed Rate Casting Pressure
Acceleration
m/s m/s mm M/s ms MPa
ms

0.20 3.2 67 4 1.5 30 65

Ｐ－3
 5. Injection Process of Die Cast

Low High
Intensify
Speed Speed

Bubble

Low Speed High Speed Intensify

Carry molten metal that poured in
sleeve by ladle to gate.
At this time, don’t make wave on
molten metal surface, and exhaust air
inside sleeve from air vent of mold to
prevent inclusion of air in molten metal.
However if it is too slow, the molten
metal will be solidified.
(Low Speed Rate)
Form products. Press and solidify the product.
High speed start from where sleeve and runner is Give a pressure before molten metal solidify.
100% filled with molten metal. The condition is that
(Intensify Time)
the air inside sleeve and runner is completely
It makes porosity smaller, and increase
exhausted.
adhesiveness to mold.
(High Speed Change Position)
(High Speed Range) (Casting Pressure)
Gate becomes narrow normally so that flow speed of
molten metal is increased and get into details as mist.
It makes smooth skin.
(High Speed Rate)
Air in product area will remain inside of product.

Ｐ－4
 6. Way to Decide Casting Condition

Machine/Mold/Product/Data
Condition Data
1) Machine DC350Ｊ－ＭＨ
Wc Wf Ａ
A) Mold Clamp Power 350ton
B) ACC Pressure Pa = 10MPa (100kg/cm2)
C) Diameter of Injection Cylinder φ125mm As = 123cm2
D) Diameter of Intensify Cylinder φ180mm Ab = 255cm2
（Ａｇ） Gate Ｂｒｏａｄ × Gate Ｔhickness
E) Diameter of Chip φ 70mm Ap = 38.5cm2
2) Mold
F) Ｓｈｏｔ Weight Wc = 900g
(Product + Over Flow + Runner + Biscuit)
G) Ｐａｒｔ Weight Wf = 700g
（７０）
(Product + Over Flow )
H) Wall Thickness tm = 2.0mm
NOTE
(Average of Thin Areas)
Below is applied for conversion of text.
I) Gate Area Ag = 1.3cm2
MPa ×10
J) Ｃａｓｔt Area A = 350cm2
10×10 = 100kgf/cm2
K) ＤｒｙＳｈｏｔ Stroke L = 337mm
kN ×0.1
L) Aluminum specific gravity r= 2.6g/cm3
3500×0.1 = 350tonf
ｍ） Ｃａｖｉｔｉｅｓ １

Ｐ－5
 ① Low Speed Rate
Carry poured molten metal with less air inclusion and temperature decrease to near the gate.

Low Speed Rate

Speed is too high. Speed is appropriate.

Chip Chip
Time

＊ Startup of low speed shall not have

start shock and shall be smooth.
(Adjust it with N11 valve.)
(1) Filling Ratio of Sleeve
It is ratio of molten metal in sleeve at pouring.

Ｓｈｏｔ Weight
Filling Ratio of
= × 100%
Sleeve
Chip Area ×ＤｒｙＳｈｏｔ Stroke × Molten Metal specific gravity

(2) Low Speed Rate Chip

Increase the low speed ratio where is less air inclusion of sleeve.
Ｄｒｙ Ｓｈｏｔ Stroke
Target of Low Speed 0.7 × Chip Diameter
Low Speed Rate =
Rate Sleeve Filling Ratio ＊ Target of Sleeve Filling Ratio 20 ～ 50%

Ｐ－6
 EX.
Chip Diameter: φ70mm Ｓｈｏｔ Weight: 900g ＤｒｙＳｈｏｔ Stroke : 337mm
Chip Area = (π/4) ×72 = 38.5cm2 Aluminium specific gravity : 2.6g/cm3

900
1) Sleeve Filling Ratio = × 100% = 27%
38.5 × 33.7 × 2.6

0.7 × 70
Injection Low Speed Forward
2) Low Speed Rate = = 0.21m/s
27 0.21m/s

② High Speed Rate

Form product, decide molten metal flow, and diffuse porosities.

1) 2) 4)

Decide filling time. Evaluate high speed rate by mold condition. Check gate speed.

3)

Check mold limit speed by machine ability.

Ｐ－7
(1) Filling Time
Molten metal need to be filled before it solidify in cavity.
Filling Time = 0.01 ×Wall Thickness ×Wall Thickness

(2) High Speed Rate by Mold Condition

Ｐａｒｔ Weight
High Speed Rate =
Chip Area × Filling Time × Molten Metal specific gravity

If it is kg/cm2, calculate as
(3) High Speed Rate by Machine Ability (Mold Limit Speed) the value is.

2
(Gate Area ) × Injection Cylinder Area × (Accumulator Pressure MPa × 10)
Mold Limit Speed = 550 ×
(Chip Area ) 3

(4) Check Gate Speed

Chip Area
Gate Speed = × High Speed Rate 20 ～ 60m/s is standard.
Gate Area

(5) High Speed Range

(Ｐａｒｔ Weight )
Product + Over Flow Weight
High Speed Range = + 1cm
Chip Area × Molten Metal specific gravity

Ｐ－8
EX. ((Ｐａｒｔ Weight )
Wall Thickness: 2mm Product + Over Flow Weight: 700g Chip Area : 38.5cm2
Gate Area : 1.3cm2 Aluminium specific gravity : 2.6g/cm3 Accumulator Pressure: 10MPa (100kg/cm2)
(Coefficient)
1) Filling Time = 0.01 × 2 × 2 = 0.04sec

700
2) High Speed Rate = = 175cm/s = 1.75m/s
38.5 × .0.04 × 2.6
Bubble

Injection Cylinder Cross Section = (π/4) × 12.52 = 123cm2

(Coefficient) (1.3)2 × 123 × 100

3) Mold Limit Speed = 550 × = 332cm/s = 3.32m/s
(38.5)3

38.5
4) Gate Speed = × 1.75 = 52m/s
1.3

700
5) High Speed Range = + 1cm = 8cm = 80mm
38.5 × 2.6

Ｐ－9
③ Casting Pressure
Accumulator pressure is able to be adjusted between
(1) Casting Pressure 9.5MPa ～ 13.5MPa (95kgf/m2 ～ 135kgf/m2) without
nitrogen gas release.
Intensify Cylinder Area As TOSCAST, accumulator pressure is adjusted
Accumulator
Casting Pressure = × × ０．９ automatically by inputting casting pressure.
Pressure
Chip Area
Accumulator Pressure Drop

(2) Intensify Time

ＡＣＣ2
Intensify Time = 0.01 × Wall Thickness (tm) × Wall Thickness (tm)
Pressure

ACC Pressure Drop １０％ﾟ

(3) Injection Power

Injection Power = Casting Pressure × Project Area

(4) Mold Limit Casting Pressure

Mold Clamp Power
Mold Limit Casting Pressure =
Project Area

Ｐ－10
EX.
Die Cast Machine: DC350Ｊ－ＭＨ Chip Diameter: φ70 Accumulator Pressure: 10MPa (100kg/cm2 )

(π/4) × 182
1) Casting Pressure = × 10 × 0.9 = 59.6MPa (596kg/cm2)
(π/4) × ７2

Wall Thickness: 2mm

2) Intensify Time = 0.01 × 2 × 2 = 0.04

= 40ms

3) Injection Power = 59.6 × 350 = 2086KN = 2086 × 0.1= 208.6T

350 × 100
4) Mold Limit Casting Pressure = = 100MPa (1000kg/cm2 )
350

Ｐ－11
 7. Casting Condition Setting

1) Injection Condition Setting

① Low Speed Rate (N11) ② Low Speed Rate (C2G11) ③ High Speed Acceleration (N12)
④ High Speed Rate (C2G12) ⑤ High Speed Range ⑥ Intensify Time (C2G15)
⑦ Casting Pressure (ACC Pressure)

2) High Speed Range

It is important for stable displacement process of air in mold and molten metal to fill cavity with molten metal in high speed from
certain position always.
Product acceptability depend on high speed range.
Basically, high speed range starts when molten metal reach to gate area. (Gate High Speed)

3) Adjustment of High Speed Acceleration

Strewing pattern of molten metal blowout from gate depend on adjustment of startup time that low speed reach high speed range.
It is adjusted with N12 valve.
It is adjustable randomly between 10 ～ 40msec for TOSHIBA die cast machine.

Ｐ－12
4) Intensify Time
As the phrase says “strike while the iron is hot”, it is important to intensify filled molten metal smoothly without burr occurrence and
keep the pressure.

It is not only compensate contraction in volume by solidification, but also compress included air maximally. Besides it makes inside
structure dens.

Intensify Time is from plunger stop to casting pressurizing start.

It is required to pressurize before molten aluminium start solidifying in cavity.

5) Casting Pressure
Casting Area × Casting Pressure shall not over mold clamp power.
Mold Clamp Power ＞ Casting Area × Casting Pressure = Mold Open Power
Guide of Casting Pressure General Parts, Appearance Parts 60MPa (600kgf/cm2)
Pressure Parts, Intensify Parts 90MPa (900kgf/cm2)

6) Thickness of Biscuit
Guide of Biscuit Thickness
Biscuit Thickness (mm) = 0.25 × Chip Diameter (mm)
If biscuit is thin, product gravity decrease because biscuit transmit pressure to molten metal in cavity effectively.

Ｐ－13
8.INJECTION WAVE READING

INTENSIFY
TIME
HIGH SPEED CASTING

Displacement
Speed/Casting Pressure/
INCREASE PRESSURE

HIGH
SPEED

LOW
SPEED

HIGH
SPEED LOW SPEED
INCREASE

HIGH SPEED
LOW SPEED TIME
SECTION

INTENSIFY ORIGINAL
POINT BISCUIT
TIME
THICKNESS

DRY INJECTION STROKE

Ｐ－14
9.Reference materials

Thickness and relations of filling time Thickness and relations of f Gate Speed

Wall Thickness filling time

Wall Thickness （ｍｍ） Gate Speed （ｍ／ｓ）
（ｍｍ） （sec ）
０．７６２ ４６ ～ ５５
１．５ ０．０１ ～ ０．０３
１．２７０ ～ １．５２５ ４３ ～ ５２
１．８ ０．０２ ～ ０．０４

２．０ ０．０２ ～ ０．０６ １．９０５ ～ ２．２８６ ４０ ～ ４９

２．３ ０．０３ ～ ０．０７ ２．５４０ ～ ２．７９４ ３７ ～ ４６

２．５ ０．０４ ～ ０．０９

２．８５８ ～ ３．８１０ ３４ ～ ４３
３．０ ０．０５ ～ ０．１０
４．５６０ ～ ５．０８０ ３１ ～ ４０
３．８ ０．０５ ～ ０．１２
６．３５０ ２８ ～ ３５
５．０ ０．０６ ～ ０．２０

６．４ ０．０８ ～ ０．３０

Ｐ－15
 10. Die Cast Machine Specification

Injection Pressurization ACC Injection (Injection

Pressurization
Die Cast Machine Cylinder Cylinder Pressure Power Power)
Ratio
Diameter Diameter (MPa) (kN) (Ton･f)
DC 135EL φ 90 φ140 2.42 9.3 143 14.6
DC 135H φ125 13.2 163 16.6
DEC150MT φ 90 φ125 1.93 15 184 19
DC 200EL φ 90 φ140 2.42 13.2 204 20.8
DC 250C φ110 φ160 2.12 13.2 266 27.1
DC 250CL, JT φ115 φ160 1.94 13.2 266 27.1
DC 350C φ115 φ180 2.45 13.2 337 34.4
DC 350CL-T, J-MT φ125 φ180 2.07 13.5 340 34.7
DC 500C φ135 φ215 2.54 13.2 480 49
DC 500CL-S, T, HT φ135 φ215 2.53 13.2 480 49
DC 650C, CL φ145 φ230 2.52 13.2 550 56.1
DC 800C, CL φ150 φ240 2.56 13.2 599 61.1
1Mpa = 10.2kgf/cm2 1kN = 0.102Ton･f 1kgf/cm2 = 0.098Mpa 1Ton･f = 9.8kN
Die Cast Machine Specification

Injection Pressurization
Pressurization cylinder Area
Cylinder Cylinder
Pressurization Ratio =
Injection Cylinder Area

Ｐ－16
 MOLD DATA TOSCAST INPUT VALUE

1. MEASURE THICKNESS OF FIXED MOLD AND MOVABLEMOLD.

FIXED MOLD MOVABLE MOLD MOLD THICKNESS

＋ ＝
㎜ ㎜
㎜

2. MEASURE DRY INJECTION STROKE. DRY INJECTION STROKE

READ INJECTION St VALUE ON
MOLD CLOSE LOW SPEED INJECTION
BODY OPERATION SCREEN.
㎜

3. MEASURE ＴＩＰ DIAMETER.

ＴＩＰ DIAMETER
CALCULATE ＴＩＰ CROSS SECTION. ＴＩＰ CROSS SECTION

RADIUS×RADIUS×3.14／4= ㎜
㎝2

BISCUIT THICKNESS
4. MEASURE BISCUIT THICKNESS.

PRODUCT WALL THICKNESS

5. MEASURE PRODUCT WALL THICKNESS

㎜ Ｐ－17
 ＳＨＯＴ WEIGHT
6. WEIGH CASTING.

(Snap off casting from gate.) ㎏ｆ

ＰＡＲＴ WEIGHT
7. MEASURE AHEAD OF GATE WEIGHT (PRODUCT AND OVERFLOW)

㎏ｆ

8. FIND PROJECT AREA OF CASTING. ＣＡＳＴ AREA

㎝2

9. MEASURE THICKNESS AND WIDTH OF GATE.

GATE THICKNESS GATE WIDTH GATE ＡＲＥＡ

× ＝
㎝ ㎝ ㎝2

1. INPUT MOLD NAME

This is the file name for saving.
Less than 8 letters.
2. SELECT MATERIAL FROM SELECT WINDOW.

3. SELECT PREPARER FORM SELECT WINDOW.

Ｐ－18
 INJECTION
TOSCAST INPUT VALUE

LOW SPEED RATE

0.7 × ０．７× ㎜
ＴＩＰ DIAMETER
1. LOW SPEED = ＝ ＝
SLEEVE FILLING ＲＡＴＥ
m/ｓ
％
ＳＨＯＴ WEIGHT
SLEEVE FILLING ＲＡＴＥ = ×１００ ％
ＴIP ＡＲＥＡ×ＤＲＹ ＳＨＯＴ STROKE× ALUMINUM ＳＰＥ
ＣＩＦＬＣ ＧＲＡＶＩＴＹ

ｇ × １００％
＝ ＝
％
× ×２．６ｇ/cm3
㎝2 ㎝

ＰＡＲＴ WEIGHT （PRODUCT + OVERFLOW WEIGH）

2. HIGH SPEED =
ＴＩＰ ＡＲＥＡ×FILL TIME× ALUMINUM ＳＰＥＣＩＦＬＣ ＧＲＡＶＩＴＹ

HIGH SPEED RATE

ｇ
＝ ＝
２．６ｇ/cm3 × × ×１００ m/ｓ

㎝2 Ｓ

FILLING TIME = 0.01×（ WALL THICKNESS× WALL THICKNESS）

＝ ０．０１× × ＝
㎜ ㎜ Ｓ
Ｐ－19
GATE SPEED CHECK
TOSCAST INPUT VALUE

ＴＩＰ ＡＲＥＡ
GATE SPEED = ×HIGH SPEED RATE
GATE ＡＲＥＡ

㎝2
× ＝
m/ｓ m/ｓ
㎝2

ＰＡＲＴ WEIGHT （PRODUCT + OVERFLOW WEIGH）

3. HIGH SPEEDＬＥＮＧＴＨ = + 10mm
ＴＩＰ ＡＲＥＡ×FILL TIME× ALUMINUM ＳＰＥＣＩＦＬＣ ＧＲＡＶＩＴＹ

HIGH SPEED ＬＥＮＧＴＨ

＝ ＋ １０㎜ ＝
㎜
× ２．６ｇ/cm3
㎝2

4. CASTING PRESSURE ＵＰ TIME

= 0.01×（ WALL THICKNESS × WALL THICKNESS） CASTING TIME

＝０．０１ × × ×１０００＝ ms
㎜ ㎜
Ｐ－20
 INTENSIFY CYLINDER ＡＲＥＡ
5. CASTING PRESSURE ＝ ×ACCUMULATOR PRESSURE×0.9
ＴＩＰ ＡＲＥＡ CASTING PRESSURE

㎝2 ㎏/㎝2
＝ × ×０．９ ＝

㎏/㎝2 FORWARD LIMIT POSITION

㎝2
6. INJECTION FORWARD LIMIT = DRY INJECTION STROKE + 10mm ㎜

MOLD CLOSE
1. IS INJECTION FORCE LESS THAN MOLD CLOSE FORCE?
CASTING PRESSURE× ＣＡＳＴ AREA = INJECTION FORCE

× ＝
MOLD CLOSE
㎏/㎝2 ㎝2 ＴＯＮ
FORCE LOAD
INJECTION FORCE

MOLD CLOSE FORCE > INJECTION FORCE ＴＯＮ ％

＋
×１００＝ １０％
SETTING MOLD CLOSE
ＴＯＮ
MOLD CLOSE FORCE LOAD
MACHINE TONNAGE ％
FORCE
INJECTION FORCE

MOVABLE MOLD FIXED MOLD

Ｐ－21
CHECK
HIGH SPEED RARE BY MACHINE CAPACITY (LIMIT SPEED OF MOLD)

LIMIT SPEED OF MOLD

(GATE ＡＲＥＡ) 2×INJECTION CYLINDER ＡＲＥＡ×ACCUMULATOR PRESSURE

× × ×
㎝2 ㎝2 ㎝2 ㎏/㎝2
＝ ５５０ × ＝
m/ｓ
× ×
㎝2 ㎝2 ㎝2

( ＴＩＰ ＡＲＥＡ ) 3

MOLD LIMIT CASTING PRESSURE

MOLD CLOSE FORCE

MOLD LIMIT CASTING PRESSURE

ＴＯＮ
＝ ×１０００＝
㎏/㎝
㎏/㎝
㎝2
ＣＡＳＴＡＲＥＡ

Ｐ－22
 POURING
1. SELECT ASSEMBLED LADLE TYPE FORM SELECT WINDOW.

（１２０）

４０

１５

２００
６ ６

１０ HOW DID IT GO?

１２０
（１３５）

（７０）

Ｐ－23