Runner and gate design.

The Important Features

Introduction;
The following is a brief summary of the important factors to consider when designing runner and gating systems for Zinc and Aluminium pressure die casting dies. In the past runner systems were designed using empirical knowledge and developed using trial and error methods which involved excessive time and often multiple die trials. Today, computer programmes exist which eliminate these problems and are able to give good results immediately but, many of the most basic design issues are often neglected during the design stage particularly if the die is designed by the tool maker without consultation to the die casting technicians. These brief notes are intended as guidelines for use during training and as an aide memoir for die design technicians and designers. They are not intended to cover all aspects of die design practice. ____________________________

Objective:
The runner and gate system should achieve the following in basic terms: Provide optimum yield; increases efficiency by optimising the casting to runner yield ratio, improve metal losses due to lower re-melt weights, reduces cycle times due to improved thermal efficiency. Produce a casting of the specified quality; in terms of finish, size and tolerance, casting integrity, mechanical properties, cycle time and consistency. Achieve first time success; to avoid wasted time on successive machine trials, delays in delivery of samples, loss of customer confidence and excessive die development costs.

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.

Runner and gate design.

Influencing factors.

Designing a runner system:

Selection of the machine should be based on several factors but not just shot weight and platen area. Most machines are supplied with a PQ2 diagram or one exists from measurements taken on other similar machines. Runner designs should be based on machine performance with a given plunger or shot sleeve diameter, known hydraulic pressure and in the case of hot chamber die casting the nozzle size. Both projected area and lock tonnage should also be considered if the proposed runner plus casting is liable to approach the machine limits.

Casting geometry:

The cavity should be positioned to promote the best cavity fill conditions while accommodating essential die features such as core slides, cooling channels, sensitive casting features, number of cavities and robotic removal constraints. Other process criteria such as second operation locations, clipping orientation, break off de-gating and finishing requirements should also be considered before the cavity position is decided.

Uniform flow path:

The runner should establish a uniform metal flow rate deigned to promote the best hydraulic system, stable metal pressure and velocity. Most computer design programmes will control these features but the designer will still have institute a flow path allows these features conform to the desired parameters.

Modern pressure die casting machines often have more power at the shot end than is required to achieve the optimum fill conditions. Consequently, the performance offers many gate area options capable of achieving the desired fill conditions the designer must select the most suitable based on the casting specification and process limitations.

Cavity fill conditions:

Cavity fill pattern:

Is invariably decided by the casting geometry and gate position but the metal pressure and velocity will have influence but to a lesser extent. The influence of casting features such as vertical surfaces and ribs, variable section thicknesses, isolated bosses and cores must be considered when the gate position is decided.

Venting and overflow wells:

Should all be considered at the design stage are directly related to the cavity fill conditions and casting geometry but also the introduction of over flow wells or pockets may have significant cost implications.

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.

Runner and gate design. Machine Performance.

Effects of change.
Injection pressure: Reduce or increase. Increased injection pressure will increase flash, raise galvanising and die erosion. Optimum pressure levels will improve casting integrity, maintain speed and velocity and improve cavity fill conditions. Reduced injection pressure reduces flow rates, and static metal pressure on hot chamber pressure die casting machines. Plunger diameter on hot chamber die casting machines smaller plungers give the best casting results with higher injection pressure and faster delivery. On aluminium cold chamber machines plunger diameter choice is less critical but effect is far more significant in performance terms - increasing delivery velocity and reducing cavity fill times. Plunger speeds - high terminal velocities can produce pressure spikes on older die casting machines leading flash and die wear. High gate speeds result in expensive die maintenance due to die erosion and galvanising. Runner Area/volume - die designer should create a uniform flow through the runner by establishing nozzle area (hot chamber) as the largest section in the runner. Progressively reducing the cross sectional area of the runner at each section to the gate which should be the smallest area in the runner system. Similarly, on cold chamber dies the sprue post runner should be the largest runner section down to the gate which should be smallest section of the runner.

Flow rate histogram.

Nozzle area

Gate Area

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.

Runner and gate design.

Runner features

Y Junction not T

Reduces area and increases pressure progressively.

Y Junction

Increases volume at the junction creating low pressure area at the centre of the gate.

T Junction

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.

Runner and gate design.

Runner features

Taper tangential runner - with shock absorber showing section change A to B to maintain pressure and velocity

Smaller diagram illustrates poor runner design small access radius, increased runner volume at the radius, small runner cross section at the end of the taper, and no shock absorber.

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.

Runner and gate design.

Runner features
Drawings Show section through sprue posts on Aluminium (top) and Zinc (bottom) dies. This area most commonly interpreted incorrectly by toolmakers. Note; The reduction from the sprue faces to die face and the size and blend radius which are struck from the same centre to ensure even transition from sprue to die.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD,. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.

Runner and gate design.

Runner features

Runner sections: Need to be adjusted by differing percentages to accommodate larger angular direction changes

30% reduction in runner area - down stream of metal flow for 900 bend.

10% reduction in runner area- down stream of metal flow for a 200 bend.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Gate Areas
Gate Areas:

Optimum for Zinc alloy pressure die-casting: Gate speed / velocity 35 45 metres per second. Cavity fill time plated or powder coated finish 20 milli seconds or functional parts 40 milli seconds. Gate depth 0.15 0.5 mm. Optimum for Aluminium alloy pressure die casting: Gate speed / velocity 25 to 35 metres per second.
To avoid die erosion and control cavity fill characteristics.

Cavity fill time end of fill temperature is most important on large castings as solidification can occur prior to cavity filling. Depth 1.25 3 mm (1.5 mm minimum for machine intensification to be effective).

Fill Pattern:
Casting geometry:
has the largest influence on cavity flow paths high metal velocity applied to vertical casting faces causes turbulence, galvanising and impedes metal. All of which can result in expensive die repairs / maintenance. Section changes and cores change pressure and direction and these effects need to be considered and understood when considering gate position options.

Zones volumes and areas; It is possible to assess parts of the casting separately and this may be advantageous if they are unlikely to be fed directly from the gate. Using computer programmes allows each separate zone to be quantified in volume and surface area terms. If treated as un-gated the fill time and end of fill temperature can be determined as a comparison with the main body of the total casting. Gating separate zones: It is possible also to examine separate zones of a given part using separate gates for each zoned area. This will often improve fill characteristics and reduce the risks of defects. The uses of multiple gates are not a risk if designed and implemented correctly. Runner will direct metal flow: It must be stressed that the gates and runner both influence flow direction. Once the runner is established metal under pressure will enter the cavity in the same direction and flow angle. Varying injection speed and metal pressure may alter this angle slightly but this is only a fine tuning method.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Fill pattern.
Influence of casting geometry:

Certain casting shapes are best filled in a predetermined way, if the tooling configuration allows. Deep boxes, where the depth is 50% of the edge length or more can be fed using the gate runner configuration shown below alternatively the box can be turned through 450 to shorten the runner distance and improve shot yield.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Fill pattern.

Ovals or round castings: Try to fill the centre first using either a runner configuration below or a more traditional fan feed. With fan feeds it is essential to get the ratio of the approach angle and width of gate correct.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Fill pattern.

Annular rings: Can be fed using the runner configuration indicated below. A small
over flow well should positioned in the centre hole to take away any lubrication fume and another well placed on the out side perimeter adjacent to the last segment of the part to fill.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Fill pattern.
Rectangular Plates: Fill across shortest distance whenever possible to cut down
flow distance and increase end of fill temperature. It is therefore advisable to avoid the option shown in the upper diagram if possible.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Fill pattern.
Diagram shows: runner developed over a period of time to resolve problems of

porosity and poor fill results. The darker blue area is approximately 6 mm deep, with a gate depth of between 1.8 and 2.5 mm. Casting weighed approximately 5 Kg and with a flow distance of 510 mm.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Fill pattern.
Diagram shows: Revised runner with balance fill and uniform gate thickness of 2

mm. The runner shows reduced shot weight by over 1 Kg and a subsequent increase in yield of 18% and a reduction in projected area of some 22% allowing improved shot speed and increased in injection pressure.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,

Runner and gate design.

Vents and Overflow wells.

Points to remember:
Over flow wells can be used to change or divert metal flow, but rarely remove gas and fume as the cavity is normally sealed before they become active. Similarly vents can only work for less than half of the cavity fill time as they are sealed off before the final fill is achieved. Use only one connection per over flow to avoid back feeding through the overflow and reintroducing gas and cold metal. Always vent over flow wells as a precaution. Over flow wells are a poor method of die heating both inefficient and wasteful. Many are lost before re-melting and therefore increase metal losses.

See reference material from ILZRO, IZA.

JWT
Sept 05 issue 5