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A Runner-Gate Design System For Die Casting Dies PDF
A Runner-Gate Design System For Die Casting Dies PDF
Abstract
Various analytical FEM, FDM tools for flow process including die casting have presented, they are only giving information
to predetermined die design whether it is proper or not. Current shop floor practice uses the trial-and-error methods to
determine new die design.
This paper describes a research work of developing computer-aided die design system for die casting. Approach to the
CAD system has been written in circumstance Auto LISP with personal computer. This system has been developed to present
algorithms for automation of die design, especially runner-gate system using 3-D geometry. This system quantifies practical
knowledge and experiences in die design as formulating procedure. It is possible for engineers to make automatic and
efficient design of and it will result in reduction of required expenses and time. It is composed of selection of cast alloy,
product design, runner-gate design etc. In addition, specific rules and equations for the system have been presented. An
example is applied to cap-shaped cast using the proposed system.
Key words : Die casting, Die design system, Rule base, Runner, Gate
NOMENCLATURE
1. INTRODUCTION
Die casting is one of the most economical casting processes for manufacturing precision shaped parts in mass
production. It is a precise casting method in which molten metal is injected at high pressure into a die cavity. As soon as the
molten metal has filled the cavity, it solidifies by fast cooling. Die-cast components are being used increasingly in the
automobile, aerospace, electronic and other industries because of their premium quality, low cost and low weight. Because of
high pressure and short cycle times involved, thin-wall sections are possible.
In die-design system of various forming processes, Shaffer developed progressive die design by computer (PDDC)
system and J.P. Kruth made efforts to develop an integrated CAD/CAM system for mould design and manufacture. J.C. Choi
developed a compact and practical CAD system for blanking or piercing of irregular shaped- sheet metal products and stator-
rotor parts.
In studies of die casting process, C.C Thai used runner-optimization design method and the abductive network in
modeling the die casting process according to the experimental data. W. Zhang researched the CAD/ CAE system that die
designer can determine the shape and dimension of runner-gating system under different casting condition. Generally
speaking, die designer still have to depend on engineer’s experiences and know-how due to lack of proper analytical ability
metal flow and velocity and heat transfer in die. Current shop floor practice uses the trial-and-error method to determine die
design, when new moulds are used. This method is costly and results in a lot of wasted casting. To solve this problem a study
was done on the runner and gate system to simulate the molten metal flow and to analyze the pressure and metal movement
during casting process. Although some finite element analysis software is capable of analyzing the melting process and flow
conditions of the products (workpiece) under various injection conditions, they are only giving some limited suggestions and
information to die design.
In this study, die design system for die casting process has been developed to present flow chart for automation of die
design, especially runner-gate system. In addition, specific rules and equations for runner-gate system have been presented to
avoid too many trials and errors with expensive equipment. It is possible for engineers to make an automatic and efficient die
design and it will result in reduction of expense and time.
An example of cast product is seen in Fig.1. It is generally composed of cast cavity, gate, runner, biscuit, overflow and
to be formed out from die. Irrespective of the shape of the cast, the quality is always determined by the runner-gate system.
Generally, the system contains their arrangements and shapes to design properly. The effects of metal velocity and die
temperature on the metal flow distance and quality are discussed.
Guide pins Surface pin
Holding Block
Overflow
Ejector pins
Cavity Block
Ejector plate
Cast
Biscuit
Shot Chamber
Fig. 1 Casting product Fig. 2 Essential components of simple die casting die
Essential components of simple casting die are illustrated in Fig.2. A die consists of two sections at the die parting plane.
It is split into two sections so that the casting can be removed after it has been formed. These two sections are called the
cover die (moving die) half and ejector die (fixed die) half. The cover die half may be machined in the solid cover die half, or
it may be inserted. The cover die half is fastened to the stationary platen on the casting machine and does not move during the
casting cycle. The ejector half is mounted on the movable platen of the machine. A cavity block that is a reproduction of a
section of the part that is to be a casting is formed or machined into two halves of the die block.
In this study, die design system means automated generation system that master mould and other components are
generated automatically when three-dimensional drawing of product is prepared. If a drawing of product is input into an
AutoCAD by output drawing file on a screen, product design will be carried out and the size of die block will be determined.
This system is roughly composed of cast (product to be formed) design, and die layout design and die generation. Fig.3
shows the flow chart of the system. The shapes of each component are determined by rule-base and are connected at
specified position by assembly flow chart. After components and casting are connected, the shapes of two die halves and
layout are determined. And die design is finished after user's confirmation. This might be analyzed by commercial CAE
software if the design is proper or not.
Selection of
gate thickness
Selection Selection
parting surface parting surface
Determination of
gate width
Mechanical Property of
cast
Determination of gate
area
Determination of
gate thickness
Determination of gate
width
No
Confirm?
Yes
Part generation
Gate
by rule base
Fig. 5 Flowchart for gate design Fig. 6 Flowchart for runner design
K = [ L + C p ⋅ (T m − T s )] ⋅ ρ ⋅ S ⋅ X (2)
The flow rate heat per unit time, q' is given by (3)
q ′ = χ ⋅ S ⋅ (T m − T d ) / X (3)
From the equation (2) and (3), filling time, tg can be obtained.
K
tg = × 0 .7 (4)
q′
Generally, the gate thickness, t is selected properly, which is between 0.5 and 3.0mm, considering trimming etc. The
width of gate L is determined by following equation from gate area calculated by equation (1).
Ag
L= (5)
t
10~20¡ Æ
, and corner radius longer than 6mm.
Side Angle
Depth(D)
Radius(R)
Width(W)
Determination of
Gate Overflow
connection location
No
Confirm?
Yes
Assembly Complete !
5. CONCLUSIONS
ACKNOWLEDGEMENTS
The authors wish to acknowledge Brain Korea 21 of Department of Mechanical Engineering, Dong-Eui University, Pusan,
Korea.
REFERENCES
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