P-Q2 Calculations format Part Name:- EPA Top Cover_D15-D17

Hydraulic system pressure (Phs) in bar 75 76.5 kg/cm2 Machine type 800T
Intensification Cylinder piston area (Aint) in cm2 441.1502944 diameter (mm) 237 Locking force in tons 800
Injection Cylinder Piston Area (Apiston) in cm2 172.0336137 diameter (mm) 148 Locking force (Fl) in KN 7848
Injection Force (Finj) in KN 129.0252103 Phs*Apiston Locking force required (Flreq) in KN 6104.0801
Plunger Area (Apl) in cm2 38.48451001 diameter (mm) 70 Safety margin in Locking Force 22.2%
Metal pressure in sleeve (Pm) in bar 335.2653061 Finj/Apl (d/(2*g))*(vg/C)^2 (d/(2*g))*(Q/(C*Ag))^2
Area of gate (Ag) in cm2 3.65
Metal flow through gate (Q) in cm3/s 14624.1138 Vm/t Apl*vpl Ag*vg P-Q2 Diagram
400
Metal flow through gate recommended (Qrec) in cm3/s 6941.128356 Vm/trec
Metal volume through the gate (Vm) in cm3 348.7531381 Apl*L2 350
Fill time actual (tact) in sec 0.023847813 Vm/(Apl*vpl*100)
Fill time recommended (trec) in sec 0.050244444 k*((Ti-Tf+S*Z)/(Tf-Td))*Tw 300
Velocity of plunger (vpl) in m/s 3.8
Velocity at gate (vg) in m/s 40.06606521 Apl*vpl/Ag 76.70635376 250 Fill time

Pressure in bar
Machine line
Maximum metal pressure in sleeve (Pmax) in bar 859.7295918 S
Recommended t (min)
flow Avg t
Emperical constant (k) in s/mm 0.035 0.035 for small to 0.047 for large castings 200 1.5 0.01 - 0.03 0.02
Maximum gate velocity : 50 m/s
Temperature of metal in gate (Ti) in deg C 630 1.8 0.02 - 0.04 0.03
150 Minimum gate velocity : 20 m/s
Minimum flow temperature of Alloy (Tf) in deg C 570 2 0.02 - 0.06 0.04
Surface temperature of die before shot (Td) in deg C 210 Actual Process
2.3point
0.03 - 0.07 0.05
100
Percentage of Allowable solids at the end of filling (S) in % 20 2.5
Actual Process line0.04 - 0.09 0.06
Casting wall thickness (Tw) in mm 3.8 50 3 0.05 - 0.10 0.07
Units conversion factor (Z) in deg C/% 3.8 3.8 0.05 - 0.12 0.08
Liquid metal density (dl) in g/cm3 2.39 0 5 0.06 - 0.20 0.12
Gravity constant (g) in m/s2 9.81 0 100000000 200000000 300000000 400000000 500000000 600000000 700000000
Discharge coefficient of the runner system (Cd) 0.5 Flow , Q2 in (cm3/s)2
Maximum velocity at gate (vgmax) in m/s 50 119.4587485 corresponding Pressure value in sleeve=(dl/(2*g))*(vg/Cd)^2
Minimum velocity at gate (vgmin) in m/s 20 19.11339976 corresponding Pressure value in sleeve=(dl/(2*g))*(vg/Cd)^3
Part weight (Wp) in gms 552
Over flow weight (Wof) in gms 281.52
Runner Weight (Wrun) in gms 524.4
Shot Weight (Wshot) in gms 1357.92
Projected area (Aproj) in cm2 710
Sleeve length after plunger (Ls) in cm 51
Fill ratio (Rf) in % 28.9%
Dry shot speed (vdry) in m/s 6.3
Maximum metal flow (Qmax) in cm3/s 24245.2413 Apl*vdry
Biscuit thickness (tb) in cm 2.5
Length of 1st phase (L1st) in cm 36.23646621
Percentage empty sleeve 71%
Total volume of sleeve 1394.542646
Plunger stroke to fill empty sleeve in cm 36.23646621
Volume of runner up to gate 123.2029509
Plunger stroke to fill runners up to gate in cm 3.201364676
2nd Phase position (Phase2pos) in cm 39.43783088
Biscuit weight in gms 229.9449473
Length of 2nd phase (L2nd) in cm 12.26353379
Venting area required (Av) in cm2 1.705436012