Nadca

NADCA
Alucast
EC-700 PQ2
Mike Ward, November, 2013

Outline
• The Shot End
• Gating
• Atomized Flow
• Scientific Principles
• Step by Step PQ2
• Worked Examples
Objectives
• To understand the relationship between

the pressure (P) applied to molten
metal and the cavity fill rate (Q).
Objectives
• For P and Q address the

relationship between
–gate area
–plunger size
–machine power
–hydraulic pressure
–atomized flow
–cavity fill rate
Objectives
• To learn how to construct the PQ2
diagram
• To learn how to calculate the

metal pressure
• To learn about the die cast

machine’s capability to generate
metal flow
Objectives
• To learn how to construct the die
cast machine’s power (characteristic)
line
• To learn how to define the operating
window for a specific die mounted in
a die cast machine with known
performance
• To work out sample problems for a
better understanding of the total PQ2
process
PQ^2 Diagram
Shot End
Injection Systems
• A variety of
injection systems
• hot chamber
• cold chamber
• Some control
speed by
• meter “IN”
• meter “OUT”
Injection Systems
• Horizontal or Vertical
Cold Hot
chamber chamber
Injection System
• Accumulators supply the hydraulic

fluid volume and power for the shot
system
• Accumulator pressure minus energy

to start fluid flow and overcome
friction results in “effective” pressure
for the shot system
Injection System
• The effective accumulator pressure and

fluid volume results in a plunger fast
shot velocity (FSV)
• The maximum FSV is called the “Dry

Shot Speed” (vds) ). It is measured with
the fast shot speed control valve wide
open with no metal in the sleeve.
Injection System
• The Dry Shot Speed is unique for every

machine and changes over time as the
machine and hydraulic fluid wear.
• The Dry Shot Speed for every die

casting machine should be measured
and documented.
Injection System
• Plunger speed reduction:
– closing the fast shot speed control valve
– providing a resistance to the plunger
motion by pushing molten metal into
the cavity,
– lowering the accumulator pressure
Injection System
• Relationship for the Power System is given
by:   2 
 v p 
psc  phs 1  
 
 
 v
  ds  
• Where:
– psc = effective pressure in shot cylinder, lbs./in2
(kg/cm2)
– phs = hydraulic system pressure, lbs./in2 (kg/cm2)
– vp = plunger velocity, in/sec (m/sec)
– vds = dry shot velocity, in/sec (m/sec)
Injection System
  2 
 v p  
psc  phs 1   
 v 
  ds  
Exercise:
Calculate psc for vp = 0
and vp = vds
Injection System
• For any given machine, the
relationship between fill rate (Q) and
metal pressure (Pm) depends on the
plunger size.
• Once a metal plunger size is
selected, the fill rate (Q) is
calculated by multiplying the area of
the plunger times the plunger
velocity and given by the following
formula:
Injection System
• Fill rate, Q Where: Q  Apt  v pt
–Q = the plunger displacement (flow)
rate, in3/sec (cm3/sec)
– vpt = the velocity of the plunger
when it is pushing molten metal,
in/sec (cm/sec)
– dpt = diameter of the metal plunger,
in. (cm)
– Apt = the area of the metal plunger,
in2 (cm2) d 2
Apt   
4
Power System
• Exercise:
• Find the fill rate (Q) when:
– Plunger diameter - 4.0 in
– Plunger velocity - 200 in/sec
2
d
Apt  Q  Apt  v pt
4
Power System
• Graph of typical pump output:
Normalized Power Index (NPI)
 2
 2
LB
  v DPH AH NPI  UB
 2
max
• vD = Dry Shot Speed

• PH = Hydraulic Pressure
• AH = Hydraulic Cylinder Area
• Ωmax = Maximum Power
• ΩUB = Maximum Usable Power
• ΩLB = Minimum Usable Power
Entrapped Air Control
• Sleeve air
– Typical % fill of aluminum shot sleeves

• 30% (70% air) to 85% (15% air)
– Important to push air ahead of the

molten metal through the cavity into
the overflows and out the vents.
– Specific plunger speeds are required for

a given plunger size and % sleeve fill
Shot End – Shot Profile
T97-063
*1997 Transaction Paper 063

~40 in/s
~120 in/s
*1997 Transaction Paper 063

First Stage Speed
• This specific plunger speed is the
“critical slow shot velocity”
• Approximated by the equation
• Valid only for fi > 50%
vcss  ccc

 100%  f
 i 

 d
 100%  pt
 
 100%  fi 
vcss  ccc   dpt
 100%% 
• Where:
– vcss = critical slow shot velocity,
in/sec (m/s)
– fi = volume fraction of shot sleeve
initially filled with molten
metal, %
– dpt = plunger diameter, in. (m)
– ccc = curve fitted constant,
22.8 in1/2/s, (0.579 m1/2/s)
• Volume fraction of shot sleeve is also
called % fill of sleeve
• Calculated by the equation
 V 
fi   
A  L  100%
 pt s 
V = Volume of metal in shot sleeve, in3 (cm3)

Ls = Length of the shot sleeve between the face of the
plunger and the face of the ejector die, in (cm)
Apt = shot plunger area, in2 (cm2)
• Exercise:
2
– Find initial percent fill and d
critical slow shot speed. Apt 
4
– When:
• Plunger diameter - 4.0 in
• Sleeve length - 40.0 in
• Total shot volume - 425.0 in3
– Calculated from the previous
example: Apt = 12.56 in2
• Substituting into the equation will
determine the sleeve fill percentage
 V 
fi     100%
A L 
 pt s 
 425in3 
fi  
 2

 100%
12.56in  40in 
fi  84.6%  85%
• Then calculate the critical slow shot
speed required
v css  c cc

 100%  f
 i 

 d
 100%%  pt
 
v css  22.8 in 0.5 

 100%  85%
/ sec 
 

 4 in
0.5
 100% 
 
v css  6.84in / sec
• Critical slow shot 
 100%  f
 d
 ccc 
i
vcss
only valid for %fill  100%



pt
over 50%
T91-058
Model For Constant Acceleration
• Best method to optimize the slow
shot velocity and shot shot length
– Calculate SSV using Garber's formula

and SSL when FSV is fully accelerated
with metal just at the ingate.
– Surround these values and do a three

of four level Taguchi experiment using
casting specific gravity as the quality
characteristic.
Gating
Gating
• Definition:
– The gating system of a die casting die
consists of a series of passages through
which molten metal flows through the
die to fill the cavity.
Gating System
• Consists of:
– Runners
• Main
• Fan
• Tangential
• Wedge
– Ingates, outgates
– Overflows, vents
– Vacuum runners
Ingate
• The gate orifice controls the flow of
metal into the die cavity
• The gating system provides flow that

has the right fill pattern
• The speed of the molten metal

through the ingate must be with
high and low limits.
Ingate Velocity
Low velocity
continuous flow
nozzle open too wide
increase in velocity
coarse flow reduction in nozzle
opening
atomized flow high velocity

small opening
Ingate Velocity
• Recommended gate velocities:
– Aluminum - 600 to 1600 in/sec
• Upper velocity limit: reduce die

erosion and soldering
• Lower velocity limit: ensure

atomized flow
Gate Velocity
• Low gate • Excessive gate
velocities; velocities:
– Poor fill – Die steel erosion

– Poor surface finish – Solder
– Entrained air/gas – Excess machine
porosity wear
– Impact pressure
spike
Other Requirements
• There are a number of other
requirements needed to make good
castings:
– correct fill pattern and gate location
– smooth flow in the runner
– repeatable plunger speed
– proper venting and/or vacuum
– proper die temperature and thermal
stability
– effective and repeatable die lube
spray
Atomized Flow
Atomized Jet Flow
• Objective:
– To understand the relationship between
velocity and gate area in order to
maintain atomized jet flow for the metal
during cavity fill.
Research
• Actual studies have been done by
Prof. J.F. Wallace, Case Institute of
Technology (today Case Western
Reserve University) with copper
alloys and determined that a specific
type of jet flow can be determined
by:
Dv 1.71
g  0.029 0.071
s K
Research
Dv 1.71
g  0.029
s 0.071
K
Where:
D = Gate parameter is Gate area divided by the sum of
the gate length and the gate depth. (For gates that
are over ten time as long as deep, the gate
parameter, D, is very nearly equal to the gate depth.)
Ρ = Density of the molten metal, lbs/in3. (kg/cm3)
vg = Velocity of the molten metal, in./sec. (m/sec.)
μ = Viscosity of the molten metal, lb/in-sec ( kg/cm-sec)
s = Surface tension of the molten metal, lb/sec2 (kg/sec2)
K = Constant
Research
• Substituting viscosity and surface tension for
specific alloys results in:
D v 1 .71
g  J
• Where:
– J = Atomization value
– D = depth of gate, in. (m)
– ρ = density of molten metal, lbs/in3 (kg/cm3)
– vg = gate velocity, in/sec (m/sec)
Atomized Flow
• Example:
– J = 750
– D = 0.050 in., depth of gate
– ρ = 0.093 lbs/in3 density of molten 380
aluminum alloy
– vg = 1000 in/sec gate velocity
– Dρvg1.71 =
(0.050in.)(0.093lbs/in3)(1000 1.71 in/sec.)
– = 627.3
– In this case, with 627.3 less than 750,
atomization is not assured.
Atomized Flow
• Calculations of low J values result in:

– Coarse particle flow
– Casting quality deterioration
• Internal poor fill and porosity
• Surface
Fill Time
Fill Time
• Objective
• To learn how to calculate theoretical
cavity fill times. This is good
starting point for process
development
• To learn how to calculate the
pressure required to push molten
metal through a gate at a specific
velocity.
Maximum Fill Time
 Ti  Tf  SZ 
t k  T
 Tf  Td 
t = maximum filling time

k = empirically derived constant
Ti = temperature of the molten metal as it enters
the die
Tf = minimum flow temperature of the metal
Td = temperature of the die cavity surface just
before metal enters
S = percent solid fraction allowable in the metal at
the end of filling
Z = units conversion factor
T = casting wall thickness
Metal Injection Temperature (Ti)
• Temperature of molten metal when it
reaches the gate
• Not directly measured
• Good estimate is an actual
measurement of molten metal
temperature in the shot sleeve
 Ti  Tf  SZ 
t k  T
 Tf  Td 
• Furnace holding temperature is:
– Approximately 50° F higher for cold
chamber die cast (Highly Suspect)
– Same temperature for hot chamber die
cast
 Ti  Tf  SZ 
t k  T
 Tf  Td 
• Filling time sensitive to metal
injection temperature
• An increase of 50° F can allow an
increase in the ideal filling time by
20%
• High injection temperatures can:
– increase shrinkage
 Ti  Tf  SZ 
– accelerate heat checking t k  T
 Tf  Td 
– accelerate die erosion
Minimum Flow Temperature (Tf)
• Minimum temperature at which
metal will flow
• Between the liquidus and solidus
temperature for the given alloy
• One value for a given
alloy Appendix 1,
Table 1
 Ti  Tf  SZ 
t k  T
 Tf  Td 
Percent Solids (S)
• Percentage amount of solidification that
casting will have at the end of cavity filling
• Large values (25% to 50%)

– Reduces need for intensification
– Thick castings will benefit
– Less porosity
• Small values (less than 10%)
– Better surface finish  Ti  Tf  SZ 
t k  T
– Thin castings will benefit  Tf  Td 
Illustrate Fill Time
Calculation
Units Conversion (Z)
• Derived from thermal properties of
the alloy
• Is the ratio of specific heat to latent
heat at a specific point of
solidification
 Ti  Tf  SZ 
t k  T
 Tf  Td 
Die Temperature (Td)
• Average temperature of the die just prior to
metal injection
• Add 50° F to measured surface
temperature
• A change in 50° F can influence the
allowable filling time by 10%
• The lower the die temperature, the shorter
the allowable filling time
• The higher the die temperature, the longer
the allowable filling time
 Ti  Tf  SZ 
t k  T
 Tf  Td 
Cavity Thickness (T)
• Identified as “typical” casting wall
thickness
• Typical casting wall thickness can be
determined by either using:
• Nominal wall thickness
• Average casting thickness if there is a
large variation of thick and thin areas
• Based on a large region farthest from
the gate  Ti  Tf  SZ 
• Volume / Surface Area t k  T  T T
 f d 
Empirical Constant (k)
• Contains all conversion factors to
make units come out right
• Describes the speed which heat
flows out of the die through die steel
designation
• Describes the heat content through
alloy designation
 Ti  Tf  SZ 
t k  T
 Tf  Td 
PQ 2 Calculations
Bernoulli’s Equation
• Relationship between pressure and flow
to force a fluid through an orifice
• Described as
2
v 2
p  v g 
 gz   constant p  
2  2g  c d 
p = metal pressure, lbs./in.2
ρ = metal density, lbs./in.3
g = acceleration of
gravity, ft./sec.2
vg = gate velocity, in./sec.
cd = coefficient of discharge
Bernoulli’s Equation
• Where:
– vg = gate velocity
Q
– Q = metal flow rate vg 
– Ag = area of gate
Ag
• Substituting into the main equation
results in
2 2
 v g    Q 
p   p  
2g  c d  2g  Ag cd 
Metal Pressure (p)
• Pressure required to force molten

metal through the die’s gate during
die filling.
2
 v g 
p  
2g  c d 
Metal Density (ρ)
• Weight per unit volume, lbs./in.3
• NADCA values shown in Appendix 1,
Table 3
• Values are at typical die cast metal
temperatures
• Molten metal suppliers use lower
values 2
 v g 
p  
2g  c d 
Discharge Coefficient (cd)
• Energy losses due to:
– Frictional losses in shot system
– Flow losses at the gate
– Modification of Bernoulli
• Numbers used
2
– Aluminum 0.5 to 0.6  v g 
p  
– Zinc 0.6 to 0.7 2g  c d 
– Magnesium 0.6 to 0.7
Figure 4-1 Discharge coefficients for various orifice shapes.

• Solving Bernoulli’s equation for the
discharge coefficient yields the
following:
2
  Q  Q
p   cd 
2g  Ag cd  2gp
g 

• We should determine the discharge
coefficients for jobs that run
successfully.
Drawing PQ2 Graph
Master Graph
• Flow rate “Q” is square root of the
linear scale
• Listed as “Q” on the squared graph
Q scale
Is the square root
of the linear scale
Multiply this by
any scale factor
as necessary,
commonly 100x Linear scale
Master Graph
Master Graph
Copy of Master Graph worksheet MACHINE _________________
used in this course HYD. CYL. SIZE ____________
HYD. PRESS. USED __________
DRY SHOT SPEED
__________
PLUNGER TIP SIZE __________
METAL
PRESSURE
(lb/in2)
0
0 200 300 400 500 600 700 800 900 1000
DATE: _______________ Q (in3/sec)

Step by Step
• The steps to determine an operating
window are:
– Determine the Machine Power Line
– Determine the
Minimum Flow Rate
– Determine the upper
and lower gate
velocity Pressures
– Draw the Die Resistance
Line (within the
operating window and
calculate the optimum
ingate area.
Determining the Machine Power Line
• The machine power line is a straight
line established by:
– One end being “static metal pressure”, (pm)
– Other end being “maximum machine flow
rate performance”, (Qmax)
• Known parameters
– Machine hydraulic pressure used for cavity
fill, (phyd)
– Shot cylinder piston diameter, (dhyd)
– Machine dry shot velocity, (vds)
– Plunger tip diameter to be used, (dpt)
• Static metal pressure is calculated

from the hydraulic pressure on the
cylinder that is transferred to the
metal through the plunger tip when
at rest at the end of cavity filling.
Hydraulic Cylinder
Piston, dhyd
Static
Metal
Pressure
pm
Plunger Tip Hydraulic Pressure

dpt phyd
 dhyd
2

pm  phyd   2 
d 
Eq. 5-1
 pt 
where:
pm = metal pressure, lbs./in2
phyd = hydraulic pressure, lbs./in2
dhyd = effective hydraulic cylinder diameter, in.*
dpt = plunger diameter, in.
* If machine has a tail rod, subtract the area of the tail rod from
the area of the hydraulic cylinder piston.
• Example: Find the static metal

pressure using the following
parameters
– Hydraulic pressure - 1500 lb/in2
– Hyd. cyl. piston dia. - 12.0 in
– No tail rod
 dhyd
2

pm  phyd   2 
d 
 pt 
Static Metal Pressure, (pm)
 dhyd  lb  12in  

2 2
pm  phyd   2  pm  1500 2 x
d  in  6.7in2 
 pt 
lb  144 
pm  1500 2 x 
in  44.89 
lb
pm  1500 2
x3.21
in
lb
pm 4812 2
in
Plot this on the “y” axis of the graph

Static Metal Pressure, (pm)
7000
6000
5000
4812 PSI
4000
3000
2000
1000
Maximum Flow Rate (Qmax)
Maximum machine performance or “maximum
fill rate” (Qmax) is calculated by multiplying the
area of the plunger times the maximum shot
speed that the machine can obtain.
  d pt
2

Qmax  v ds  
 4 
 
where:
vds= maximum dry shot speed
dpt= diameter of plunger
• Maximum shot speed (vds) is
determined by having the speed
control valve wide open and making
a “dry” shot (no metal)
• Put rags or gloves in shot sleeve to
protect the tip and die
• Remove shot rod (hot chamber),
prevent shot cylinder from
bottoming
• Example: Find the maximum fill
rate using the following parameters:
• Plunger diameter - 6.7 in
• Dry shot velocity - 160 in/sec @
1500 lb/in2
 d
2

Qmax  v ds  pt

 4 
 
 d 2 
Qmax 
 v p 
p

4 
 
 2 
Qmax  160

in  6.7in  
sec  4 

 
in 2
Q max  160 x 35.257 in
sec
3
in
Qmax  5641
sec
Plot this on the “x” axis and connect the points
Machine Power Line
4812 PSI
5641 in3/sec
Machine Power Line
• The power line is only good for the
machine/sleeve combination in this
example
• Process can run anywhere under the
line
• First process boundary
Machine Power Line (MPL)
• Machine conditions can change that
will alter the machine power line
– Hydraulic pressure
– Plunger size
d 2   d 2 
pm  phyd  
hyd
 Qmax 
 v p 
p

 d 2 
 pt  4 
 
Hydraulic Pressure Changes
• Higher pressure
– More fluid volume
– Increases dry shot speed
– Increases static metal pressure
• Lower pressure
– Less fluid volume
– Decreases dry shot speed
– Decreases static metal pressure
• Example: Plot a new power line with
a higher pressure and higher
resultant dry shot speed
• Hydraulic pressure - 1600 lb/in2
• Calculate effect of hydraulic pressure
change to static metal pressure
d 2 
  
hyd
pm  phyd  d 2 
 pt 

12.0in
2
lb
pm  1600 x
in2
6.7in
2
lb
pm  5132
in2
• For an unknown value of dry shot
velocity use the following
relationship to determine the new
value of Q2
Q12  P2
Q2 
P1
Q2 =
[ ( 56412 x 1600) ½
(1500)
]
Q2 = 5826 in3/sec
Pm = 5132 PSI
Qmax = 5827 in3/s

Higher Hydraulic Pressure
7000
6000
5000
4000
3000
Lower Hydraulic Pressure
2000
1000
Plunger Size Changes
• Plunger/Sleeve Size Changes
– Same dry shot speed
– Same hydraulic pressure:
• Increasing plunger size
– Reduces static metal pressure
– Increases fill rate
• Decreasing plunger size
– Increases static metal pressure
– Decreases fill rate
• Example: Plot a new machine power
line with an increase in the plunger
size
– Hydraulic pressure - 1500 lb/in2
– Hyd. cyl. diameter - 12.0 in
– Dry shot speed - 160 in/sec
Static Metal Pressure Maximum Flow Rate
 d hyd
2
  2 
 v pt 
d pt 
pm  p hyd  2  Q  4 
 d 
max
 
 pt 
in   7in  
 2
lb  12in  
2
pm  1500 2   Qmax  160

in  7in 
 2  sec  4 

3
lb Qmax  6157in
pm  4408 sec
in 2
7000
4812 PSI, 6.7Ø
6000
5000
4000
3000
4408 PSI, 7.0 Ø

2000
1000
5641 in3/sec
6154 in3/sec
Machine Power Line
• Every die cast machine should have
dry shot speeds determined at
specific shot pressures
• Dry shots should be measured
annually
• Process and Design Engineering
must know the machines'
capabilities
Minimum Flow Rate (Qth)
• The minimum fill rate is plotted as a
vertical line on the master graph. To
the left of this line, fill times are too
long.
• Cavity fill time can be determined
by:
– Gating equation (75% of calc. value)
– Data base similar parts
– Experience
• NADCA fill time equation
 Ti  Tf  SZ 
t  k  T
 Tf  Td 
• General practice (aluminum)

Appendix 1 Table 4
• Fill rate is described as the rate a die
casting cavity is filled with molten
aluminum
Vcav
Qth 
t
• Where:
– Qth = minimum fill rate, in3/sec
– Vcav = casting and overflow
volume, in3
–T = theoretical fill time, sec.
• Cavity volume is the amount of metal
that flows through the gate during
filling
• includes casting
W
• includes overflows V 
cav

• Where:
– Vcav = volume of metal passing
through the gates, in3
– W = weight of metal passing through the
gates, lbs.
–ρ = molten alloy density, lbs/in3
Example: Calculate the minimum fill rate to
produce a 380 alloy aluminum casting per the
following parameters
Weight of metal through gates - 33.72 lb
Die temp. at metal injection - 4000 F
Metal temp. at gate - 11800 F
Casting thickness - 0.200 in
Estimated % solids - 30%
H-13 die steel
Step 1: Calculate maximum fill time.

Step 2: Calculate volume through gate
Step 3: Calculate theoretical fill rate.
• Step 1: Calculate maximum fill time.
 Ti  Tf  SZ  Z = 6.8 0F/%
t  k  T k = 1.2 sec/in
 Tf  Td  Tf = 10600 F
• Given: Ti, S, Td, and T
• Look up at Table 1 in
Appendix 1: k, Tf, and Z
 1180  1060  30(6.8) 

t  1.2 0.200 t 0.118sec
 1060  400 
Minimum Fill Rate (Qth)
• Step 2: Calculate volume through
gate W
v cav 

33.72lb
v cav 
lb
.093 3
in
3
v cav  363in
Minimum Fill Rate (Qth)
• Step 3: Calculate theoretical fill rate.
Vcav
Qth 
t
363in3
Qth 
.118sec
in3
Qth  3076
sec
Plot this value as a vertical line on the master graph

3076 in3/sec.
Metal Pressures Through Gate
• Pressure required to push the liquid
metal through the gate
• Calculated by using “Bernoulli’s
Equation” 2
 v g 
p  
2g  c d 
• Use maximum and minimum gate
velocities to establish the upper and
lower boundaries of an operating
window on the master graph.
• Gate velocity ranges
– Use formula to determine low limit
– Use 1600 in/sec as high limit
• Low gate velocities may result in
non-atomized flow
• High gate velocities may result in an
increase in die erosion and solder
• The metal pressure lines are plotted
as horizontal lines on the PQ2
diagram
• Example:
Calculate the recommended maximum
and minimum metal pressure lines for a
large aluminum die casting per the
following parameters:
• Maximum gate velocity - 2500 in/sec
• Minimum gate velocity - 2000 in/sec
• Coefficient of discharge - 0.5
• Aluminum density - 0.093 lb/in3
• Acceleration of gravity - 386 in/sec2
2
 v g 
p  
2g  c d 
• Maximum gate velocity: 2

0.093  2500  2
p 
max
772.8  0.5 
pmax  3009lb / in
• Minimum gate velocity:
2
0.093  2000  2
pmin 
772.8  0.5  pmin  1925lb / in
3009 PSI
1925 PSI
Process Operating Window
• Area within all the boundaries calculated
• Process should run inside this process
operating window
7000
6000
5000
4000
3000
2000
1000
Die Line
• The die line is described as the total
gate area for the process
• Identifies a series of points (line)
within the operating window
• Draw a straight line from the graph
“origin” through a desirable process
point.
Die Line
Die Line
3009 PSI
1925 PSI
Die Line
• Identify fill rate (Q) and pressure (p)
from the process point
• Substitute into an Bernoulli’s
equation and solve for gate area (Ag)
2
  Q 
p  
2g  Ag cd 
Die Line
Pick a point !
3009 PSI
1925 PSI
Q = 3200 in3/sec
P = 2500 psi
Die Line
Substituting:
2 2
p
 v g  Q   Q 
 
2g  c d 
vg  p  
Ag 2g  Ag cd 
Solving for Ag:
Q
Ag 
p2g 
cd

Die Line
Q
Ag 
p2g 
Given: cd

P = 2500 lb/in2
Q = 3200 in3/sec 3200
cd = 0.5 Ag 
2500772.8
g = 386.4 in/sec2 0.5
ρ = 0.093 lb/in3 0.093
Ag  1.4in2
Optimizing PQ 2
Optimizing for Yield
• Several alternative metrics
considered
– Operating window area
• X – “the bigger the machine the better”
– Die line length
• X - “the bigger the machine the better”
– Shot Yield = Part Volume/Shot Volume
• X – small gate and small plunger pushes
operating point to window corners
• Normalized power index, NPI
Normalized Power Index (NPI)
 2
 2
LB
  v DPH AH NPI  UB
 2
max
• vD = Dry Shot Speed
• PH = Hydraulic Pressure
• AH = Hydraulic Cylinder Area
• Ωmax = Maximum Power
• ΩUB = Maximum Usable Power
• ΩLB = Minimum Usable Power
Lower Flow Rates
2
QM  max
2  PSu  PMmax   Q2
max ref
PSu3
2
Qmft PSl3
NPIDL*  1  2
max  PSl  PMmin 
NPI increases
Optimal Die Line
Higher Flow Rate
2
QM  max
2  PSu  PMmax   Q2
max ref
PSu3
QM2 max PM min PSl3
NPIDL*  1  2
max PM max  PSl  PM min 
NPI constant
Optimal Die Line
Ideal
PM max 2
2
Qref  Qmft
PM min
2
QM  max
2  PSu  PMmax   Q2
max ref
PSu3
NPI at Optimal Die Line
2 3
Q P
NPIDL*  1  LB min Sl
 2
max  PSl  PM min 
• NPI increases with increasing power

(decreasing machine line slope) until
reference flow rate reached
– Optimal gate area is constant
• NPI remains constant with further
increases in power
– Optimal gate area increases
NPI at Optimal Die Line
2 3
QLB P
NPIDL*  1  2min Sl
max  PSl  PM min 
• NPI increases with increasing power

(decreasing machine line slope) until
reference flow rate reached
– Optimal gate area is constant
• NPI remains constant with further
increases in power
– Optimal gate area increases
Optimal Power and Pressure
3
PSu PM max 2
Maximize : max
2
 Qmft
 PSu  PMmax  PMmin
3
PSl
Minimize :
 PSl  PMmin 
Power requirements increase rapidly if
3
PSu  PM max
(tangent point below max metal pressure) 2
Procedure
• Determine operating window and static
pressure constraints based on part and
requirements
• Compute reference flow rate
• Determine static pressures
• Compute optimal shot power max *
• Select machine such that max  max

*
• Select plunger satisfying static pressure

constraints and QMmax  Qref for selected
power
• Compute optimal die line and optimal gate
area
Summary and
Worked Example
Summary
• PQ2 development is a good process
starting point
• Allows us to adjust the process on
paper for machine/die combinations
rather that cutting and welding on a
die
• Not to be used to predict process
parameters after cavity is full
Worked Example 1
• Determine the total gate area and required fast shot velocity
to produce an aluminum casting in die cast machine #100 with
the following parameters:
• Hydraulic cylinder diameter 5.0 in
• Plunger diameter 3.0 in
• Max. hydraulic pressure 1200 lb/in2
• Dry shot speed @ max. press. 140 in/sec
• Casting weight (through gate) 4.0 lb
• Wall thickness 0.120 in
• Requires good surface finish (S) 10
• Gate velocity ranges 1000-1600 in/sec
• Density of aluminum 0.093 lb/in3
• Coefficient of discharge (Cd) 0.5
Construct the machine power line
Static Metal Pressure - Eq. 5-1 Maximum Flow Rate - Eq. 5-3
 dhyd
2
   d p2 
pm  phyd   2  Qmax  vp  
d   4 
 pt   
lb  5 .0in 2

 Qmax  140
in  3.143.0in
2


pm  1200 2 x sec  
in  3.0in 2  4 
lb in3
pm 3333 2 Qmax  990
in sec
Theoretical Fill Rate (Qth)
• Calculate theoretical fill time.
 T  T  SZ 
• Given: S, and T t  k  T
i f
 T T f  d
• Look up at Table 1 in Appendix 1: k,

Ti, Td, k, Tf, and Z
 1200  1060  10(6.8) 
• k = 0.866 t  0.866
 1060  650
0.12

• Ti = 1200 °F
• Td = 650 °F t  0 .0527 sec
• Z = 6.8 °F/%
• Tf = 1060 °F
Calculate volume through gate Calculate fill rate
W Vcav
v cav  Qth 
 t
4.0lb 43in3
v cav  Qth 
lb .053sec
.093 3
in
3 in3
v cav  43.0in Qth  811
sec
Plot this value as a vertical

line on the master graph
811 in3/sec.
Construct the gate velocity pressure lines
For vg= 1600 in/sec For vg= 1000 in/sec
2
 v g   v g 
2
pmax    pmin   
2g  c d  2g  c d 
2
3
.093lb / in 1600in / sec 
2
.093lb / in3 1000in / sec 
pmax  pmin 
772.8in / sec  .5 
 772.8in / sec  .5 

pmax  1232lb / in 2
pmin  481lb / in2
Process Window
Gate Area (Ag)
• Determine the total gate area.
• Within the process window, identify
a point within the window.
• Estimate value for Q at a metal
pressure of 856.5 (midpoint of 481
PSI to 1232 PSI)
• Estimate the fill rate (Q) and
substitute into Eq. 5-10 to
determine total gate area.
Gate Area (Ag)
pm = 856.5 lb/in2
Q = 850 in3/sec, est.
Q
A 
p 2 g 
g
c d

Ag  0 .637 in 2
Gate Area (Ag)
0.637 in2
Fast Shot Velocity (Vpt)
• Rearrange Eq. 5-3 to solve for vpt
and substitute fill rate (Q) and
plunger diameter (dpt)
  d p2   4 
Q  vp   v pt  Q 2 
 4   d 
   pt 
 4 
v pt  850in / sec
3

2 
 3.143.0in  
v pt  120.2in / sec
Worked Example 2
• Determine the theoretical fill time for
a #3 zinc die casting when:
• Die temp. at cavity fill 350 F
• Metal temp. at cavity fill 790 F
• Ave. wall thickness 0.060 in
• Estimated % solids 25%
• H-13 die steel
Theoretical fill time calculation
• Factors not listed in the known
parameters can be found in Table 1 of
Appendix I.
• Empirical Constant (k) 0.866
• Minimum metal flow temp. (Tf) 720 °F
• Solids Factor (Z) 4.5 °F/%
  0

 7900 F  7200 F  25% 4.5 F  
 T  Tf  SZ    %  
t  k  i T t  0.866sec/ in 
0 0 0.060in
 Tf  Td   720 F  350 F 
 
 
t  0.026sec
Worked Example 3
• Determine if an existing process for
a 380 aluminum casting is correct
and determine if any changes can be
made to improve the process.
• The casting has minimal final
machining and the surface will be
painted.
• Internal porosity is not an issue, but
surface finish is a major issue.
Procedure
• Establish the existing process
• Compare to theoretical “best”
process
• Establish “best” process for existing
machine
Machine parameters:
• 450 Ton machine
• Hydraulic Cylinder Diameter
5.0 in (no tail rod)
• Maximum hydraulic pressure
2000 lb/in2
• Maximum dry shot speed
150 in/sec
Die Parameters
• Plunger diameter 3.0 in
• Working sleeve length 30 in
• Total shot weight 7.0 lb
• Total metal through gates 5.5 lb
• Average gate thickness 0.050 in
• Total gate area 0.260 in2
• Average casting
wall thickness 0.130 in
Process Parameters
• Die temperature at start
of fill 550 °F
• Metal temperature at gate 1200 °F
• Process shot hydraulic
pressure 2000 lb/in2
• Process slow shot speed 5 in/sec
• Process fast shot speed 70 in/sec
• Process fill time 0.120 sec
Static Metal Pressure - Eq. 5-1 Maximum Flow Rate - Eq. 5-3
 dhyd
2

pm  phyd   2    dp2 
d  Qmax  vp  
 pt   4 
 
lb  5 .0in 2

 in  3.143.0in 
2

pm  2000 2 x Qmax  150 
in  3.0in 2
sec  4 

lb in3
Qmax  1060
pm 5556 2 sec
in
Evaluate the current process
Determine the actual fill rate.
Calculate volume through gate Calculate fill rate

W Vcav
v cav  Qth 
 t
59.1in3
Qth 
0.120sec
in3
Qth  492
sec
• Determine the actual process
operating point, Q,P
• Q is known, 492 in3/sec.
• Gate area in known, 0.26 in2
• Solve Bernoulli’s equation for P
• Show the process point on the
master graph.
Solve for pressure
Substituting:
yields
Actual operating point

Q=492, P=1724
Determine theoretical fill time
• Process parameters.
 Ti  Tf  SZ 
• Temp. of metal at gate (Ti) 1200°F t  k  T
 Tf  Td 
• Temp. of die at fill (Td) 550°F
• Ave. casting thickness (T) 0.130 in

  0

 12000 F  10600 F  10% 6.8 F  
• Parameters found in Appendix I, Table 1   %  
t  0.866sec/ in 
1060 0
F  550 0
F 0.130in
 
 
• Minimum flow temperature (Tf) 1060°F  
• Solids factor (Z) 6.8°F/%

t  0.046sec
• Empirical constant (k) 0.866 sec/in
• Good surface finish and thin casting
• % Solids (S) 10%

Determine theoretical fill rate
Volume is 59.14 in3 (previously calculated)
Plot this value on the master graph.

DATE: _______________
7000
MACHINE 450 Ton
HYD. CYL. SIZE 5.0 in
HYD. PRESS. USED 2000lb/in2
6000 DRY SHOT SPEED 150 in/sec
PLUNGER TIP SIZE 3.0 in

5000
4000
METAL
PRESSURE
(lb/in2)
3000
2000
1000
0
0 100 200 300 400 500 600 700 800
900 1000
200 400 600 800 1000 1200 1400 1600
1800 2000
Q (in3/sec)
Machine power line is not capable to attain the calculated fill rate.
Finish PQ2 diagram, then determine what process changes to make.
• Add gate velocity pressure lines and process window
• Gate velocity ranges for small to medium castings
from Appendix I, Table 2. 1000 - 1600 in/sec
2
2  v g 
 v g  pmin   
pmax    2g  c d 
2g  c d 
2 2
3
.093lb / in 1600in / sec  .093lb / in3 1000in / sec 
pmax  pmin 
772.8in / sec  .5 
 772.8in / sec  .5 

pmax  1232lb / in2 pmin  481lb / in2

DATE: _______________
7000
MACHINE 450 Ton

5000
4000
METAL
PRESSURE
(lb/in2)
3000
2000
1000
Process Window
0
0 100 200 300 400 500 600 700 800
900 1000
200 400 600 800 1000 1200 1400 1600
1800 2000
Q (in3/sec)
Machine power line is not capable to attain the calculated fill rate.
Finish PQ2 diagram, then determine what process changes to make.
• Need to alter the machine power line
to allow the process window to be
under the machine power line
• Increase hydraulic pressure
• Increase plunger size
• Hydraulic pressure is already at
maximum, try a larger plunger tip.
3.75 in. Ø ?
Determine Machine Line
Calculate new pm and Qmax and plot on diagram
for 3.75 dia. tip.
Static Metal Pressure Maximum Flow Rate

 d hyd
2

p m  p hyd  2 
 d 
 pt 
lb
p m  3556
in 2
Determine 3.75in Machine Line
DATE: _______________
7000
MACHINE 450 Ton

5000
4000
METAL
PRESSURE
(lb/in2)
3000
2000
1000
Process Window
0
0 100 200 300 400 500 600 700 800
900 1000
200 400 600 800 1000 1200 1400 1600
1800 2000
Q (in3/sec)
Determine Gate Area
• Determine the gate area for a die
line passing through the lower left
corner of the “Process Window”
• P,Q for this point are known,
• P = 481 PSI
• Q = 1286 in3/sec.
Determine Gate Area
Metal pressure 481 lb/in2
Fill rate 1286 in3/sec
Determine 3.75in Machine Line
DATE: _______________
7000
MACHINE 450 Ton

5000
4000
METAL
PRESSURE
(lb/in2)
3000
2000
1000
Process Window
0
0 100 200 300 400 500 600 700 800
900 1000
200 400 600 800 1000 1200 1400 1600
1800 2000
Q (in3/sec)
1.286 in2 gate area

Determine fast shot velocity
Any Question?

Nadca - PQ2

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Nadca - PQ2

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Mike Ward, November, 2013

• Step by Step PQ2

• To understand the relationship between

• For P and Q address the

• To learn how to calculate the

• To learn about the die cast

• Accumulators supply the hydraulic

• Accumulator pressure minus energy

• The effective accumulator pressure and

• The maximum FSV is called the “Dry

• The Dry Shot Speed is unique for every

• The Dry Shot Speed for every die

• vD = Dry Shot Speed

– Typical % fill of aluminum shot sleeves

– Important to push air ahead of the

– Specific plunger speeds are required for

*1997 Transaction Paper 063

*1997 Transaction Paper 063

V = Volume of metal in shot sleeve, in3 (cm3)

v css  22.8 in 0.5 

– Calculate SSV using Garber's formula

– Surround these values and do a three

• The gating system provides flow that

• The speed of the molten metal

atomized flow high velocity

• Upper velocity limit: reduce die

• Lower velocity limit: ensure

– Poor fill – Die steel erosion

• Calculations of low J values result in:

t = maximum filling time

• Large values (25% to 50%)

• Pressure required to force molten

Figure 4-1 Discharge coefficients for various orifice shapes.

DATE: _______________ Q (in3/sec)

• Static metal pressure is calculated

Plunger Tip Hydraulic Pressure

• Example: Find the static metal

Plot this on the “y” axis of the graph

Qmax = 5827 in3/s

pm  1500 2   Qmax  160

4408 PSI, 7.0 Ø

• General practice (aluminum)

Step 1: Calculate maximum fill time.

 1180  1060  30(6.8) 

Plot this value as a vertical line on the master graph

• Maximum gate velocity: 2

Solving for Ag:

• NPI increases with increasing power

max  PSl  PM min 

• NPI increases with increasing power

• Select machine such that max  max

• Select plunger satisfying static pressure

• Look up at Table 1 in Appendix 1: k,

Plot this value as a vertical

Calculate volume through gate Calculate fill rate

Actual operating point

• Ave. casting thickness (T) 0.130 in

• Solids factor (Z) 6.8°F/%

• Good surface finish and thin casting

• % Solids (S) 10%

Plot this value on the master graph.

PLUNGER TIP SIZE 3.0 in