S.

No DESCRIPTION PAGE

1 SCOPE 2

2 APPLICATION 2

3 REFERENCES 2

4 TERMINOLOGY 2

5 OWNERSHIP 2

6 BODY OF THE STANDARD 2

DIE CASTING DIE COMPONENTS

7 2
CALCULATIONS
DIE CASTING DIE POTENTIAL DEFECTS AND
8 8
CAUSES
DIE CASTING DIE MATERIAL AND
9 9
CHARACTERISTICS

10 REVISION HISTORY 10

1 SCOPE:

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 This guideline provides information on Die casting Die components various design
calculations, generic parameter inputs, potential defects and causes and material
characteristics as a ready reference for all the die casting die products designed,
developed

2 APPLICATION:
All Die casting die products developed by XXX

3 REFERENCES:
This standard is developed based on project Know-How and lessons learnt.

4 TERMINOLOGY:
Standards terms and definitions used as per current engineering and industry practices.

5 BODY OF THE STANDARD:

6 DIE CASTING DIE COMPONENTS CALCULATIONS:

6.1 Weight of casting (A) : unit in gms

6.2 Density (B): Unit in gms/cm^3

6.3 Density based on alloy used for casting Al- 2.6 to 2.7; Zn-7.13; Cu-8.8; Mg- 1.7

6.4 Projected Area of Casting =Surface Area: Unit in cm^2

6.5 Volume of Casting = A (Wt of Comp) / B (Density) (Unit in cm^3)

6.6 Shot Weight = Wt of Casting + (Wt of Runner + Overflow) + Wt of Biscuits

Wt of Runner + Overflow – 10% of Wt of Casting

Wt of Biscuits – 20% of Wt of Casting

6.7 Gate Velocity (Vg) : Unit in m/sec ( Provided in table 2 )

6.8 Gate Thickness – Hg (in mm) = Hg = n/3 – n/4 (n – thickness of casting )

6.9 Volume of metal through the gate P : Unit in cm3

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6.10 P = volume of casting + volume of overflow (10% of volume of casting)

6.11 Fill Rate (Q): Unit in cm3/sec.

6.12 Q = (P x 1000) / t ( t – fill time in milliseconds)

6.13 Gate area (Ag): Unit in cm2

6.14 Gate area (Ag) = Fill date (Q) / [100 x Gate velocity (Vg)]

6.15 Gate Length ( Lg) (in mm) = [Gate area (Ag)x 100 ] / Gate thickness (Hg)

6.16 Runner Area (Ar) (in cm^2) = 1.25 Gate area (Ag) – 1.6 Gate area (Ag)

6.17 Runner Depth (D)(in mm) = (Ar / 1.6)^(1/2) - (Ar / 2)^(1/2)

6.18 Runner Width (W) (in mm) = 2* Runner Depth (D)

6.19 Locking Force (F) (in Metric Tonnes) = (A X P) / 1000
A – Projected Area (in cm^2)
P – Specific injection pressure (in kg / cm^2)

6.20 Machine Specification: Selected based on locking force

6.21 Effective Plunger Stroke (cm) : Maximum plunger stroke – 20/25 mm for
biscuits
6.22 Plunger Diameter – d (cm)

Shot weight = Plunger Area x Eff. Plunger Stroke x 0.75 x 2.5 (gm)
Shot weight = [ (Π X d2 ) / 4 ]x Eff. Plunger Stroke Plunger x 0.75 x 2.5 (gm)
4x Shot wt = (Π X d2 ) x Eff. Plunger Stroke x 0.75 x 2.5 (gm)
d2 = ( 4 x shot wt) / (Π X Eff. Plunger Stroke x 0.75 x 2.5)

d = [ ( 4 x shot wt) / (Π X Eff. Plunger Stroke x 0.75 x 2.5) ]^(1/2)

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6.23 Injection Pressure Guideline (Kg/cm^2)

Injection pressure for Injection pressure

Description
Zinc Aluminium / Magnesium

Decorative part 100 - 200 200 - 400

Engineering part 200 - 300 400 - 600

Pressure tight part 250 - 400 800 - 1000

6.24 Gate velocity Range (Kg/cm^2)

Wall section in ( mm ) Gate velocity ( m/sec)

0 – 0.762 46 - 55
1.27 – 1.525 43 - 52
1.905 – 2.286 40 - 49
2.54 – 2.794 37 - 46
3.175 – 3.87 34 - 43
4.572 – 5.08 31 - 40
3.75 and above 28 - 35

 Use lower gate velocity for warmer dies and hot metals
 Use higher gate velocity for colder dies and colder metals

6.25 Alloy and Die temperature guideline:

Alloy Metal temperature (C) Die temperature (C)
Zn alloy 393 393
Mg alloy 657 332
Al alloy 657 332

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6.26 Die Filling time guideline:
Applicable for Zinc, Aluminium and Magnesium alloys
Average Wall thickness Maximum Die filling time
( in mm) ( In milli Seconds)

1.0 10 - 30

1.5 10 - 35

1.8 20 - 40

2 30 - 60

2.5 40 - 90

3.0 50 - 100

4.0 50 - 120

For higher wall thickness > 4.0 mm ; 7 msec increase per 0.5mm wall thickness
increase.

6.27 Gate thickness guideline:

Wall thickness Gate thickness – Al Gate thickness – Mg (

( in mm) ( in mm) in mm)
0.75 to 1.5 0.5 to 0.8 0.5 to 0.6

1.5 to 2.5 0.8 to 1.25 0.6 to 0.85

2.5 to 4.0 1.25 to 1.6 0.85 to 1.35

6.28 Ejection System:

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 Assume the ejection area to be 4% of the area of the casting

Total Ejecting area = Projected area of Component X 4%

Area of selected Ejector Pin Diameter = D

Area of Ejector Pin = ( Π X D^2 ) / 4

No of Ejector Pins Required = Total Ejection Area / Area of Ejection Pin

6.29 Draft Guideline:

Description Draft on Draft angle in degrees

Core < 6.35 mm 0

Zinc Die casting with side
Core > 6.35 mm 0.15
core
Cavity 0 – 0.15
Core 0.5
Zinc Die casting - Normal
Cavity 0.125 – 0.25
Aluminium Die casting - Core 2
Normal Cavity 0.5

7 DIE CASTING DIE POTENTIAL DEFECTS AND CAUSES:

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 POTENTIAL DEFECTS CAUSE OF POTENTIAL DEFECT

 Injection pressure too high

Flash
 Clamp force too low

 Insufficient shot volume

Un filled sections  Slow injection
 Low pouring temperature

 Injection temperature too high

Bubbles
 Non-uniform cooling rate

Hot tearing  Non-uniform cooling rate

 Cooling time too short

Ejector Marks
 Ejection force too high

8 DIE CASTING MATERIALS AND CHARACTERISTICS:

Material Characteristics

 Low density
 Good corrosion resistance
 High thermal and electrical conductivity
Aluminium Alloy
 High dimensional stability
 Relatively easy to cast
 Requires use of a cold chamber machine

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  High density
 High ductility
 Good impact strength
 Excellent surface smoothness allowing for painting or
Zinc Alloy plating
 Easiest to cast
 Can form very thin walls
 Long die life due to low melting point
 Requires use of a hot chamber machine
 Very low density
 High strength-to-weight ratio
Magnesium Alloy
 Excellent machinability after casting
 Use of both hot and cold chamber machines
 High strength and toughness
 High corrosion and wear resistance
 High dimensional stability
Copper Alloy
 Highest cost
 Low die life due to high melting temperature
 Requires use of a cold chamber machine

9 REVISION HISTORY:

REV NO DATE REVISION DETAILS REMARKS

000 XXXX New release

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