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11.Electrode Design.
12.Prepare WireCut data for Ejector pins and other required.
13.Prepare 2D Drawings for Manufacturing.
14. Prepare BOM for Inhouse & Outsource.
15. Trail Parameter
Input From Customer (2D Drawing & 3D Model)
Good designs start with knowledge of the customer requirements.
✔ 2D Drawing we get following point:
1.Alloy Specification
2.Dimension Tolerance
3.Porosity
Requirement
4.Surface Finish, And any other type of requirement.
✔ Other Requirement (Gate position ,Ejector positions, Parting Line)
✔ 3D Model we use for prepare casting model for Core & cavity
extraction and die design work.
Do Feasibility Study & Prepare a presentation.
In feasibility study we analyse every thing before starting die
design from 2D Drawing to Final Machining Operation. We make
a presentation in which we add what we are planning for every
step of die design and shear this ppt with costumer. This ppt also
use for any Quarry ,modification required, General information
and communicate with costumer.
✔ For Example Following things we consider for
feasibility:
1. Define Moving Side ,Fix side & Slides Area on part.
2. Show parting line created in part by Moving side, Fix side,
Slides, Core pin & Loose punch.
3. Show Simple sketch for gate location and cavity layout.
4. Show Draft angle available on Moving side, Fix Side, and
Slides Area. Also show If any undercut formed.
5. Request for modified or approval for correction in part.
6. Show Ejector pin or Marking locations in part .
7. Analyse minimum radius, minimum wall thickness in model to
see it is feasible or not.
8. Any 2D open point from drawing mention it. Also mention
general information given in drawing.(Surface Finish, Porosity
Requirement, Tolerance Standard)
9. Do Feasibility study for every machining operation. If any
resting pad required take approval for that.(Resting pad,
Clamping, and locating holes)
10. General information about number of cavity, machine type &
tonnage.
In ppt we added these things in fusibility stage and shear this ppt
with costumer .
Prepare a feasibility Sheet.
In a feasibility sheet we mention Total Shot weight, Component
Weight, Number of cavity, Machine tonnage and type, Surface
finishing required, Number of machine operation required, Number
of gauges required for inspection .This sheet also use for
costing.(for tools, gauges, manpower, electricity, surface treatment
operation And any other cost)
Drawing Numbering, Model Inspection, Model
Correction & Communicate with Customer through
feasibility ppt for any quarry.
In this process we 1st Numbering the customer machining drawing.
After that we measure every dimension with 3D model and create
a report. After that if we find any NG Dimension we correct it or
request to customer for correction. Then we add draft on part
according to parting line.in correction process we also consider
tolerance of dimension and modified some dimension for increase
dimension stability during life of die. In this process We also add
machining allowance for making casting model.
Cavity Layout Design?
Follow things consider for cavity layout design:
1. Try to keep gate location same in every component.
2. The Material should reach the gate same time.
3. Keep the Runner path as short as possible from Biscuit.
4. Keep the Runner path equal length fromevery component to
biscuit.
5. The shot design according to lode balance in tie bar .
6. During cavity placement keep in mind ,if component have a
slide and we are using cylinder for that .cylinder do not fall with
tie bar.
tie bar. cylinder tie bar.
cylinder
t A
15.24
30
25.4 7.95
50.8
76.2
101.6
127
Die Casting Gating Design –Flow Chart
Define
Machine Cooling
Parameter Ejection
Define
Runner Vent &
Design Over
Calculate
Flow
Gate gate area
Velocit
Fill
Calculation y
Machine time
Watch My Die Casting Die Design Playlist
Tonnage
Calculation
There are some stapes for good gate design
1. Understand Casting Requirement.
2. Understand the flow pattern & create segment accordingly.
3. Calculate cavity fill time & metal flow rate for each segment.
4. Calculate gate area for different segment.
5. Design runner according to machine like fast shot velocity,
plunger sizes, and casting pressures.
6. Design the vent and overflow system.
7. Go for flow analysis through simulation software.
Understand Casting Requirement
Casting requirement is set according to application of casting by
costumer . they may be Related to tolerance, Surface finish
,porosity ,etc.
the requirements for surface Finish or porosity may change
the machine needed, and may be need to change in the gating
design. If this is discovered after the die is built and many not
decisions have been made, any changes will be expensive for
everyone.
Understand the flow pattern & create segment accordingly
✔ Following Question you can ask to understand the flow pattern.
1. Where is the most logical and available place for the metal to
come in?
2. Where is the most logical and available place for the air to
escape?
3. What obstacles to the metal flow will be encountered inside the
cavity?
4. What pattern is best to satisfy the quality requirements?
Flow Pattern Guide Line:
1. Flow must be distributed.
2. Minimum gate thickness for aluminium 1mm.it can be less if
metal is clean enough.
3. Direct flow towards critical area’s.
4. Metal velocity higher then the normal.(40m/sec)Leads to better
finish surface but not exceed 50m/sec. gate velocity above
50m/s. Leads to gate erosion & soldering.
5. Minimum 2mm gate required to control porosity in case of
aluminium.
6. Provide thick gate near shrinkage porosity area.
7. Avoid direct hitting of material and vertical wall or core.
8. Avoid mixing of metal flow’s between Segments.
9. Avoid direct impact of flow in groove area’s.
Calculate cavity fill time & metal flow rate for each
segment.
Calculate gate area for different segment.
We already make video on how to calculate gate area, in video
you can also find to cavity fill time & metal flow rate.
Runner sprue
Thickness Plunger ø
Diffuser
Biscuit
Cone
HT
Overflow use to reduce to mix non-metallic partial and air entrapment, it
help to improve the die filling and quality of casting.
If cavity have two or more gate,3D Model of casting divided
Into several segments according to the flow paths, the overflow of each
segment will be proportion to volume of segment. The flow distance of
molten metal also affects the volume of overflow due to the heat loss.
The overflow size is large when flow distance increases.
Generally the overflow is located at
the point the flow reaches last or the
point where two flows meet.
Vents are necessary in die casting .vent are use for scape the
air out from die during cavity filling. When air vent is not
provided in insert air mix with the metal and it will create gas
porosity. It is difficult in die casting to vent all the air. If the die is
designed with insufficient vents, over time the air will find a way
out. The die will flash, and some of the flash will stick to the die
causing inserts to be cracked .This all can be avoided by
designing proper vents.
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