Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

Design and Development of Pressure Die Casting

Parts
K.Rajasekar G.Priya
Assistant Professor, Mechanical Engineering Department Assistant Professor, Mechanical Engineering Department
Paavaai Group of Institutions, Paavaai Group of Institutions,
Erode, India Salem, India

Abstract— Pressure die casting process involves producing I. CHARACTERISTICS OF MOLTEN ALUMINIUM
accurately dimensioned parts, by forcing molten metal under Molten aluminium alloys are extremely reactive and combine
pressure in to split metal dies, which are later on opened to
readily with other metals, with gases, and sometimes with
allow the casing to be ejected. The main goal of project involves
modeling of aluminum castings and to compare with customer refractories. Molten aluminium dissolves iron from crucibles.
model and also developing the Die Design for “E6 UPPER Therefore, aluminum is usually melted and handled in
BODY”. This involves making the necessary modifications, refractory (most often, silicon carbide) containers. High-
which rectify the problems identified in the previous design. The alumina brick bonded with phosphoric acid is ordinarily used
post-casting operations are partially eliminated by changing the for furnace linings. The surface tension of molten aluminium
ejector pin positions. The previous offset design in injection is high and when augmented by the formation of film of
point is remodeled such that the length of feeding system is oxide, surface tension is so great that it causes difficulty in
reduced and the forces acting on the tie bars are balanced. The casing thin sections. Alloy additions reduce surface tension,
orientation of the component in the assembled die housing is
but broaden the solidification range, which is likely to cause
changed so that the forces acting on the side cores are minimized
to a large extent. The conventional design of spring-supported shrinkage problems. The surface tension of molten
side-cores is modified and a new design is proposed. aluminium is great enough to keep a charge of fines floating
on top of the molten bath. Compositions that are high in alloy
Keywords—Die,Ejector pin, Air Vent, Hot-tearing content, such as the high-silicon die casting alloys are
susceptible to precipitation of the alloying elements, thus
INTRODUCTION
forming sludge. Thereafter of sludge formation increases as
Aluminium diecasting is a process where molten aluminium the temperature of the molten bath decreases.
alloy is injected into a casting die under high pressure and at Aluminium alloys solidify with a maximum of
a controlled temperature. The mold had two sections, the” nearly 10% volume contraction, which must be considered in
cover” half and the “ejector” half. The die may also have the design of the gating system for a casting. Molten
additional moveable segments called slides or pulls, which aluminum weighs only 145 to 150 lb per cubic foot, whereas
are used to create features such as undercuts or holes which solid aluminum weighs 160 to 165 lb per cubic foot.
are parallel to the parting line (Fig. No: 1.1)
Aluminium diecasting dies are run in cold chamber diecasting II. LITERATURE REVIEW
machines. These machines are operated at the required
High Pressure Die Casting (HPDC) is an important process
temperatures and pressures to produce a quality part to net-
for manufacturing high volume and low cost components.
shape or near net-shape specifications. Aluminium diecasting
Examples from the automotive industry include automatic
can be readily machined, anodized, painted or powder coated.
transmission housings, piston heads and gearbox components.
Some of the more typical application for aluminium die
The geometric complexity of the dies leads to strongly three-
castings are: enclosures for the electronics industry, hand and
dimensional fluid flow with significant free surface
power tools, hardware, applications, pump parts, plumbing
fragmentation. Crucial to forming homogeneous cast
parts, parts for the automotive industries, sports and leisure,
components with minimal entrapped voids is the order in
home appliances, and communications.
which the various parts of the die fill and the positioning of
the gas exists. This determined by the design of the gating
system and the geometry of the die.
 Ejector pin marks are on jigging surface, so that this
surface needs post-casting processes.
 The previous design in injection point is offset, so
that the length of feeding system is increased.
 The locking forces needed on the side cores are
Fig 1.1: COLD CHAMBER more.
 The conventional design of spring-supported to side-
cores is modified, because while die is mounting and
dismounting from the machine, the projected screws
may chance to touches the tie bars.

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Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

A. Objective Of The Project magnitude of metal shrinkage on die parts as metal cools in
The main objective of this project is to 3D Modeling of the die.
pressure die casting parts 12. Specify die cast threads over cut threads when a net
 END COVER savings will result.
 VALVE BODY 13. Die-castings which affect the appearance of a
 E6 UPPER BODY ((including core &cavity finished product may be designed for aesthetics, and to
extraction) harmonize with mating parts.
 R12 BODY 14. Inserts should be designed to be held firmly in place
 Design the die-casting die for the component “E6 with proper anchorage provided to retain them in the die-
UPPER BODY”. casting.
Which involves necessary modifications in manufacturing 15. Design parts to minimize flash removal costs.
“E6 Upper Body” 16. Never specify dimensional tolerances closer than
o Elimination of ejector pin marks on jigging essential. This increases costs.
surface. 17. Design dies castings to minimize machining.
o Injection position is aligned in along y-axis, so
that length of feeding system is minimised and C. Pressure Die Casting Die Design
locking force needed on side cavities is reduced. Inputs from the customer can be received in the following
o Feeding system redesigned, so that molten ways.
metal reaches at all peak points at a time.  3D casting model without 2D drawings and drafts in
Spring support to side cores is modified. the model
 2D drawings only
B. 3d Modeling And Component Design  3D machined model
Advice on designing die-castings is usually based upon  3D model in IGES format
desirable practices or situations to avoid. However, like most  Sample casting /final machined part
rules, there are exceptions. These affect costs, appearance  Solid model is made if it is not there.
and/or quality of final products. Listed below are guides that  Study of component /casting.
should be considered when designing and modeling for die-  Machine selection
casting:  Identification & selection of the parting line.
1. Specify thin sections that can easily be die cast and  Introduce drafts in the model before giving fillets.
still provide adequate strength and stiffness. Use ribs  Perform draft check on the model & rectify if
wherever possible to attain maximum strength, minimum necessary.
weight.  Splitting & extracting the fixed & moving halves of
2. Keep sections as uniform as possible. Where inserts respectively.
sections must be varied, make transitions gradual to avoid
 Gating Design
stress concentration.
 Optimum Gate, Runner & Overflows are designed.
3. Keep shapes simple and avoid nonessential
projections.  Design of other die elements, ejection, guide &
4. A slight crown is more desirable than a large flat cooling system.
surface, especially on plated or highly finished parts.  Design review /Design approval
5. Specify coring for holes or recesses where savings in  Complete detailing is done.
metal and overall costs outweigh tooling costs. Complete die design in 3D (Pro-E) & 2D
6. Design cores for easy withdrawal to avoid manufacturing drawings in Pro-e/Auto CAD is released for
complicated die construction and operation. manufacturing.
7. Avoid small cores. They can be easily bent or
broken necessitating frequent replacement. Drilling or D. Softwares Used For Die Design
piercing small holes in die-castings is often cheaper than the Pro/E:It is a suite of programs that are used in design,
cost of maintaining small cores. analysis & manufacturing of a virtually unlimited range of
8. Avoid use of undercuts, which increase die or products.
operating costs unless savings in metal or other advantages Pro/E is a parametric feature based solid modeling system.
fully warrant these extra costs. Parametric means that the physical shape of the part /assembly
9. Provide sufficient draft on sidewalls and cores to is driven by the values assigned to the attributes of its features
permit easy removal of the die casting from the die without & the feature dimensions or other attributes at any time
distortion. Solid modeling means the computer model created is able to
10. Provide fillets at all inside corners and avoid sharp contain all the information that a real solid object should
outside corners. Deviation from this practice may be have.
warranted by special considerations
11. Die casting design must provide for location of
ejector pins. Take into consideration the effect of resultant
ejector marks on appearance and function. The location of
ejector pins is largely determined by the location and

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Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

DiEdifice A. Moving Core Mechanisms

DiEdifice provides the designer with an intelligent & Cores with axis not parallel to the die movement are called
powerful Tool for designing PDC dies, thereby reducing the movable cores. These cores must be withdrawn by a separate
complexity & lead-time of the die design process. mechanism before the casting is ejected from the die by
The knowledge base comprises of engineering methods, mechanical slides, by hydraulic actuated mechanism, by Dog
heuristic rules & other manufacturing & operational Leg cam and by Rack And Pinion.
considerations. (Fig. No: 6.1)
DiEdifice takes a solid model of the component to be cast & The movable die elements needed to build up die
also of the die blocks as the input and through an interactive surfaces. These are used when it becomes impossible to avoid
process with he user, designs the feeding, gating & cooling under cuts in the casting. These slides must be retraced before
system. the casting ejection.
Features The core must be shaped, so it is loose and free to move once
 Calculation of filling parameters. the die has opened.
 Gating System Design The core must not be shaped so that it can get
pinched between other parts of the die as those parts and core
 Overflow design
wrap and change size due to their thermal gradients.
 Gate & Gate Runner design
 Runner design
 Venting calculations
 Gating Systems Analysis (Health Checks) B. Mechanical Core Slider
The locking wedge locates the core and retains its
 Air Entrapment
position against the force of the molten metal pressure. The
 Dynamic injection pressure
actuating mechanism must strip the core from the casting.
 Fettling Factor, Yield, Reynolds Number The actual moving of the core should require little force,
 Cooling System Calculations although the simple lifting of big cores can require a
 Total cooling load required substantial mechanism.
 Total effective cooling length required The angle pin is fixed cover die and extends through
 Ejection System Calculations a hole in the core block. The hole in the core block is larger
 Total ejection load required than the angle pin. As the die opens, the angle pi moves
 Number of ejector pins required through the clearance until at some point it contacts the core
 Standard Parts library block. Also, as the die opens, the locking wedge withdraws
 DiEdifice comes with a inbuilt in DME Catalog from the core. The amount of die opening at the time, the
 Provision for creating a customized library of parts angled pin contacts the core block is known as the dwell.
Once contact is made, the angle of the pin will force the core
to move away from the casing. The distance the core will
III. PQ2 CALCULATIONS move (i. e travel) determined by the length of the core pin
 Objective is to make a design that will have the die and its angle. (Fig. No: 6.2)
& machine operates within the range of developed
operating window. C. Force Calculation
 PQ2 predicts whether a given die will operate when The angle of the angle pin, and the angle of the wedge, also
mounted on a machine with known performance. determines the amount of machine locking force that must be
 Inputs Required allocated to „hold‟ the core.
 Dry shot speed The projected area must be selected in the plane that
 Shot pressure used for dry shot is normal (i.e. 90o) to he direction of core travel, the forces
 Shot cylinder bore diameter applied by the injected metal should be computed and
 Shot stroke recorded for all moving cores.
 Total shot weight Finger cam angle of inclination Ф= 18o-22o
 Safety factor for machine Angel of wedge= Ф+ 2o Force FY= FX TanФ
 Estimated gate area Ф=angle of finger cam inclination
 Desired gate thickness
 Weight of metal through gate
 Liquid density for this alloy Ejector pins
 Projected area
 Coefficient of Discharge - Cd est. Machine speed
setting (Cold Chamber, Al. 0.35)
 Establish plunger diameter
 Establish operating pressure Proposed Design
 Maximum fill time
 Maximum gate velocity
 Minimum gate velocity

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Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

Applications And General Notes

Suitable for marine 'on deck' castings. Water-cooled
manifolds and jackets, motor-car and road transport fittings;
Ejector thin sections and intricate castings such as motor housings,
meter cases and switch-boxes; for very large castings, e.g.,
pins cast doors and panels where ease of casting is essential; for
chemical and dye industry castings, e.g. pump parts: for paint
industry and-food and domestic castings. In general use where
marine atmospheres or service conditions make corrosion
resistance a matter of major importance. LM20 is generally
only preferred to LM2 or LM24 when the castings are used in
aggressive media, requiring the higher resistance LM20 offers.
Existing design Where the very highest resistance is required, then LM6 may
be found superior to LM20. LM20 has slightly better
Machinability castability than LM6. [5]
Castings made in lm20 are rather difficult to machine. This Design Calculations And Results
is due to their tendency to drag and rapid tool wear caused by Component volume=135100 mm3
the high silicon content. The higher copper content does Density=0.00278g/ mm3
reduce the problem of drag compared to lm6. No. Of cavities=1
Carbide-tipped tools with large rake angles and relatively low Projected area of component=5814.58 mm2 (In pull direction)
cutting speeds give comparatively good results. A cutting Surface area of =53370 mm2
lubricant and coolant should be employed. Mass= 375.578 gm

Corrosion Resistance Machine Tonnage Calculations

LM20 exhibits high resistance to corrosion under both Specific injection pressure for pressure tight casting=800
ordinary atmospheric and marine conditions. For the severest bar= 8 kgf/ mm2
conditions this property can be further enhanced by anodic Projected area of shot (projected area including overflows
treatment. LM20 is only marginally worse than LM6 with and feed system)=
respect to corrosion resistance. =Projected area of component X1.3
=6194.31X1.3=8052.603 mm2
Anodising: Locking force required for the die=projected area of shot X
LM20 can be anodized by any of the common processes. sp.injection pressure
The resulting protective film ranging in color from grey to =8052.603x8=64,421.04 kgf/ mm2 =64.04 T
dark brown. The surfaces of diecasting are generally not Projected area of side core 1=4185.00 mm2
suitable for decorative anodizing. Projected area of side core 2=3525.00 mm2
Casting Characteristics: Force acting on side core1= projected area of core X
Fluidity - Can be cast into thinner and more intricate sections sp.inj.pressureXtan 200
than many other types of casting types. =4185 X8X tan 200=12183.37 kg/mm2=12.183T
Force acting on side core2=3525X8X tan 20 0=10261.98
Pressure Tightness - Especially suitable for teak-tight kg/mm2=10.261T
castings. Total locking force required=82.97 T
Taking factor of safety 1.2
Hot-tearing - Castings tend to exhibit complete freedom from Total tonnage required for locking =99.50T
hot-tearing. Hence we can select 250T machine according to the tonnage.

Typical Pouring Temperature - Pouring temperatures for C. Shot capacity calculation

diecasting depend very largely on the particular casting and Shot volume=volume of component + overflow and feed
the machine and vary too widely for a typical temperature to system, excluding
provide useful guidance. The melt should not, however, be biscuit
allowed to stand at temperatures only a little above the =Component volume X 1.3
freezing range or the bottom of the melt may become =135100 X1.3=175630 mm3
enriched in such elements as iron and manganese Shot weight= 375.578 X1.3=488.25 g

Patternmakers' Shrinkage: 1.3% or 1/75. Machine Tonnage Calculations

Specific injection pressure for pressure tight casting=800
bar= 8 kgf/ mm2

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Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

Projected area of shot (projected area including overflows Plunger Diameter Calculation
and feed system)= Volume of shot = volume of shot sleeve
=Projected area of component X1.3 Total volume of casting and feed system= total volume in the
=6194.31X1.3=8052.603 mm2 shot sleeve
Locking force required for the die=projected area of shot X 175630+(∏d2/4)= (∏d2/4) X (370) X 0.5
sp.injection pressure Where h is the biscuit height, 0.5 the fill ratio, 370 is
=8052.603x8=64,421.04 kgf/ mm2 =64.04 T effective stroke
Projected area of side core 1=4185.00 mm2 d=36.26, Considering plunger diameter 60 mm
Projected area of side core 2=3525.00 mm2
Force acting on side core1= projected area of core X Plot The M/C Power Line.
sp.inj.pressureXtan 200 Pm = Ph *(dh2/dp2)
=4185 X8X tan 200=12183.37 Where
2
kg/mm =12.183T Pm = metal pressure (kg/cm2) (704.17kg/cm2)
Force acting on side core2=3525X8X tan 20 0=10261.98 Ph =hydraulic pressure (kg/ cm2) (150kg/cm2)
kg/mm2=10.261T dh =effective hydraulic cylinder diameter (cm) (130 mm)
Total locking force required=82.97 T dp =plunger diameter (60 mm)
Taking factor of safety 1.2 Metal Pressure is plotted on the Y-Axis of the Graph
Total tonnage required for locking =99.50T Qmax =VpX dh2/ dp2
Hence we can select 250T machine according to the tonnage. Where
Vp = maximum dry shot speed (cm/sec) (4.5 m/s)
Shot Capacity Calculation dp =plunger diameter (cm) (60 mm)
Shot volume=volume of component + overflow and feed Qmax = maximum fill rate (cm3/s) (12717 cc/sec)
system, excluding Qmax is plotted on the X-Axis
biscuit Join the Pm on Y-axis & Qmax on the X-axis
=Component volume X 1.3 So the process can run anywhere under the line.
=135100 X1.3=175630 mm3 This is the first process boundary
Shot weight= 375.578 X1.3=488.25 g
Table 1: Machine Specifications Calculate The Theoretical Fill Rate (Qth)
Locking force
Tonnes
250
Qth = Vcav/t
Also Vcav = W/p
Where
Hydraulic ejection force Tonnes 15 Vcav = Volume of metal through the gate
W = Weight of metal passing through the gates (kg)
Die mounting plates HX V mm Xmm 800X 850 p = Molten alloy density (kg/cm3) ( 2.78 g/cm3)
Qth = Theoretical fill rate (1804.94 g/cm3)
t = k*T*(Ti-Tf+SZ)/(Tf-Td)
Space bar between tie bars HXV mm Xmm 500X 550
Where
t = ideal filling time (sec) (0.08 sec )
Tie bar diameter mm 100
k = Empirically derived constant (sec/cm) (0.0346 sec/cm )
Ti = temperature of the molten metal as it enters the die
Max. die height mm 750 (oC) (650 oC)
Tf = minimum flow temperature of the metal (oC) (570 oC)
Min. die height mm 225 Td = temp. of the die cavity surface just before the metal
enters. (oC)
Die opening stroke mm 500
(200 oC)
S = % of solid filling allowable in the metal at the end of
filling. (%) (30%)
Injection plunger stroke mm 350 Z = unit conversion factor (oC/%) (4.8oC/%)
T = Average casting thickness (mm) (4 mm)
Ejection stroke adjustable mm 100 From this acceptable process can run to the right of the fill
rate as long it is below the M/C performance line.
Machine area m2 5.9 X1.6
Metal Pressure (P)
Capacity of oil tank
lts
550 P =(p/2g)*(Vg/Cd) 2
Where
P = metal pressure
Plunger diameter mm 40~85 Vg = Gate velocity (40 m/s)
p =Aluminum Density (2.78 g/cm 3)
Shot capacity for aluminium Kg 0.8~3.6 Cd = coefficient of discharge (0.35)
g = acceleration due to gravity 9.8 m/s2

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Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

Corresponding to two gate velocities (Max. & Min.) we get Ap=shot plunger area (cm2)
two Pressure values
Process point will be in the center of the process window due Plunger Velocity, (Vp)
to normal variation within the die cast process. (Vp)= (Vp)= (QthX 4)/(∏ X dp2X0.01)/100
Once the process point is decided, total gate area (Ag) can be = 0.64 m/s
determined by
P =(/2g)*(Vg/Cd)2 OVERFLOWS:
Design Considerations
Ag Vg =Q/Ag
 Depth of overflow must not be great, as the
Ag =Q/Vg (45.1mm2) solidification will take time leading to increase cycle
Result time.
Gate Depth = 1.5 mm  Overflow should be so provided that heat will enter
Gate length=30.1 mm the appropriate area of the die.
Type of gate =Ring Gate  Shape should be such that it can be easily cut into the
Total ring gate area is divided in to equal 2 segments steel.
according to the each segmented weight of casting, so that  Generous radii to be provided at the bottom / corners
metal will reach the metal in all peak points at a time. of the overflow.
Ring gating is not advisable for multiple cavities.  Each overflow should have one ejector pin & the pin
is cut short so a cylindrical lug is cast over it. This
Runner Design Considerations lug ensures that the overflow will be ejected straight
 Width of the runner should not exceed twice the for the first 6 mm. (Fig. No: 8.3.2)
depth  Better to have series of small overflow than one long
 Runner area should be equal to 1.2 times total area overflow.
of all the gates.  If the metal flow a long distance, the overflow size
 Side of the runner away from the gate is slightly should be enlarged.
angled to provide draft for ejection.  Overflow should be sized according to the vol. of
 The side next to the gate has a definite angle A, cavity from which the overflow receives the molten
approach angle, which directs the metal in to the metal.
gate.  Thickness of segment Cavity Fill Time Overflow
 Bottom is flat but the corner is radiused
 The runner as approaches the sprue/ biscuit it will IV. AIR VENTS:
become progressively larger, reason being cross-
section must equal all the gate cross-section down Vents /Air passages lead out of overflows in certain
the stream. castings or directly from the edge of the castings.
 It is desirable to have additional enlargement of
about of about 10% at the sprue / biscuit. [2] [4] Design Considerations
 Metal flow paths should be such that die vents
Calculations should be the last area to be filled with molten metal
W= width of the runner during the fill time.
d = depth of the runner  Total vent cross section should be minimum 50% of
And w<= 2d the gate area.
Runner area = 1.2*Total Gate Area  Depth of vents at die inserts should be 0.25- 0.3 mm.
1.5 *d*d = 45.1*1.2  Ejector Pins are used for venting by grinding flats on
d = 6.02mm sides
w = 12.12 mm  It should be between (0.05-0.15) at the end of die
half or after a distance of (1.5 – 0.2) from the cavity
Slow Shot Sleeve Velocity (V1) edge.
Vss= (V1)=slow shot sleeve velocity= Ccc(100%- Venting analysis using Die Edifice Software provides
fi/100%)X(dp)0.5 information regarding the total volume of air that needs to be
Vss= slow shot velocity (m/s) vented from the die based on casting, material properties &
fi=Volume fraction of shot sleeve initiating filled with no. of casting present. Depending on this volume and the
molten metal(%) parameters (% of vents open, depth of vents, temperature in
dp=plunger diameter(mm) the cavity, factor of venting, initial pressure of air& max.
Ccc=curve fitted constant (0.579 m/s) pressure permissible) established in the settings.
fi=(Vt/(Ap*ls))*100 it calculates the dimensions of the vents & the velocity of air
Vt= volume of metal ladled in to shot sleeve (cm3). being vented.
ls= length of the shot sleeve between the face of the plunger
and face of the
Ejector die (cm)

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Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

V. EJECTION SYSTEM DESIGN VI. EJECTOR PLATE TRAVEL DESIGN

Casting contract on solidification. It results CONSIDERATIONS
in forces of shrinkage & contraction, which must be overcome  Stops should be used to establish proper spacing.
when the casting is ejected Without it entire surface contact will be there which
To avoid damage of surface & to decrease the ejection may stick due to grease /oil. Also foreign material
forces the die-casting must be designed with some would prevent the die from seating properly.
tapers/drafts.  Flat parts require 6 mm. (Twice to it is very
Design Considerations common)
 Ejection Force = f (alloy, core size, draft on core,  Deep / min. drafted castings require more.
center distance between cores, chill time, gate  25-38 mm on dies for manual casting removal.
velocity, injection pressure)  Extra travel carries the cast shot out from the various
 Ejection Force is directly proportional to chill time, contours.
Injection pressure& gate velocity  Dies built for automatic casting removal will require
 Ejection Force is inversely proportional to Iron more ejector pin travel.
content.  Travel of ejector plate is limited by positive stops.
 Amount of draft depends on the arrangements of die  Backstops located behind the Ejector Plate in direct
cast part in the die. line with the Return pins will ensure plate stops in
correct position.
Other factors are  There should be a backstop for each Return Pin.
 Diameter of Back Stop similar to Return Pin &
 Shape
height sufficient to provide clearance to the cap
 Die Casting Alloy screws.
 Area of contracting surface  Forward position of the Ejector Plate is limited by
 Wall thickness Forward Stops. Forward stops should be placed in
 Depth (T) of the core surface. (Most important) line with the Bumper Pins & its diameter. Height of
 Taper (N) is expressed as percentage of depth of the forward stops must be in accordance with he desired
core surface plate travel. [5](Fig. No: 8.3.1, 8.3.2,8.3.3)
N = (Kt/100)*T +(Kb/100)*B
B = width of the core Thermal Work Determination
For Aluminum Liquid metal loses its heat & metal shrinks during
Draft for outer surfaces in % of T (Kt) = 0.2-0.5 solidification. Heat loss occurs through the die features &
Draft for inner surfaces in % of T (Kt) = 0.5 though the evaporating waters which is applied as medium
Draft widthwise (Kb)= 0.2 for the die coat. If the rate of heat flow is too fast it will result
Oil based release agents decrease the compared to water in cold shuts & chill marks. If it is too slow it will extend the
based lubricants because cycle time of the die reducing productivity. Long cycle times
 Wet ability of oil to water is better. if operate early may also cause
 Cooling capacity of oil is less than water base  Ejection problems
lubricants.  Hot cracking
 Ejection pin may push through the liquid metal &
Design Considerations the casting may explode
 An ejector pin is provided directly behind all limited  Cause the metal to stick to the surface of the die
draft areas.
 Uniform pattern of ejection points is provided. Relative rates of heat transfer is very important
 Provide at least one ejector for each overflow. During this stage metal having more heat content behave as
 Avoid ejector pins over moving cores. riser feeding the metal of the shrunk portion, leading to
 Avoid ejector pin in line with cover die cavity / porosity. Pressure is applied to the molten metal with
features that are fragile or that will form hardware Machine Injection Plunger to force liquid metal from the
quality surface finishes on the casting. biscuit/runner area into such voids as they develop. But if the
 Ejector Pins mark (protrusion/ depression) <=0.4 area of rapid solidification is between the plunger & the
mm & should be given where acceptable. (Fig. No: liquid metal it results in blockage leading to void & porosity.
8.31)  Shape of uniform thickness casting can influence the
 Sometimes holes formed in the casting by circular solidification pattern due to the
core pins have min. draft & create ejection restricted/unrestricted areas of heat flow.
problems. In this Sleeve ejector provides a uniform  Core in heavy sections will cause large voids
ejection around the core pin. [6] adjacent to the cores.
 Die should be designed to remove heat from the
heavy section at faster rates than from thin section
surroundings.

Volume 3, Issue 26 Published by, www.ijert.org 7

Special Issue - 2015 International Journal of Engineering Research & Technology (IJERT)
ISSN: 2278-0181
NCRAIME-2015 Conference Proceedings

 It is required to balance these influence of various Waterline Location

heat inputs & heat flow restrictions. Amount of heat that must enter any particular section can be
computed.
Basic Heat Content Of Sections Heat moves from higher temp. to lower temp.
Qj = R*Vj*[(Ti-Te) (Cp)+L] (Tc – Td)/d = Qj/ (k*A)
Qj = rate at which the basic heat content of thermal section j where
is put into the die (watts) Tc = average cavity surface temp (oC)
Vj = volume of thermal section (mm3) Td = Interior die temperature ( oC)
Ti = injection temperature of the casting. (oC) D = distance from cavity surface to Td (mm)
Te = ejection temperature of the casting. (oC) Qj = rate at which the heat must flow through the j zone of
Cp = specific heat of the alloy being cast the die (watts)
L = Latent heat of the alloy being cast (Joules/mm3) K = thermal conductivity
A = cavity surface area of j zone (mm2)
R = casting rate (cycles/sec) Also
Again Qj = hc*A*(Td-Tw)
A = area of water line
Q = Qj - (R*Aj*Aw)
Td = temperature of die around waterline
Q = rate of thermal work to be processed by internal features Tw = temperature of water flowing through the waterline.
of the die hc = heat transfer coefficient W/(m2*C)
Aj = cavity surface area of section j (mm2) Minimum distance between water lines & other features of
Aw = heat removed by water spray (Joules/(shot*mm2) the die
All dimensions are in mm
An expected heat loss to evaporation is subtracted from basic
heat content of the die.
Only after this die cooling mechanism is worked out. VIII. CONCLUSIONS
Cooling the die, or part of it with surface water evaporation
can shorten the effective die life of the material.  3D Modeling of Aluminium castings and verified of
Heat loss by water to evaporation amount of water is model with customer model by Inspection report.
determined.  General approach through out the work was to take
If water is more, it will bounce without much heat. up a system its element, its purpose; design
The water that leaves as steam carries 2475 KJ/Liter. considerations followed by design calculations&
Approximately water supply will remove 4.9 J/mm2 per shot recommended values for the E6 UPPER BODY.
 The use o PQ2 Graph allows us to calculate the
Procedure various parameters with in the process limit.
 The runners, casting, overflows must be divided into  Die design of E6 UPPER BODY involves changing
thermal sections. the orientation of component in die, so that forces
 Then the basic heat content is computed for each acting on side cores are distributed.
section.
 Heat to be removed by the water spray is deducted
IX. REFERENCES
from the total thermal work to determine the heat
that will be processed through the die. 1. Die Casting Product Design, the die casting society of India,
New Delhi.
Diagram is prepared showing how the water is applied 2. E.A Herman, 1979, Die Casting Dies (NADCA), Society Of Die
Casting Engineers, USA
VII. THERMAL CONTROL FEATURES 3. Walkington, Bill - PQ2 Handouts (NADCA), Society Of Die
Casting Engineers, USA
Input of heat to the die is intermittent. Each time a shot is
4. Scott Kirkman - Gating Design (NADCA) Society Of Die
made a load of heat is transferred to the die .Die must process Casting Engineers, USA
that load of heat before the next load arrives. 5. Engineering properties of aluminium alloys-1981, International
Waterlines are the drilled hole through which cooling water is Lead Aluminium Research Organization, New York (Vol. 5)
6. Design Standards, Sundaram Clayton standards, Chennai.
pumped is the primary thermal control feature in the die. It is
[1] 1989.
dynamic control as the flow rate can be adjusted.

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