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Die Casting Runner Design Guide

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16 views2 pages

Die Casting Runner Design Guide

Uploaded by

basarica
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Die Casting Runner Design Guide - Steps for How to Design the Die Casting Runner | Diecasting-mould

The runner of a mold is a passage connecting the sprue and the gate where molten metal enters the cavity, die casting runner design is important to d
good runner design can make the filling process of liquid metal more stable, exhaust more smoothly, and obtain high-quality castings, also conducive

Die Casting Runner Design Guide & Tips - Steps for How to Design the Die Casting Runner
When designing die casting runner, the following steps are often required.
1. Casting analysis
– Die casting material type and size: different alloys have different solid-liquid phase temperatures, fluidity, different performance in the flow process
weight of the casting directly determine the amount of metal, so the volume or weight of the casting is the most basic constraint parameter for the run
– Wall thickness: wall thickness largely determines the distribution of hot spot, while the cooling speed of thin wall area is faster, which needs higher
the opposite is true for thick wall area. In addition, the area where the thickness changes abruptly is also the part where defects are easy to occur.
– Casting shape: the geometric shape of the casting affects the design of the runner. For example, the cylindrical part and the square box part require
with complex shapes, it is often necessary to arrange the inlets according to the geometric characteristics of different regions after the partition.
– Quality requirements: the quality requirements of castings include surface quality requirements, air tightness requirements, mechanical strength req
the design of die casting runner, but also determine many production factors such as die casting machine, production cycle, process parameters, etc.

2. Determine the entrance of molten metal and exhaust port


According to the first step of casting analysis, it is first determined where the liquid metal enters into the runner system and where the exhaust overflo
basic flow characteristics of castings are fixed after the entrance and exhaust port are determined. Generally speaking, some common design princip
regime characteristics, such as:
– Shortest distance. The longer the distance is, the lower the temperature of the liquid metal is, the less fluidity is likely to occur, resulting in all kinds
– Thin wall preposition. Because of the fast cooling of the thin-walled area, if the thin-walled area is located at the end of the filling, it is easy to produ
recommended to take the thin-walled area as the front end of the process. If it has to be rear-mounted due to structural reasons, a half channel can b
supplement.
– Damping. Some casting structural characteristics will have a strong obstacle to the flow of liquid metal, such as deep shell casting, make deep mold
speed is high, and can better fill the mold.

3. Calculate the maximum filling time and gate speed


Gate flow x filling time = casting volume, and casting volume is a fixed value, shorter filling time will inevitably require faster filling speed, which also
But if the liquid metal velocity is too high, it will bring erosion defects and affect the die life; If the speed is too low, it is easy to have the problem of in
for the die casting, the filling time should be in a reasonable range to ensure that the casting is in a good casting space.

4. Casting divisions
When the gate speed, area, and filling time are determined, it is necessary to set the zone according to the casting flow characteristics. The casting i
corresponding to a gate. This has the advantage of ensuring smooth filling.

5. Calculate the amount of metal in each area


According to the volume of each zone determined in the previous step, determine the size of each corresponding gate, so as to ensure that the amou
match the corresponding zone volume, and ensure that each strand of liquid metal can reach the exhaust position when filling completed, also avoid
greatest extent.

6. PQ diagram check
PQ diagram is a pressure flow diagram. After selecting parameters such as suitable tonnage of die casting machine, hammer diameter, and pressure
the PQ diagram to ensure that the current flow design can match the appropriate machine equipment. Only when the working point of the machine is
PQ diagram and there is a large process margin, the next step of runner modeling design can be started.

7. Create runner and exhaust


– Simultaneous arrival: the time of liquid metal arriving at each gate should be as consistent as possible. In order to achieve this goal, it is necessary
channels. The flow distance of the middle branch channel is short, so the flow length can be increased.
– Cross-sectional area descending: the cross-sectional area of the runner must be gradually reduced with the flow direction, so as to ensure that the
be involved in the air due to the increase of the runner.
– The cooling condition of the runner. The runner is usually designed to be flat, and the aspect ratio must meet a certain range. If the runner is too thi
of the runner, which affects the dimensional accuracy of the casting due to the shrinkage deformation of the runner. However, if the flow channel is to
easy to cause the third phase pressure maintaining failure, and it is unable to transfer the pressure to the casting for feeding. The runner and overflow
mold temperature, which is conducive to heat supplement for some thin-walled parts of the casting.
8. Simulation and comparison of multiple designs
In practical work, there are usually many kinds of runner schemes, which need to be simulated and compared to select the best one with the best pro
defects for subsequent trial production. The simulation can not only analyze the flow process and solidification process in advance, but also analyze t
mechanical properties, etc. in the design stage, it can consider the quality control in the later stage, and help the design idea of poor filtration.

9. Runner adjustment and optimization


After the design is determined, it may be necessary to optimize the runner design, such as adjusting the gate of a branch runner to change the flow ra
improve the local flow pattern, etc. It should be noted that any change of runner and gate should not affect the process parameters determined in the

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