DIE CASTING CALCULATIONS

1. Wt of casting (gms)
2. Density(gms/cc): based on alloy used for casting. Al- 2.6 to 2.7; Zn- 7.8; Cu-9;
Mg- 1.7
3. Projected Area Casting

: Surface Area (cm2)

4. Volume of Casting cm 3

: (Wt of Comp) / Density

5. 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. Gate Velocity (Vg) in m/sec (Refer Table 2)
7. Gate Thickness Hg (mm) , Hg = n/3 n/4 , n thickness of casting
8. Volume of metal through gate : P (cm3)
.

P = vol of casting + vol of overflow (10% of vol of casting)

9. Fill Rate (Q) cm3/sec

.

Q = (P x 1000) / t ; t fill time in milli secs

10. Gate area (Ag) (cm2)

.

Ag = (Q) / (100 x Vg)

11. Gate Length Lg (mm)

.

Lg = ( Ag x 100 ) / Hg

12. Runner Area Ar (cm2)

.

Ar = 1.25 Ag 1.6 Ag

13. 13 Runner Depth D (mm)

D = (Ar / 1.6)(1/2) - (Ar / 2)(1/2)

14. Runner Width (W = 2D) (mm)

15. Locking Force F (Metric Tonnes)
.

F = ( A X P) / 1000
i. A Projected Area (cm2)
ii. P Specific injection pressure ( kg / cm2)

16. Machine Specification:- Select Machine based on the locking force.

17. Effective Plunger Stroke (cms) : Maximum plunger stroke 20/25 mm for
biscuits
18. Plunger Diameter d (cm)
.

Shot wt = Plunger Area x Eff. Plunger Stroke x 0.75 x 2.5 (gm)

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

4 x Shot wt = ( X d2 ) x Eff. Plunger Stroke x 0.75 x 2.5 (gm)

d2 = ( 4 x shot wt) / ( X Eff. Plunger Stroke x 0.75 x 2.5)

d=

[ ( 4 x shot wt) / ( X Eff. Plunger Stroke x 0.75 x 2.5) ]

TABLE I Specific Injection Pressure

Zn
100
200
Engineering Parts
200
300
Pressure Tight Parts 250
400
Decorative Parts

Al or Mg
200 400
400 600
800 1000

TABLE II Gate Velocity Ranges

Thinnest Wall Thickness (mm)
0 0.762
1.27 1.525
1.905 2.286
2.54 2.794

Gate Velocity Range (m/sec)

46 55
43 52
40 49
37 46

3.175 3.87
34 43
4.572 5.08
31 40
3.75 - Above
28 35
Use lower values for warmer dies and hot metals
Use higher values for colder dies and colder metals
TABLE III METAL & DIE TEMPERATURE
Alloy
Zn Alloy
Mg Alloy
Al Alloy

Metal Temperature
393 C (740 F)
657 C (1215 F)
657 C (1215 F)

Die Temperature
393 C (740 F)
332 C (630 F)
332 C (630 F)

Die Filling Time

For Zn, Al, Mg Alloys
Average Wall Thickness (mm) Max Die Filling Time (milli sec)
1
10 30
1.5
10 35
1.8
20 40
2.0
30 60
2.5
40 90
3
50 100
4
50 120
For higher values fill time 7ms for every 0.5mm wall thickness
For Brass
Average Wall Thickness (mm)
1.5
1.75
2
2.5
3
4

Max Die Filling Time (milli sec)

20 25
25 30
25 35
30 40
35 45
40 50

Highest value apply for Al

Medium value apply for Zn
Lowest value apply for Mg
TABLE IV Gate Thickness
Wall Thickness (mm) Gate Thickness (mm)
Al
Mg

0.75 1.5
1.5 2.5
2.5 4

0.5 0.8 0.5 0.6

0.8
0.6 0.85
1.25
1.25
0.85 1.35
1.6

Ejection System
Assuming ejecting 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 = A
Area of Ejector Pin = ( X A2 ) / 4
No of Ejector Pins Required = Total Ejection Area / Area of Ejection Pin