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Comprehensive Guide to Die Casting Theory and Calculation for Precision Manufacturing

Detailed overview of die casting methods, machine specifications, process parameters, and calculation techniques for optimizing casting quality and efficiency in manufacturing.

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･ CASTING THEORY ･ CASTING CALCURATION TOSHIBA MACHINE Co., Ltd. DIE CAST MACHINE ENGINEERING Div. Ｐ－ 1
1. DEFINISION OF DIE CAST Casting method that mass produce castings with highly accurate and excellent surface by pressing molten metal into precision mold, and products cast by this method. 2. FLOW OF FULL AUTO CYCLE (DIE CAST MACHINE) RELEASE AGENT SPRAY → MOLD CLOSE → POURING → INJECTION → PRODUCTS COOLING → MOLD OPEN → EJECTION → TAKE OUT → PLUNGER LUBRICATION 3. DIE CAST IS ONE OF CASTING METHOD Switch air and molten metal in mold cavity at high speed before the alloy molten metal solidify, then ram down it with high pressure. SHAPE OF PRODUCT CASITNG CONDITION ALLOY CHARACTERISTICS CASTING SYSTEM MELTING TREATMENT MOLTEN METAL DIE CASTING MOLD CASTING MACHINE MATERIAL Ｐ－ 2
4. DIE CAST PRODUCTS Good die castings have good appearance, high accuracy of dimension, and no porosity. HDD (hardware desk drive) Ｐ－ 3 MOLD DATA CHIP DIAMETER 70 m m PRODUCT WALL THICKNESS 2.0 m m PRODUCT WEIGHT 430 g PROJECT AREA 430 cm2 MATERIAL ADC12 MELTING TEMP 680 ℃ CASTING CONDITION LOWSPEED RATE 0.55 m/s 100 m m 50 ms 3.2 m/s 15 ms 0.55 m/s 50 ms 800 kgf/cm ㎝ 2 HIGH SPEED SECTION HIGH SPEED INCREASE HIGH SPEED RATE SLOW DOWN TIME SLOW DOWN RATE PRESSURISE TIME CASTING PRESSURE
5. DIE CASTING PROCESS LOW SPEED HIGH SPEED INTENSIFY CARRY MOLTEN METAL SHAPE THE PRODUCT. RAMDOWN PRODUCTS Pressure before molten metal start to solidify. (INTENSIFY TIME) Make porosity smaller and increase adhesion to mold. (CASTING PRESSURE) THAT IS POURED IN SLEEVE BY LADLE TO Start high speed when sleeve and runner is filled with molten GATE. metal 100 .  The air in sleeve and runner comes out completely. Don’t make wave on surface of molten metal and exhaust (SWITCHING POSITION: HIGH SPEED SECTION) air in sleeve from air vent of The gate is tighten normally, mold, to prevent air taking in molten metal that pass through molten metal. the gate is getting faster. It However if it is too slow, the molten metal start to solidify. makes molten metal into a mist to get into details of product, and make smooth surface. (HIGH SPEED RATE) The air in product area doesn’t come out completely. HIGH SPEED INTENSIFY LOW SPEED AIR BUBBLE Ｐ－ 4
MACHINE ･ MOLD ･ PRODUCT ･ DATA CONDITION DATA 1. MACHINE DC350CL-T A) MOLD CLOSE FORCE B) ACC PRESSURE 350ton Pa = 100kg/cm2 C) INJECTIONCYLINDER DIAMETER φ125mm As = 123cm2 D) INTENSIFY CYLINDER DIAMETER φ180mm Ab = 255cm2 E) Ｔ IP DIAMETER φ70mm Ap = 38.5cm2 2. MOLD F) ＳＨＯＴ WEIGHT G) Ｐ Ａ Ｒ Ｔ WEIGHT H) WALL THICKNESS I)GATE AREA J) Ｃ Ａ Ｓ Ｔ AREA K) DRY Ｓ Ｈ Ｏ Ｔ STROKE Wc= 900g (PRODUCT+OVERFLOW+RUNNER+BISCUIT) Wf= 700g (PRODUCT+OVERFLOW) tm= 2.0mm (AVERAGE VALUE OF THIN AREA) Ag = 1.3cm2 A = 350cm2 L = 337mm L) ALUMINUM Ｓ Ｐ Ｅ Ｃ Ｉ Ｆ Ｌ Ｃ Ｇ Ｒ Ａ Ｖ Ｉ Ｔ Ｙ Ｍ ） Ｃ Ａ Ｖ Ｉ Ｔ Ｉ Ｅ Ｓ r = 2.6g/cm3 １ HOW TO SETTLE CASTING CONDITION （１３ ５） ２０ ０ （１２ ０） （７ ０） １２ ０ １ ０ ６ ６ １ ５ ４ ０ ４ ０ １ ３ ３ ° Ｐ－ 5
D S R W C O E L D E P A E S E E TIME At start up, the speed rate shall be smooth without start shock up to specified speed rate. (Adjust with N11 valve.) 1. LOW SPEED TRANSFER POURED MOLTEN METAL TO NEIGHBORHOOD OF GATE WITH LESS AIR TAKING IN AND LESS TEMPERATURE DECREASE. LOW SPEED RATE IS TOO FAST Ｔ Ｉ Ｐ LOW SPEED RATE IS APPROPRIATE Ｔ Ｉ Ｐ LOW SPEED SPEEDUP TIME ADJUSTING VALVE （ N11 ） A B P T A B P T C2G1N212 HIG HISGPHESEPDEREADTSEPEED UP C2G11 LOW SPEED RATE DG11 LOW SPEED DG12 HIGH SPEED ● ● ● Ｐ－ 6 ●
(1) SLEEVE FILLING ＲＡＴＥ Sleeve filling factor is that percentage of molten metal in sleeve when molten metal poured. SLEEVE FILLING ＲＡＴＥ = TARGET OF SLEEVE FILLING FACTOR 20 ～ 50 (2) LOW SPEED Increase low speed rate in sleeve area without air taking in. ＳＨＯＴ WEIGHT Ｔ IP ＡＲＥＡ × ＤＲＹ ＳＨＯＴ STROKE× ALUMINUM ＳＰＥＣＩＦＬＣ Ｇ ＲＡＶＩＴＹ ×100 LOW SPEED = SLEEVE FILLING ＲＡＴ Ｅ (COEFFICIENT) 0.7× ＴＩＰ DIAMETER Ｐ－ 7
EXAMPLE Ｔ IP DIAMETER:φ70mm ＳＨＯＴ WEIGHT: 900g DRY ＳＨＯＴ STROKE: 337mm Ｔ IP ＡＲＥＡ =(π/4)×72 ＝ 38.5cm2 ALUMINUM ＳＰＥＣＩＦＬＣ ＧＲＡＶＩＴＹ : 2.6g/cm3 1) SLEEVE FILLING ＲＡＴ Ｅ = 2) LOW SPEED = = 0.21m/s 900 ×100 =  2 7 38.5×33.7×2.6 0.7× 7 0 2 7 DRY Ｓ Ｈ Ｏ Ｔ STROKE ＊ ２ ７ ％ 0.21m/s Ｐ－ 8
2. HIGH SPEED RATE SHAPE PRODUCT, SETTLE FLUIDITY, AND DIFFUSED POROSITY. (1) CASTING FILL TIME Need to cast before molten aluminum solidify in cavity. FILL TIME = 0.01× （ WALL THICKNESS× WALL THICKNESS ） (2) HIGH SPEED RATE BY MOLDCONDITION HIGH SPEED = ＴＩＰ ＡＲＥＡ ×FILL TIME× ALUMINUM ＳＰＥＣＩＦＬ Ｃ ＧＲＡＶＩＴＹ Ｐ Ａ Ｒ Ｔ WEIGHT （ PRODUCT + OVERFLOW WEIGH ） 1) Ｐ－ 9 2) 4) 3) CHECK LIMIT SPEED OF MOLD BY MACHINE CAPACITY DECIDE FILLING TIME CONFIRM GATE SPEED FIND HIGH SPEED RATE WITH MOLD CONDITION
(3) HIGH SPEED RARE BY MACHINE CAPACITY (LIMIT SPEED OF MOLD) NOTE) Actual injection speed ignore valve and pipe resistance, and considered only filling resistance. (4) CHECK GATE SPEED GATE SPEED = ×HIGH SPEED 20 ～ 60m/s is the target. ＴＩＰ ＡＲＥＡ GATE ＡＲＥ Ａ HIGH SPEED ＬＥＮＧＴ Ｈ = + 1cm LIMIT SPEED OF MOLD = ( ＴＩＰ ＡＲ ＥＡ ) 3 (GATE ＡＲＥＡ ) 2 ×INJECTION CYLINDER ＡＲＥＡ ×ACCUMULATOR PRESSURE ×550 Ｐ－ 10 (COEFFICIEN T) (5) HIGH SPEED Ｌ Ｅ Ｎ Ｇ Ｔ Ｈ Ｐ Ａ Ｒ Ｔ WEIGHT （ PRODUCT + OVERFLOW WEIGH ） ＴＩＰ ＡＲＥＡ × ALUMINUM ＳＰＥＣＩＦ ＬＣ ＧＲＡＶＩＴＹ
EXAMPLE WALL THICKNESS : 2mm ( ＰＡＲＴ WEIGHT) PRODUCT + OVERFLOW WEIGHT: 700g ＴＩＰ ＡＲＥＡ : 38.5cm2 GATE Ａ ＲＥＡ : 1.3cm2 ALUMINUM ＳＰＥＣＩＦＬＣ ＧＲＡＶＩ ＴＹ : 2.6g/cm3 ACC PRESSURE: 100kg/cm2 (COEFFICIENT) 1) FILL TIME = 0.01×2×2 = 0.04sec 2) HIGH SPEED = = 175cm/s = 1.75m/s 3) LIMIT SPEED OF MOLD = (COEFFICIENT) × 550 = 332cm/s = 3.32m/s 4) GATE SPEED = ×1.75 = 52m/s 5) HIGH SPEED ＬＥＮＧＴＨ ＝ + 1cm = 8cm = 80mm 700 38.5×0.04×2.6 INJECTION CYLINDER ＡＲＥＡ = (π/4)×12.52 = 123cm2 1.32×123×100 38.53 38.5 1.3 700 38.5×2.6 1.75m/s 5 ２ m/s Ｐ－ 11
ACCUMULATOR PRESSURE DROP (2) CASTING PRESSURE Ｕ Ｐ TIME CASTING PRESSURE ＵＰ TIME = 0.01× （ WALL THICKNESS × WALL THICKNESS ） (3) INJECTION FORCE INJECTION FORCE = CASTING PRESSURE× CASTING AREA MOLD LIMIT CASTING PRESSURE = ＴＩＰ Ａ ＲＥＡ (4) MOLDLIMIT CASTING PRESSURE MOLD CLOSE FORCE CASTING AREA ×ACCUMULATOR PRESSURE×0.9 CASTING PRESSURE = 3. CASTING PRESSURE （ １ ） CASTING PRESSURE INTENSIFY CYLINDER ＡＲ ＥＡ Ｐ－ 12 ACCUMULATOR PRESSURE
EXAMPL E DIE CAST MACHINE: DC350CL ＴＩＰ DIAMETER: φ70 ACCUMULATOR PRESSURE: 100kg/cm2 1) CASTING PRESSURE = ×100×0.9 = 596kg/cm2 2) CASTING PRESSURE ＵＰ TIME = 0.01×2×2 = 0.04 =40ms 3) INJECTION FORCE = 596×350 = 208600kg/cm2 =208.6T 4) MOLD LIMIT CASTING PRESSURE = = 10000kg/cm2 (π/4)×182 (π/4)×72 PRODUCT WALL THICKNESS: 2mm 350×1000 35 0 596kg/cm2 Ｐ－ 13
Ｐ－ 14 4. CASTING CONDITION SETTING 1) INJECTION CONTDITION SETTING ① LOWSPEED INCREASE (N11) ② LOWSPEED RATE (C2G11) ③ HIGH SPEED INCREASE (N12) ④ HIGH SPEED RATE (C2G12) ⑤ HIGH SPEED SECTION ⑥ INTENSIFY TIME (C2G15) ⑦ CASTING PRESSURE (ACC PRESSURE) 2) HIGH SPEED SECTION It is important that molten metal fill in cavity at high speed from unchanging position, because it affects stability of switching process of air and molten metal in mold. Product performance hinges on high speed section. Basically, make it in high speed around molten metal approach to gate area. (gate high speed) 3) ADJUSTMENTOF HIGH SPEED INCREASE Rise time adjustment from low speed to high speed determine flying pattern of molten metal spout from gate. Use N12 valve. TOSHIBA die cast machine is adjustable in10 ～ 40m/sec at one’s option.
Ｐ－ 15 4) INTENSIFY TIME It is important to intensify smoothly and keep the pressure of filled molten metal without burr, as the proverb goes ｢ strike the iron while it is hot ｣ . The reason is because that it is effective to help cubic volume shrinkage, compress air mixed in, and densify internal organization. Intensify time is the time from plunger stop to casting pressure apply. Pressurization is required before molten aluminum starts to solidify in cavity. 5) BISCUIT THICKNESS The target of biscuit thickness BISCUIT THICKNESS (mm) = 0.25×CHIP DIAMETER (mm) If the biscuit is thin, specific gravity of product decrease because biscuit spread effective pressure (gate riser effect) throughout in cavity.
INTENSIFY TIME HIGH SPEED LOW SPEED LOW SPEED INCREASE SPEED CASTING PRESSURE DISPLACEMENT LOW SPEED HIGH SPEED INCREASE ACCUMULATOR PRESSURE CASTING TIME CASTING PRESSURE HIG H SPEED HIGH SPEED ＬＥＮＧ ＴＨ TIME ORIGINA L POINT BISCUIT THICKNESS DRY INJECTION STROKE ５ . INJECTION WAVE READING Ｐ－ 16
1Mpa=10.2kgf ／ cm2 1kgf ／ cm2=0.098Mpa ６． MACHINE MAIN SPECIFICATION VALUE MACHINE INJECTION CYLINDER DIAMETER INTENSIFY CYLINDER DIAMETER ＡＣＣ PRESSURE (Mpa) INJECTION PRESSURE (Ton ･ f) DC 135EL φ 90 φ140 9.3 14.6 DEC150MT φ 90 φ125 15 19 DC 200EL φ 90 φ140 13.2 20.8 DC 250C φ110 φ160 13.2 27.1 DC 250CL,JT φ115 φ160 13.2 27.1 DC 350C φ115 φ180 13.2 34.4 DC 350CL-T,J-MT φ125 φ180 13.5 34.7 DC 500C φ135 φ215 13.2 49 DC 500CL-S,T,HT φ135 φ215 13.2 49 DC 650C,CL φ145 φ230 13.2 56.1 DC 800C,CL φ150 φ240 13.2 61.1 INJECTION CYLINDER DIAMETER Ｐ－ 17 INTENSIFY CYLINDER DIAMETER ＡＣＣ PRESSURE
Ｐ－ 18 MOLD THICKNESS ㎜ DRY INJECTION STROKE ㎜ TOSCAST INPUT VALUE ＋ ＝ ㎜ ㎜ MOLD DATA 1. MEASURE THICKNESS OF FIXED MOLD AND MOVABLEMOLD. FIXED MOLDMOVABLE MOLD 2. MEASURE DRY INJECTION STROKE. MOLD CLOSE LOW SPEED INJECTION READ INJECTION St VALUE ON BODY OPERATION SCREEN. ㎝ 2 3. MEASURE ＴＩＰ DIAMETER. CALCULATE ＴＩＰ CROSS SECTION. ＴＩＰ CROSS SECTION RADIUS×RADIUS×3.14= ㎜ ＴＩＰ DIAMETER 4. MEASURE BISCUIT THICKNESS. ㎜ BISCUIT THICKNESS 5. MEASURE PRODUCT WALL THICKNESS ㎜ PRODUCT WALL THICKNESS
Ｐ－ 19 ㎏ ｆ ＳＨＯＴ WEIGHT ㎏ ｆ ＰＡＲＴ WEIGHT 6. WEIGH CASTING. 7. MEASURE AHEAD OF GATE WEIGHT (PRODUCT AND OVERFLOW) (Snap off casting from gate.) 8. FIND PROJECT AREA OF CASTING. ㎝ 2 ＣＡＳＴ AREA × ＝ ㎝ ㎝ 9. MEASURE THICKNESS AND WIDTH OF GATE. GATE THICKNESS GATE WIDTH ㎝ 2 GATE ＡＲ ＥＡ 2. SELECT MATERIAL FROM SELECT WINDOW. 3. SELECT PREPARER FORM SELECT WINDOW. 1. INPUT MOLD NAME This is the file name for saving. Less than 8 letters.
Ｐ－ 20 ０．７ × ㎜ ＝ ＝ ％ INJECTION 1. LOW SPEED = 0.7 × ＴＩＰ DIAMETER SLEEVE FILLING ＲＡＴＥ TOSCAST INPUT VALUE m/ ｓ LOW SPEED RATE ％ × ㎝ 2 × ２．６ ｇ /cm3 ㎝ ＝ ＝ × １００ ％ SLEEVE FILLING ＲＡＴＥ = ＳＨＯＴ WEIGHT Ｔ IP ＡＲＥＡ × ＤＲＹ ＳＨＯＴ STROKE× ALUMINUM ＳＰＥ ＣＩＦＬＣ ＧＲＡＶＩＴＹ ｇ × １００％ ｇ ２．６ｇ / cm3 × × １０ ０ ＝ × ㎝ 2 Ｓ ＝ m/ ｓ HIGH SPEED RATE ＝ ０．０ １ × × ㎜ ＝ ㎜ Ｓ FILLING TIME = 0.01× （ WALL THICKNESS× WALL THICKNESS ） Ｐ Ａ Ｒ Ｔ WEIGHT （ PRODUCT + OVERFLOW WEIGH ） 2. HIGH SPEED = ＴＩＰ ＡＲＥＡ ×FILL TIME× ALUMINUM ＳＰＥＣＩＦＬ Ｃ ＧＲＡＶＩＴＹ
Ｐ－ 21 ＋ １０ ㎜ ＝ × ２．６ｇ /cm3 ㎝ 2 ＝ ㎜ HIGH SPEED ＬＥＮＧ ＴＨ TOSCAST INPUT VALUE ＝０．０１ × × ㎜ × １００ ０＝ ㎜ 4. CASTING PRESSURE ＵＰ TIME = 0.01× （ WALL THICKNESS × WALL THICKNESS ） ms CASTING TIME ㎝ 2 ㎝ 2 × ＝ m/ ｓ m/ ｓ GATE SPEED CHECK GATE SPEED = ＴＩＰＡＲ ＥＡ GATE ＡＲＥ Ａ ×HIGH SPEED RATE 3. HIGH SPEED ＬＥＮＧＴ Ｈ = Ｐ Ａ Ｒ Ｔ WEIGHT （ PRODUCT + OVERFLOW WEIGH ） + 10mm ＴＩＰ ＡＲＥＡ ×FILL TIME× ALUMINUM ＳＰＥＣＩＦＬ Ｃ ＧＲＡＶＩＴＹ
Ｐ－ 22 ＝ × ０．９ ＝ ㎏ / ㎝ 2 ㎝ 2 × ㎝ 2 ×ACCUMULATOR PRESSURE×0.9 5. CASTING PRESSURE ＝ ＴＩＰ Ａ ＲＥＡ INTENSIFY CYLINDER ＡＲ ＥＡ ㎏ / ㎝ 2 CASTING PRESSURE ㎜ FORWARD LIMIT POSITION 6. INJECTION FORWARD LIMIT = DRY INJECTION STROKE + 10mm ㎏ / ㎝ 2 ㎝ 2 ＴＯ Ｎ MOLD CLOSE 1. IS INJECTION FORCE LESS THAN MOLD CLOSE FORCE? CASTING PRESSURE× ＣＡＳＴ AREA = INJECTION FORCE × ＝ ％ ＋ １０ ％ ％ MOLD CLOSE FORCE LOAD SETTING MOLD CLOSE FORCE LOAD ＴＯＮ × １００ ＝ ＴＯ Ｎ INJECTION FORCE MACHINE TONNAGE MOLD CLOSE FORCE > INJECTION FORCE MOVABLE MOLD FIXED MOLD INJECTION FORCE MOLD CLOSE FORCE
MOLD LIMIT CASTING PRESSURE CHECK HIGH SPEED RARE BY MACHINE CAPACITY (LIMIT SPEED OF MOLD) ＝ ㎏ / ㎝ 2 m/ ｓ ＝ ５ ５ ０ × × × × ㎝ 2 ㎝ 2 ㎝ 2 × ㎝ 2 ㎝ 2 × ㎝ 2 LIMIT SPEED OF MOLD (GATE ＡＲＥＡ ) 2 ×INJECTION CYLINDER ＡＲＥＡ ×ACCUMULATOR PRESSURE MOLD CLOSE FORCE ＴＯＮ × １００ ０＝ ㎝ 2 ㎏ / ㎝ ＣＡＳＴＡ ＲＥＡ ＝ ( ＴＩＰ ＡＲ ＥＡ ) 3 MOLD LIMIT CASTING PRESSURE ㎏ / ㎝ Ｐ－ 23
２０ ０ （１２ ０） １２０ （１３５） （７０） １ ０ ６ ６ ４ ０ １５ POURING 1. SELECT ASSEMBLED LADLE TYPE FORM SELECT WINDOW. HOW DID IT GO? ダ営技 ０４．０ １． １５ 渡 辺 Ｐ－ 24
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