PRODUCTION OF CASTING

CastCalc

PRODUCTION OF CASTING · HPDC

Shot & Gating Studio

● ALL CHECKS PASS

Part numberPart nameCustomer

Input variables

Machine

Hyd. pressure 148 kgf/cm²Cylinder Ø Dn 115 mmDry shot Vd 4.5 m/sPenetration 230 mmStroke 415 mm

Plunger diameter, Dpmm

Casting

Casting wall thicknessmmCasting weight (per cavity)gWeight of overflow (per cavity)gWeight of runnergBiscuit thicknessmmNumber of cavitiesMaterialDensityg/cc

Die & gating

Fix side housingmmDiffuser projectionmmTarget gate velocitym/sMin. gate velocitym/sMax. gate velocitym/sRunner ratio (× gate area)×Targeted fill timesGate depthmm

Constants & assumptions

Empirical constant, ks/cmMetal temp entering die, Ti°CMin. flow temp, Tf°CDie surface temp, Td°CSolid fraction at end of fill, S%Conversion factor, Z°CCoefficient of discharge, Cd

Machine tonnage selection

Projected area of casting (per cavity)cm²Overflow area ratio× castRunner area ratio× castSpecific injection pressurekg/cm²Machine efficiency%Side core areacm²Wedge lock angle°

Output parameters

Process checks

Static metal pressure Pm782.92 kgf/cm²> 300 kgf/cm²

Targeted fill time0.028 s< 0.045 s

Fill ratio Fi38 %25 – 45 %

Plunger velocity v22.58 m/s< 0.8·Vd = 3.6 m/s

Gate velocity30 m/s25 – 40 m/s

Operating point inside machine lineinsideP,Q under MPL

Machine tonnage196.6 T≤ 250 T

PQ² diagram

The yellow operating point must sit under the blue machine power line, on the orange die line, and between the green (min) and red (max) gate-velocity pressure limits.

Shot weight & sleeve

Cavity volume (casting + overflow)142 cc

Weight of biscuit98.1 g

Shot weight681.3 g

Effective shot sleeve length365 mm

Yield46.2 %

Machine power line

Static metal pressure, Pm782.9 kgf/cm²

Max (dry shot) flow rate, Qm8,831 cc/s

Fill time & fill rate

Theoretical fill time0.0296 s

Theoretical fill rate4,792 cc/s

Targeted fill rate, Q5,071 cc/s

Metal pressure for target gate velocity

Metal pressure127.4 kgf/cm²

Accumulator pressure24.09 kgf/cm²

Gate parameters

Gate area (theoretical)159.7 mm²

Targeted gate area169 mm²

Gate width (at chosen depth)84.5 mm

Runner area (ratio × gate)253.5 mm²

Actual gate velocity30 m/s

Shot model

Fill ratio, Fi38 %

Critical slow shot velocity, Vss (V1)0.08 m/s

Start of fast shot distance, S1272.7 mm

Fast shot stroke length, S272.3 mm

Plunger velocity, v22.58 m/s

Vent area0.254 cm²

Machine tonnage

Projected area — casting90.8 cm²

Projected area — overflows36.3 cm²

Projected area — runners54.5 cm²

Projected area — biscuit19.6 cm²

Total projected area204.8 cm²

Total force required (locking force)196.6 TON

Required intensification pressure151.2 kg/cm²

Cast pressure (kg/cm²)	Intensification pressure (kg/cm²)
500	94.5
600	113.4
700	132.3
800	151.2
900	170.1
1000	189
1200	226.8

Parameter sheet (for shop floor)

#	Parameter	Units	Design value
1	Machine	-	250 TOSHIBA CHINA
2	Hydraulic pressure	kgf/cm²	148
3	Plunger diameter (Dp)	mm	50
4	Casting wall thickness	mm	2.5
5	Casting weight	g	157.47
6	Weight of overflow	g	20
7	Weight of runner	g	228.2
8	Weight of biscuit	g	98.1
9	Biscuit thickness	mm	20
10	Alloy	-	AlSi132
11	Shot weight	g	681.3
12	Effective shot sleeve length	mm	365
13	Metal temperature at holding furnace	°C	660
14	Accumulator pressure	kgf/cm²	24.09
15	Targeted gate area	mm²	169
16	Start of fast shot distance (S1)	mm	272.7
17	Fast shot stroke length (S2)	mm	72.3
18	Plunger velocity (v2)	m/s	2.58
19	Specific injection pressure	kg/cm²	800
20	Total projected area	cm²	204.8
21	Total force required	TON	196.6
22	Actual gate velocity	m/s	30
23	Vent area	cm²	0.254
24	Required intensification pressure	kg/cm²	151.2

Same layout as the workbook's "Parameter Sheet". Actual machine-trial values (solidification time, spray time, water flow rates) are recorded at the press.

Design & developed by Mudassir Shaik (skmudassir.in)