Runner and gate design.

The Important Features

Introduction;

The following is a brief summary of the important factors to consider when designing runner
and gating systems for Zinc and Aluminium pressure die casting dies.

In the past runner systems were designed using empirical knowledge and developed using trial
and error methods which involved excessive time and often multiple die trials. Today,
computer programmes exist which eliminate these problems and are able to give good results
immediately but, many of the most basic design issues are often neglected during the design
stage particularly if the die is designed by the tool maker without consultation to the die casting
technicians.

These brief notes are intended as guidelines for use during training and as an aide memoiré for
die design technicians and designers. They are not intended to cover all aspects of die design
practice.

____________________________

Objective:

The runner and gate system should achieve the following in basic terms:

• Produce a casting of the specified quality; in terms of finish, size and tolerance,
casting integrity, mechanical properties, cycle time and consistency.
•

• Achieve first time success; to avoid wasted time on successive machine trials, delays
in delivery of samples, loss of customer confidence and excessive die development
costs.
•

• Provide optimum yield; increases efficiency by optimising the casting to runner yield
ratio, improve metal losses due to lower re-melt weights, reduces cycle times due to
improved thermal efficiency.

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 Runner and gate design.

Influencing factors.

Designing a runner system:

Selection of the machine should be based on several factors but not just shot weight and platen
area. Most machines are supplied with a PQ2 diagram or one exists from measurements taken
on other similar machines. Runner designs should be based on machine performance with a
given plunger or shot sleeve diameter, known hydraulic pressure and in the case of hot
chamber die casting the nozzle size. Both projected area and lock tonnage should also be
considered if the proposed runner plus casting is liable to approach the machine limits.

Casting geometry:
The cavity should be positioned to promote the best cavity fill conditions while accommodating
essential die features such as core slides, cooling channels, sensitive casting features, number
of cavities and robotic removal constraints. Other process criteria such as second operation
locations, clipping orientation, break off de-gating and finishing requirements should also be
considered before the cavity position is decided.

Uniform flow path:

The runner should establish a uniform metal flow rate deigned to promote the best hydraulic
system, stable metal pressure and velocity. Most computer design programmes will control
these features but the designer will still have institute a flow path allows these features
conform to the desired parameters.

Cavity fill conditions:

Modern pressure die casting machines often have more power at the shot end than is required
to achieve the optimum fill conditions. Consequently, the performance offers many gate area
options capable of achieving the desired fill conditions – the designer must select the most
suitable based on the casting specification and process limitations.

Cavity fill pattern:

Is invariably decided by the casting geometry and gate position but the metal pressure and
velocity will have influence but to a lesser extent. The influence of casting features such as
vertical surfaces and ribs, variable section thicknesses, isolated bosses and cores must be
considered when the gate position is decided.

Venting and overflow wells:

Should all be considered at the design stage – are directly related to the cavity fill conditions
and casting geometry but also the introduction of over flow wells or pockets may have
significant cost implications.

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.
 Runner and gate design.

Machine Performance.

Effects of change.

Injection pressure: Reduce or increase.

• Increased injection pressure – will increase flash, raise galvanising and die erosion.
Optimum pressure levels will improve casting integrity, maintain speed and velocity and
improve cavity fill conditions.
Reduced injection pressure – reduces flow rates, and static metal pressure on hot
chamber pressure die casting machines.
• Plunger diameter – on hot chamber die casting machines smaller plungers give the
best casting results with higher injection pressure and faster delivery. On aluminium
cold chamber machines plunger diameter choice is less critical but effect is far more
significant in performance terms - increasing delivery velocity and reducing cavity fill
times.
• Plunger speeds - high terminal velocities can produce pressure spikes on older die
casting machines leading flash and die wear. High gate speeds result in expensive die
maintenance due to die erosion and galvanising.
• Runner Area/volume - die designer should create a uniform flow through the runner
by establishing nozzle area (hot chamber) as the largest section in the runner.
Progressively reducing the cross sectional area of the runner at each section to the gate
which should be the smallest area in the runner system. Similarly, on cold chamber dies
the sprue post runner should be the largest runner section down to the gate which
should be smallest section of the runner.

Flow rate histogram.

Nozzle area

Gate
Area

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 Runner and gate design.

Runner features

‘Y’ Junction not ‘T’

‘Y’ Junction
Reduces area and increases pressure progressively.

‘T’ Junction
Increases volume at the junction creating low pressure area at the centre of the gate.

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.
 Runner and gate design.

Runner features

Taper tangential runner - with shock absorber – showing section change A to B to

maintain pressure and velocity

Smaller diagram – illustrates poor runner design small access radius,

increased runner volume at the radius, small runner cross section at the end of the taper,
and no shock absorber.

THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.
 Runner and gate design.

Runner features

Drawings – Show section through sprue posts on Aluminium (top) and Zinc (bottom)
dies.
This area most commonly interpreted incorrectly by toolmakers.
Note; The reduction from the sprue faces to die face and the size and blend radius
which are struck from the same centre to ensure even transition from sprue to die.

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 Runner and gate design.

Runner features

Runner sections: Need to be adjusted by differing percentages to

accommodate larger angular direction changes

30% reduction in runner 10% reduction in runner

area - down stream of metal area- down stream of metal
flow – for 900 bend. flow – for a 200 bend.

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 Runner and gate design.

Gate Areas

Gate Areas:
Optimum for Zinc alloy pressure die-casting:
• Gate speed / velocity – 35 – 45 metres per second.
• Cavity fill time – plated or powder coated finish – 20 milli seconds or functional
parts – 40 milli seconds.
• Gate depth – 0.15 – 0.5 mm.
Optimum for Aluminium alloy pressure die casting:
• Gate speed / velocity – 25 to 35 metres per second.
To avoid die erosion and control cavity fill characteristics.
• Cavity fill time – end of fill temperature is most important on large castings as
solidification can occur prior to cavity filling.
• Depth 1.25 – 3 mm (1.5 mm minimum for machine intensification to be effective).

Fill Pattern:

Casting geometry: has the largest influence on cavity flow paths – high metal velocity
applied to vertical casting faces causes turbulence, galvanising and impedes metal. All of which
can result in expensive die repairs / maintenance. Section changes and cores change pressure
and direction and these effects need to be considered and understood when considering gate
position options.

Zones volumes and areas; It is possible to assess parts of the casting separately
and this may be advantageous if they are unlikely to be fed directly from the gate.
Using computer programmes allows each separate zone to be quantified in volume and
surface area terms. If treated as un-gated the fill time and end of fill temperature can
be determined as a comparison with the main body of the total casting.

Gating separate zones: It is possible also to examine separate zones of a given part
using separate gates for each zoned area. This will often improve fill characteristics
and reduce the risks of defects. The uses of multiple gates are not a risk if designed
and implemented correctly.

Runner will direct metal flow: It must be stressed that the gates and runner both
influence flow direction. Once the runner is established metal under pressure will
enter the cavity in the same direction and flow angle. Varying injection speed and
metal pressure may alter this angle slightly but this is only a fine tuning method.

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 Runner and gate design.

Fill pattern.

Influence of casting geometry:

Certain casting shapes are best filled in a predetermined way, if the tooling
configuration allows. Deep boxes, where the depth is 50% of the edge length or more
can be fed using the gate runner configuration shown below – alternatively the box
can be turned through 450 to shorten the runner distance and improve shot yield.

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 Runner and gate design.

Fill pattern.

Ovals or round castings: Try to fill the centre first using either a runner
configuration below or a more traditional fan feed. With fan feeds it is essential to get
the ratio of the approach angle and width of gate correct.

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 Runner and gate design.

Fill pattern.

Annular rings: Can be fed using the runner configuration indicated below. A small
over flow well should positioned in the centre hole to take away any lubrication fume
and another well placed on the out side perimeter adjacent to the last segment of the
part to fill.

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 Runner and gate design.

Fill pattern.

Rectangular Plates: Fill across shortest distance whenever possible – to cut down
flow distance and increase end of fill temperature. It is therefore advisable to avoid
the option shown in the upper diagram if possible.

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 Runner and gate design.

Fill pattern.

Diagram shows: runner developed over a period of time – to resolve problems of

porosity and poor fill results. The darker blue area is approximately 6 mm deep, with
a gate depth of between 1.8 and 2.5 mm. Casting weighed approximately 5 Kg and
with a flow distance of 510 mm.

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 Runner and gate design.

Fill pattern.

Diagram shows: Revised runner with balance fill and uniform gate thickness of 2
mm. The runner shows reduced shot weight by over 1 Kg and a subsequent increase
in yield of 18% and a reduction in projected area of some 22% allowing improved shot
speed and increased in injection pressure.

THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,
 Runner and gate design.

Vents and Overflow wells.

Points to remember:

• Over flow wells can be used to change or divert metal flow, but rarely remove
gas and fume as the cavity is normally sealed before they become active.

• Similarly vents can only work for less than half of the cavity fill time as they are
sealed off before the final fill is achieved.

• Use only one connection per over flow to avoid back feeding through the
overflow and reintroducing gas and cold metal.

• Always vent over flow wells – as a precaution.

• Over flow wells are a poor method of die heating both inefficient and wasteful.
Many are lost before re-melting and therefore increase metal losses.

See reference material from ILZRO, IZA.

JWT
Sept 05 – issue 5