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A completed PQ2 diagram is shown bellow. Noticed that the gole is to predict where a
given die will operate when mounted on a machine with known performance. Also shown
is an operating window that developed to match the needs of the casting quality
requirements. The object is to make a design that will have the die and the machine
operate within the range of the developed operating window.
The first step in constructing the PQ2 diagram is to plot the machine power line. The
machine power line is a straight line with one end represented by the static metal
pressure and the other end represented by the maximum machine flow rate performance
(dry shot speed) as it is calculated with a know shot sleeve diameter.
The static metal pressure is calculated from hydraulic pressure on the cylinder that is
transferred to the metal cylinder that transferred to the metal through the plunger tip.
The hydraulic pressure used is the shot bottle pressure or the hydraulic pressure used
during the cavity-filling portion of the cycle, not the final intensified pressure. The
formula used is:
Pm = ph *(dh2/dp2)Eq. 1
Where:
in cm
Pm
Tailrod
ph
Plunger
Hydraulic cylinder piston
dh2 = dc2 dr 2
Where:
Pm
kg/cm2
Q (cm
/sec) Casting Excellence
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Excellence
The other end of the machine line is defined as the maximum machine performance.
It is calculated by multiplying the maximum dry shot speed(at the hydraulic shot
pressure used above) time the area of the plunger.
Qmax = vp * ( dp2/4)
Eq. 2
Where.
Pm
kg/cm2
Q (cm3/sec)
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Pm
kg/cm2
Q (cm3/sec)
Lower hydraulic pressure
Smaller plunger
Larger plunger
Pm
kg/cm2
Smaller plunger
Q (cm3/sec)
Larger plunger
T
Ti
Tf
Td
S
Z
Filing time can also be chosen by experience or general practice as shown in bellow
table.
Cavity volume is the amount of metal that flows through the gate during the cavity fill.
Volume are calculated by .
Where :
Vcav =
W =
Once the volume, and filling time is known the filling rate Q can be calculated by
Pm
kg/cm2
(cm3/sec)
3.Metal Pressure
To further identify a proper die cast process gate area and the velocities through gate
play a major role. The next step is identify the metal pressure required to move metal
through the gate at different values of gate velocity.
Bernoullis Equations
Gate velocity is the speed at which molten metal moves through an orifice or gate.
The load on the die casting machines injection system comes from the force
required to push the molten metal through the die orifice or gate and can be
represented as the discharge pressure that is developed when the metal is forced
through the gate at the desire gate velocity.
pm
Where :
p = metal pressure in kg/cm2
g = 981
cm/sec2
vg = gate velocity cm/sec
cd = coefficient of discharge
cd for Al - 0.5 to o.6
Zinc 0.6 to 0.7
Mg 0.6 to 0.7
Velocity of the gate is calculated by using
Vg = Q/ Ag ..
Eq. 7
m/sec
Pm
kg/cm2
(cm3/sec)
Pm
kg/cm2
Prepared by
Maheshwar N Morab