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A RUNNER-GATE DESIGN SYSTEM FOR DIE CASTING DIES

Chang-Ho Kim *, Taek Hwan Kwon**


* Dept. of Mechanical Engineering, Dong-Eui University, Kaya-Dong 24, Pusanjin-Ku, Pusan, Korea, 614-714
** Graduate School, Dept. of Mechanical Design Engineering, Pusan Nat'l University, #30 Jangjeon-Dong, Kumjeong-Ku,
Pusan, Korea, 609-735

Abstract
Various analytical FEM, FDM tools for flow process including die casting have presented, they are only giving information
to predetermined die design whether it is proper or not. Current shop floor practice uses the trial-and-error methods to
determine new die design.
This paper describes a research work of developing computer-aided die design system for die casting. Approach to the
CAD system has been written in circumstance Auto LISP with personal computer. This system has been developed to present
algorithms for automation of die design, especially runner-gate system using 3-D geometry. This system quantifies practical
knowledge and experiences in die design as formulating procedure. It is possible for engineers to make automatic and
efficient design of and it will result in reduction of required expenses and time. It is composed of selection of cast alloy,
product design, runner-gate design etc. In addition, specific rules and equations for the system have been presented. An
example is applied to cap-shaped cast using the proposed system.

Key words : Die casting, Die design system, Rule base, Runner, Gate

NOMENCLATURE

Qa volume of cavity to be filled, cm3


Vg main gate velocity, m/sec
tg filling time, sec
K heat capacity per unit volume, cal
q' the rate heat evolved per unit time during solidification, cal/sec
L latent heat during solidification, cal/g
Cp specific heat of molten metal, cal/g

Tm temperature of molten metal,
Ts solidus temperature,
Td die temperature,
density of alloy, g/cm3
S radiation area, cm2
X a half thickness of cast, cm
thermal conductivity of alloy, cal/cm
sec

1. INTRODUCTION

Die casting is one of the most economical casting processes for manufacturing precision shaped parts in mass
production. It is a precise casting method in which molten metal is injected at high pressure into a die cavity. As soon as the
molten metal has filled the cavity, it solidifies by fast cooling. Die-cast components are being used increasingly in the
automobile, aerospace, electronic and other industries because of their premium quality, low cost and low weight. Because of
high pressure and short cycle times involved, thin-wall sections are possible.
In die-design system of various forming processes, Shaffer developed progressive die design by computer (PDDC)
system and J.P. Kruth made efforts to develop an integrated CAD/CAM system for mould design and manufacture. J.C. Choi
developed a compact and practical CAD system for blanking or piercing of irregular shaped- sheet metal products and stator-
rotor parts.
In studies of die casting process, C.C Thai used runner-optimization design method and the abductive network in
modeling the die casting process according to the experimental data. W. Zhang researched the CAD/ CAE system that die
designer can determine the shape and dimension of runner-gating system under different casting condition. Generally
speaking, die designer still have to depend on engineers experiences and know-how due to lack of proper analytical ability
metal flow and velocity and heat transfer in die. Current shop floor practice uses the trial-and-error method to determine die
design, when new moulds are used. This method is costly and results in a lot of wasted casting. To solve this problem a study
was done on the runner and gate system to simulate the molten metal flow and to analyze the pressure and metal movement
during casting process. Although some finite element analysis software is capable of analyzing the melting process and flow
conditions of the products (workpiece) under various injection conditions, they are only giving some limited suggestions and
information to die design.
In this study, die design system for die casting process has been developed to present flow chart for automation of die
design, especially runner-gate system. In addition, specific rules and equations for runner-gate system have been presented to
avoid too many trials and errors with expensive equipment. It is possible for engineers to make an automatic and efficient die
design and it will result in reduction of expense and time.

2. STRUCTURE OF CASTING PRODUCT AND DIE

An example of cast product is seen in Fig.1. It is generally composed of cast cavity, gate, runner, biscuit, overflow and
to be formed out from die. Irrespective of the shape of the cast, the quality is always determined by the runner-gate system.
Generally, the system contains their arrangements and shapes to design properly. The effects of metal velocity and die
temperature on the metal flow distance and quality are discussed.
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