International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 08 Issue: 08 | Aug 2021 www.irjet.net p-ISSN: 2395-0072

Methodology of Die Design for HPDC

Bharat Sharma

Director of steady die casting solutions, 3/154, Arawali Vihar, Bhiwadi, India.
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Abstract - HPDC die design is a very easy game, yes you can
cast your casting as you desire. This can only happened when
you can design casting feeding system scientifically, with the
help of fluid mechanics principle, you should understand the
thermal balancing of metal flow system, you should
understand flow path of solidification. Your expertise require
to maintain volume to surface area ratio in decreasing order
from diffuser to casting filling end point. In this paper we will
discuss machine tonnage, plunger size selection, gate area
calculation and it’s distribution, filling time calculation, biscuit
thickness validation, air vent area, jet flow validation, runner
size calculation, HPDC machine parameter calculation like
plunger high speed, plunger slow speed calculation,
intensification pressure , fast shot length , gate velocity, first
phase length and intensification phase length.

Key Words: Die design, hpdc, gate area, runner design,

plunger high speed, machine tonnage, etc

1. INTRODUCTION

Welcome to Steady Die Casting Solutions, I got this

opprtunity from my valuable customer I don’t want to share
his name. Through this paper I just want to give some
understanding of calculated die design and hpdc machine
running parameter. Die designer this is for you , you should
design Hpdc machine parameter as you design your die your
are the only one who knows your child better. You design Part projected projected area: 22171.96 mm2
casting biscuit thickness also don’t let it be like it’s
production people job, no this is your job. Yes my dear die
designer this your job you should tell him this much of
biscuit thickness you have to maintain. So all the parameter I
have calculated step by step in this paper

1.1 Part Detail Available

Part weight: 1431 gm

Core one projected area; 1256.63 mm2

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
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= 335.08 * .30
= 100.52 cm2

Total projected area = ( Total part projection area + Runner

projection area )
= 335.60 + 100.52
= 435.60 cm2

Machine Tonnage = Total projection area * casting pressure

= 435.60 * 800
=348480 kg
= 348.48 Ton ( Clamping force )
= 348.48 * 1.2
= 418.17 Ton ( Opening force )

Note : - As information available customer using 1100 ton

machine, due to die mold design.

2. Distributor length = 640 mm

Core two projected area; 21093.17 mm2

3. Shot weight = ( Cavity weight + Runner

weight + Biscuit weight )

= ( 1431 + 1431 * .3 + Biscuit weight )

1.2 Calculation
= 1431 + 429.3 + (( Pie * d * d) / 4 * h )
Part projected area = 221.71 cm2
Overflow projected area @10% minimum and 15% = 1860.3 + ( Pie * d * d * h
maximum = 221.71*.15 = 33.25 cm2
)……………………………………………………………………
Slide or core projection area
…………( 1 )
= 12.56 * tan20 + 210.93 * tan 20
= 12.56 * .36 + 210.93 * .36 Where h is biscuit thickness.
= 4.52 + 75.6
= 80.12 cm2 Shot sleeve filling ratio = ( Shot volume ) / (
Shot sleeve volume )
Total part projected area = ( Part projected area ) + (
Overflow projected area ) + ( Core projected area )
= 221.71 + 33.25 + 80.12 Shot volume = Shot sleeve volume * filling
= 335.08 cm2 ratio
Runner projected area = Total part projected area * .3

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 08 Issue: 08 | Aug 2021 www.irjet.net p-ISSN: 2395-0072

Put shot volume value from eqn ( 1 ) As we know that part total volume divided
into two part
689 + (( Pie * d * d) / 4 * h ) = ( Pie * d * d) / 4
* distributor length * .40 ( @40% filling ratio Part 1 volume = 743 / 2.55 = 291.37 gm /
)………( 2 ) cm3

4. Cavity filling time

Cavity filling time = K * T * ( Ti - Tf + S * Z ) / (

Tf - Td )

Where,

K = Empirical constant = .034 Sec / mm

T = Casting minimum thickness = 5 mm

Ti = Temperature of molted metal as it enters

the die = 680 degree centigrade.

Tf = Minimum flow temperature = 630

Part 2 volume = 604 / 2.55 = 236.86 gm /cm3
degree centigrade.

Td = Temperature of die cavity surface = 180

degree centigrade.

S = Allowable percent solid fraction, it’s

depends upon casting minimum thickness for
5 mm = 30 %

Z = Unit conversion factor = 4.8

t = (.034 * 5 * ( 680 - 630 + ( 30 * 4.8 ) ) / (

630 - 180 )

= .07 sec
Ratio of part 1 volume to part 2 volume
5. Gate area
Part 1 volume / Part 2 volume = 291.37 /
Gate area = ( Weight after gate ) /( Filling 236.86 = 1.23
time ) * ( Density ) * ( Gate velocity )
Part 1 gate area / Part 2 gate area = 1.23
= 1645.65 / ( .07 * 2.55 * 4000 )
Part 1 gate area = 1.23 * part 2 gate
= 2.30 cm2 area………………………………………………………………
…( 3 )
= 230 mm2
Total gate area = part 1 gate area + part 2
gate area
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230 = 1.23 * part 2 gate area + part 2 gate So,

area = part 2 gate area * ( 1.23 + 1 )
G1 = w, * t, = 126.86 mm2
Part 2 gate area = 230 /2.23 = 103.13 mm2
w1 = 126.86 / 2 = 63.43 mm
Part 1 gate area from equation …….( 3 )
G2 = w2 * t2 = 103.13 mm2
Part 1 gate area = 1.23 * 103.13 = 126.86
w2 = 103.13 / 2 = 51.56 mm
mm2
Where,
Note: We select gate thickness2 mm for
atomize flow. w1 and w2 are gate 1 and gate 2 width
respectively.
6. Check for atomize flow :-
With the help of given data we know that G1
Vg^1.71 * Tg * p >= 400
fill 60% of part and G2 fill 40 % of part.so,
Where, runner volume divided as ; -

Vg = gate velocity ( Inch / Sec ) For G1 = Runner vol. = 159000 * .60 = 95400
mm3
Tg = Gate thickness ( Inch )
For G2, Runner vol. = 159000 * .40 = 63600
P = density of metal ( lb / inch^2 )
mm3
J = The atomization factor
We also know that total runner projected
( 1574.8 )^1.71 * .078 * .092 = 2104 > 400 area = 10000 mm2

So, 2 mm gate thickness will give us atomize For G1 projection area = 10000 * .6 0= 6000
flow, which is great. mm2

Table -1: Sample Table format For G2 projection area = 10000 *.40 = 4000
7. Runner design mm2

We already calculated runner weight without Runner length for G1 = w1 * L1 = 6000 mm2
biscuit = 429.3 grm
L1 = 6000 / 63.43 = 94.59 mm
Runner vol. = 429.3 / 2.7 = 159 cm3 = 159000
mm3 Runner length for G2 = w2 * L2 = 4000 mm2

We have to select two runner for two gates. L2 = 4000 / 51.56 = 77.57 mm

Gate -1 = 126.86 mm2 = G1 Note; Both runner distance from diffuser

should be equal as shorter one.
Gate -2 = 103.13 mm2 = G2
So both runner length = 77.57 mm
As we select gate thickness 2mm, which is
suitable for atomize flow. Add “ Y “ section = 94.59 - 77.57 = 17 mm

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 08 Issue: 08 | Aug 2021 www.irjet.net p-ISSN: 2395-0072

63.43 mm

19.5mm 19.5mm
19.5mm 19.5mm

78 mm

From above figure :-

T( AA ) = 19.5 * tan20 = 6.63 mm

W ( AA ) = 63.43 * tan40 = 53.22 mm
T ( BB ) = 39 * tan20 = 13.26 mm
W ( BB ) = 53.22 * .97 = 51.62 mm
T ( CC ) = 58.5 * tan20 = 19.89 mm
W ( CC ) = 51.62 *.97 = 50.07 mm
T ( DD ) = 78 * tan20 = 26.52 mm
W ( DD ) = 50.07 * .97 = 48.57 mm
Where,
Where,
T ( AA ), T ( BB ), T ( CC ), and T ( DD ) are
W ( AA ), W ( BB ), W ( CC ) and W ( DD ) are
runner thickness at AA , BB, CC, and DD cross
runner width at AA, BB, CC and DD cross
section.
section area.
Important Note; Same you can calculate for
Runner width calculation for G2
G2

Runner width calculation for G1 51.56 mm

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 08 Issue: 08 | Aug 2021 www.irjet.net p-ISSN: 2395-0072

W ( A’A’ ) = 51.56 * tan40 = 43.26 mm 1. Biscuit Thickness = T ( FF ) * 1.25 = 40

mm
W ( B’B’) = 43.26 * .97 = 41.96 mm
Now from equation …..( 1 )
W ( C’C’ ) = 41.96 * .97 = 40.70 mm
Shot volume = 689 + ( 3.14 * d * d * 4 ) / 4
W ( D’D’ ) = 40.70 * .97 = 39.48 mm
= 689 + 3.14 * d *d
Where, …………………………………………………………………….(
W ( A’A’), W ( B’B’ ), W ( C’C’ ) and W ( D’D’ ) 4)
are runner width at A’A’, B’B’, C’C’ and D’D’
cross section area.
Put shot volume value in equation …( 2 )
Calculation for ‘ Y ‘ section
from equation…( 4 )

689 +( 3.14 * d * d ) / 4 * 4 = ( 3.14 *d * d * 64

* .40) / 4

( 3.14 * d * d ) / 4 * ( 25.6 - 4 ) = 689

d * d = 40.76 cm2

d = 6.3 cm

d = 63 mm ( Plunger Diameter )

W ( DD ) = 48.57 mm Selected plunger diameter = 70 mm

W ( D’D’ ) = 39.48 mm 9. High speed length

Than, High speed length = Volume ahead gate /

Plunger area
W ( EE ) = 1.4 * ( 48.57 + 39.48 ) = 88 mm
= ( ( Part weight +
W ( FF ) = 1.3 * W ( AA ) = 1.3 * 53.22 = 69 mm overflow weight ) / 2.55 ) / ( 3.14 * 3.5 * 3.5 )
Here W ( AA ) consider because maximum = ( ( 1431 + ( 1431 * .15 ) )
runner width at starting. / 2.55 ) / 38.46
And, = 645.09 / 38.46
T ( FF ) = ( G1 runner length + Y section = 167 mm
length ) * tan20
10. Intensification phase length
= ( 78 + 17 ) * .34 = 95 *.34 = 32 mm
Intensification phase length = ( Biscuit
8. Biscuit Thickness thickness + mechanical delay + electrical
delay )

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= 40 + 10 + 10 = 800 * .20

= 60 mm = 162.94 kg / cm2

11. First phase length 3. CONCLUSIONS

First phase length = ( Distributor length - ( Yes, we have design die parameter and hpdc machine
parameter as we desired casting quality. Yes, we need to take
High speed length + Intensification phase some minor correction during machine parameter
length ) validation. We have validated first phase length and speed
on machine for minimum air entrapment. We need to
= ( 640 - ( 167 + 60 ) = 413 mm increase intensification pressure from 160 kg/cm2 to 200
kg/cm2 for shrinkage free casting. We also use SDS process
validation tool to validate our process parameter and we
12. First phase speed
have done also pq2 analysis with the help of SDS pq2
analysis tool. we don’t need to any changes in die . We get
First phase speed = ( 22.8 * ( 100 - filling the desire quality in T0 trial.
ratio % ) / 100 ) * plunger diameter^1/2
We give satisfactory time during die design. We are more
= ( 22.8 * ( 100 - 40 ) / 100 ) * 70^1/2 focused towards feeding system during die design we ensure
there will be no breakup in between solidification due to
uneven volume to surface area ratio. We select filling time
= 13.68 * 8.3 = 114.45 mm / s for desired quality surface. I mean we analyze each and
every parameter which is responsible to get desired casting
v1 = .11 m / s quality, so that we can get reult without hit and trial.

13. Fast shot speed REFERENCES

Fast shot speed = ( Vol ( part + overflow ) / [1] F. C. Bennett : Transactions of the 4th SDCE Congress,
(1966), No.503
plunger area ) / ( filling time ) [2] W. Venus : Anschnittechnik für Druckguβ, Gieβerei-
Verlag G.m.b.H. (1975), 27
= 167 / .07 = 2385.71 mm /s [3] F. C. Bennett : Transactions of the 4th SDCE Congress,
(1966), No.503
v2 = 2.38 m/ s [4] W. Venus : Anschnittechnik für Druckguβ, Gieβerei-
Verlag G.m.b.H. (1975),
14. Gate velocity [5] D. F. Allsop and D. Kennedy: Pressure Diecasting, Part 2,
The Technology of the Casting and the Die, (Pergamon
Press, Ltd., New York, 1983) p. 6.
Gate velocity = ( plunger area * fast shot [6] T. Kanno: An Introduction to die casting technology,
speed ) / ( gate area ) (Nikkan-kogyo sinbunsha, Tokyo, 1997) pp. 227–247.
[7] K. Isobe, H. Noguchi and K. Kato: Tetsu-to-Hagane 77
(1991) 1680– 1687.
= ( 38.46 * 2.38 ) / 2.3
[8] S. Ono, K. Minami, T. Ochiai, T. Iwadate and S. Nakata:
Trans. Jpn. Soc. Mech. Eng. C 61 (1995) 2141–2146.
Vg = 39.79 m/s ( Perfect ) [9] A. Wang, P. F. Thomson and P. D. Hodgson: J. Mater.
Process. Technol. 60 (1996) 95–102.
15. Intensification pressure [10] S. Hamzah and U. Stahlberg: J. Mater. Process. Technol.
110 (2001) 324–333.
Intensification pressure = Casting pressure * [11] M. Motomura, H. Ono, T. Mishima, H. Miyaji and K. Tada:
Abstracts of the Meeting of the JILM 76 (1989) p. 195.
( Plunger diameter / Injection piston [12] M. Motomura, H. Ono, T. Mishima, H. Miyaji and S. Fukai:
diameter )^2 Abstracts of the Meeting of the JILM 78 (1990) p. 59.

= Cp * ( dp / Dip )^2

= 800 * ( 7 / 15.5 )^2

© 2021, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 300
 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 08 Issue: 08 | Aug 2021 www.irjet.net p-ISSN: 2395-0072

BIOGRAPHIES

Bharat Sharma
Director of Steady Die Casting
Solution.
’
st Author
Photo

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