Die Casting Process Design Defined:

The die casting process relies on controlling a number of critical variables.

Specifically, they are:

• Alloy temperature during injection
• Cavity fill time, expressed in milliseconds
• Die temperature measured in the die cavity area
• Gate velocity, expressed in feet, meters or inches per second
• In the cold chamber process, critical slow shot velocity expressed in meters or inches per second
• Transition point from slow to fast shot speed.
• Cavity pressure during intensification expressed in P.S.I. or Kg/cm
• Hydraulic intensification pressure, expressed in P.S.I. or Kg/cm
• Rise time to intensification expressed in milliseconds
• Controlling the locking force on the die, expressed in U.S. or metric tons
• Limiting the force on the die faces and platens expressed in tons/square inch or tons/square centimeter

It has been common practice in the die casting industry to "wing it" and "find" a usable process by tedious trial and error. This lead to the term of "black art die casting". However computerized process monitoring has enabled us to easily measure all the above. In addition the methodology and software is readily available to predict or design the optimum process values for all the above parameters. Providing us with "Process design".

Dr. Die Cast software was created to fill the need for a quick, accurate method to solve for the best process. It is spreadsheet based, easy to use and proven in the factory making millions of successful castings. Our users are loyal, just ask them. To talk to a happy customer, e-mail RMcClintic@DrDieCast.com for references.

 

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Revised: October 2016

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