Welcome to the Dr. Die Cast gating and process design program

To use, you will need the following information:

Recorded by : Date:

1. Die #

2. Machine # you expect to run in, or are setting up.

Note: The machine #'s should include the Division number, followed by the machine number, for example at Division #2, machine #3 would be 203, Division #4 machine # 16 would be 416, etc.

3. Total shot weight including runner and biscuit or sprue.

4. Weight of one casting, including overflows.

5. Number of cavities.

6. Minimum "significant" wall thickness.

7. Plunger tip diameter in inches or millimeters.

8. Available stroke in inches or millimeters.

9. Thickness of gate entry or "in gate".

a. If multiple entries are used, measure all of them. Total, then calculate average, then enter average.

b. If multiple cavities are used, enter thickness from one representative cavity. If die has a lot of wear, you may need to take several measurements, calculate average, and enter average.

10. Width of "in-gate". If multiple entries are used, total them for one cavity.

11. Maximum plunger diameter. This could be present or planned.

12. Desired gate velocity, usually 100 to 160 feet/ second. (1200 to 1920 inches/second).

(Velocities below 100 feet/second usually result in cold defects or metal laps). (Velocities above 160 feet/second in aluminum casting generally 1. accelerate gate erosion, and 2. generally result in solder in or adjacent to the gate entry or cores).

Successful zinc jobs will generally operate at higher gate velocities such as 140 to 180 feet/second especially for decorative chrome plated products.

13. Desired "in-gate" thickness.

a. A wide thin gate trims easier.

b. "In-gate" thickness should not exceed 1/3 of adjacent wall thickness.

c. Under size "in-gate" can cause problems outlined above in item #12.

14. Desired "in-gate" width.

a. Use gate splitters to avoid soldering on cores, blades, or metal savers.

b. See note 13.c. above

15. Projected area, (width X length + area in sq. in.). Think of it as the area of

the shadow cast by the casting.

a. Be sure to include area of sprue, runner, and over-flows.

Notes:

1. Maximum hydraulic pressures given will squeeze metal at maximum rated tonnage.

2. Required velocities will frequently exceed the machine capability. When this occurs, you may elect to install a larger cold chamber of gooseneck, or eliminate one or more cavities.

Machine information required follows. (For complete information see Machine capabilities information page.)

1. Rated locking tonnage (tons)

2. Maximum "dry" fast shot velocity , Inches/second (I.P.S.) or (meters/second) M/S.

3. Maximum intensifier pressure, pounds / square inch (P.S.I.) or KG

4. Shot cylinder bore diameter, inches or millimeters.

5. Machine mfg. with reference number. (i.e. B&T #3)

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