BASICS OF GATING

RUNNER DESIGN
 SYNAPSIS

1.TONNAGE CALCULATION

2.PQ2 FOR PRE RUNNER DESIGN

3.TIE BAR LOADING

4.CALCULATE GATE AREA AND GATE

LOCATION

5.CASTING PROFILE

6.CASTING ORIENTATIONS

7.RUNNER DESIGN

8.RUNNER SECTION REPORT

9.FLOW ANALYSIS
 PROCEDURE
FOR
RUNNER(GATING) DESIGN
 Steps for the Runner Design
 Catching tendency.

 Mention the critical areas.

 Selection of Ingate location.

 Select the Types of gate.

 Tonnage calculation.

 Pq2 diagram for plunger selection and discharge.

 Machine offset distance confirmation.

 Runner design for several orientations.

 Steps for the Runner Design
 Validate the Runner model by section report.

 Find the Tie bar loading in AMB.

 Do filling simulations in flow cast (Pressure and Velocity).

 Ensure the Metal gate velocity and Metal flow direction.

 Analyze that the Metal flows through the Critical profile or not.

 Finalize the Casting Orientation based upon above steps.

 To find out the last filling area of the casting.

 Mention the Overflow location to designer based upon the

last filling and air pocket formation.
 Steps for the Runner Design

 Do the full flow simulation(After receiving Reverse DBM) to find

out Hotspot location for providing the necessary cooling in that
area.

 Analyze the Shrinkage porosity and micro porosity in the flow

simulation and give suggestion to apply the squeeze pin or cooling
to eliminate or shift the porosity location.

 Documentation the Flow simulation results.

 TONNAGE & GATE AREA CALCULATIONS
PROJECTED AREA
WORKING FORMULAE
CASTING WEIGHT : 55O gms.
RUNNER WEIGHT : 220 gms.

TOTAL WEIGHT : 770 gms.

Weight 770 Note: Depth is not to be

(1) Volume = = = 285 CC considered
Density 2.7

(2) Tonnage = Projected area x Sp. Int. Pressure = 180 Cm2 x 800 Kg / Cm2
» = 144000kg
= 144 Tons
(3) Fill time (t) = 40 milliseconds (std)

(1)Discharge (Q) - m/sec = Volume / Fill time = 285 /40/1000 = 7125 CC/Sec
= 7.12 ltrs / Sec
•Q = A x v where v = 40 m/sec (std)

•Gate Area = A = Q/v = 7125 CC/Sec = 1.78Cm2

40x100 Cm/sec = 1.78 Cm2 x 100 = 178 mm2
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 CASTING QUALITY Vs FILL TIME

SURFACE FINISH QUALITY FACTORS –

• Fill time will be extremely important, and will affect all

factors in the design effort

SURFACE FINISH FILL TIME

AVERAGE MEDIUM TO HIGH

GOOD MEDIUM TO LOW

EXCELLENT LOWEST POSSIBLE

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 VARIABLE FACTORS - GATE

VARIABLE FACTORS ON GATE DESIGN

(1) Q = A x v - For Constant discharge

(1) Ø 40 Ø 50 --- “Q” Changes thro plunger diameter

Ø 40 Ø 50
(1) Fill Ratio =

(1) Fill time variations Q V/t t

“t” can vary with respect of Q i.e., Q1 Q2
t

(5) Cavity Pressure P1 ∞ Gate velocity

 GATE - LAND

GATE SOLDERING

THICKNESS STUDY & LAND

 Basic types of gate

EDGE GATE CENTRAL INJECTION GATE

RING GATE SPOON GATE GATE

FACE GATE

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TONNAGE CALCULATION
 1.TONNAGE CALCULATION

TOTAL
REQUIRED TONNAGE = PROJECTED * SPECIFIC INT * FOS
PRESSURE
AREA

= 197.57 * 800 * 1.2

= 189.66 Tons
 FILL RATIO

TOTAL SHOT SLEEVE LENGTH = 430 mm

FIXED DIE THICKNESS = 58.2 mm

PLUNGER PRE-ENKAGE = 20 mm

SPREADER PROJECTION = 35.23 mm

PLUNGER DIAMETER = 90 mm

FULL SHOT VOLUME = 1.144*10^6 mm³

20
STEP 1

TOTAL LENGTH = ( TOTAL SHOT SLEEVE LENGTH +

FIXED DIE THICKNESS +

PLUNGER PRE-ENKAGE -

SPREADER PROJECTION )

= 430 + 58.2 + 20 - 35.23

TOTAL LENGTH = 543.43 mm

STEP 2

SHOT SLEEVE VOLUME = (π/4) *(D²) * L

Where,
D – PLUNGER DIAMETER
L – TOTAL LENGTH

= (π/4) *(90²) * 543.43

SHOT SLEEVE VOLUME = 3457152.28 mm³

STEP 3

FULL SHOT VOLUME

FILL RATIO = * 100
SHOT SLEEVE VOLUME

1.144*10^6
= * 100
3.457*10^6

FILL RATIO = 33.09 %

 2.PQ2 DIAGRAM
Log p + 2logQ = C
 3.TIE BAR LOADING

CGS
X= 0.767mm
Y= 106.11mm
Z= -38.52mm
 DEVIATIONS FOR TIE BAR LOADING

X = 0.76mm
Y= 18.89mm
TIE BAR LOADING
 4.GATE AREA CALCULATION

CASTING WEIGHT 168.87 grms

Step 1
WEIGHT 168.87
VOLUME = =
DENSITY 2.7

VOLUME = 62.5 cc

Step 2

FILL TIME = 40 millisec (standard)

Step 3

CASTING
TONNAGE = * SPECIFIC INT
PROJECTED
PRESSURE
AREA

= 197.57 * 800 * 1.2

= 189.66 Tons

Step 4

VOLUME 62.5
DISCHARGE = =
FILL TIME (40/1000)

= 1562.5 cc/sec = 0.156 lits/sec

step5

VELOCITY = 40 m/sec (standard)

step6

Q 1562.5
GATE AREA = =
V (40*100)

= 0.39 cm²

GATE AREA = 39 mm²

 GATE LOCATION

GATE SHEET FEEDING VIEW

 6.CASTING ORIENTATION VIEW

FRONT VIEW BACK VIEW

 7.RUNNER SECTION DETAILS

Runner area to be increase 1.5

R1 R2
times for each branches to
develop better flow and to
G1 G2
provide good pressure drop at
the gate entry
R1 R2
R1 = 240mm²
R3 R3 R2 = 240mm²
R3 = 552mm²

GATE LAND = 1.5 mm G1 = 168mm²/CAVITY

GATE THICKNESS = 2 mm G2 = 168mm²/CAVITY
REQ GATE AREA = 42.5mm² PLUNGER DIAMETER = 60mm
ACT GATE AREA = 168mm²
8.FLOW SIMULATION
ANALYSIS
 OVERVIEW

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 TYPES OF FLOW SIMULATION
1, PRESSURE SIMULATION

2,VELOCITY SIMULATION

3,TEMPERATURE SIMULATION

4,AIR ENTRAINMENT SIMULATION

5,SOLIDIFICATION SIMULATION

6,POROSITY SIMULATION

7,TRACER SIMULATION

8,SHOT SLEEVE SIMULATION

9,COOLING EFFECTIVENESS

10,THERMAL DIE CYCLING

 Flow-3D Boundary Conditions :

Alloy ADC12

Metal Temperature 6600 C

Die Temperature 1500 C

37
 Design Value For Reference:

Gate Velocity 40.00 m/sec

Specific Injection Pressure 800 bar

Plunger Velocity 1st 0.2 m/s

Plunger Velocity 2nd 2.8 m/s

Plunger Diameter 60 mm

38
 Fill Time Data
Gate Entry Time 0.2023 sec

Component End Time 0.2265

sec

Component Fill Time 0.0242

sec

39
 FLOW SIMULATION AT THE BEGINING

Simulation up to gate entry. 40

Simulation up to 60%
0f cavity fill time 41
Simulation up to 70%
0f cavity fill time 42
 Based upon this simulation we proceed for die
design process
Simulation complete 43
560°C
660°C

0 m\s
40m\s

44
Simulation up to gate entry. 45
Simulation up to 60%
of cavity fill time 46
Simulation up to 70%
of cavity fill time 47
Simulation completed 48
49
Simulation up to gate entry. 50
Simulation up to 60%
of cavity fill time 51
Simulation up to 70%
of cavity fill time 52
Simulation completed 53
54
55
56
57
Simulation completed 58
TRACER SIMULATION
SHOT SLEEVE SIMULATION
 SHOT SLEEVE SIMULATION
1 3

4
2
 ACADIA DIFFUSER PLATE SHOT SLEEVE SIMULATION

5 7

6
8
 COOLING EFFECTIVENESS

Without cooling With cooling

THERMAL DIE CYCLING