DC SCHOOL TEXT

BOOK
CASTING
TECHNOLOGY

CASTING

THEORY

TOSHIBA MACHINE Co., Ltd.

DIE CAST MACHINE ENGINEERING DIV.

 PREFACE
Die cast boast a high productivity besides the products have excellent property of dimension accuracy, thin wall and
lightweight, casting surface etc. Therefore die castings have an important part to play in supplying light metal materials
mainly in automobile industries.
To produce die cast products, die cast technology is required: that mold, casting, materials, and melting etc put together.
Especially, the issues of alloy solidification/cooling that are applied to casting generally and physical principle of heat
transfer to mold shall be got in die cast technology basically. As die casting method, molten metal is filled in mold cavity
with high-speed and high-pressure by plunger that moves by liquid pressure cylinder. This is large difference with other
casting method mechanically. In face of this mechanical relations as casting theory, it is able to explain hydraulically.
Selection of mechanical requirement (filling requirement) to fill injected molten metal to mold cavity in every corner and
the cross section of sprue that is decided by the mechanical requirement etc are the theoretical idea of casting. Die
cast products has various economical advantages, and at the same time, there are quite a lot of problems as material
such as gas hole, shrinkage porosity, shortage of actual strength by oxide film or broken solidified piece etc.
The recent required quality for die cast products grow increasingly sever. Use vacuum casting method or partial
pressurizing casting method in combination with die casting method to this requirements, and also specific casting
method die cast machine is developed to ensure high quality aluminium castings.
This article is designed to achieve high quality and low cost with full of machine property, and define how to decide
injection condition common to TOSHIBA die cast machines or how to decide gate system for mold design etc. It
appreciates to be a help for daily operation.
Conversion of Unit
This article is included International System of Units (SI Units) and Non-SI Units. Normally below is applied but below
right side is applied for non-SI units machine.
Type of Value

SI Unit

Pressure

MPa

(Example)

10

Side of Power

kN

(Example)

3500

Normal
Conversion
MPa 10.2
10 10.2 = 102
kN 0.102
3500 0.102

Nom-SI Unit

Conversion for This

kgf/cm2 kg/cm2

Article

MPa10

102

1010 100kgf/cm2

tonf ton

kN0.1

357

35000.1 350tonf

1. Definition of Die Cast

This is a mass-production casting method that produce castings with high property and smooth skin by pressing
molten metal into accuracy mold. It also means the casting products created by this method.

2. Operation of Full Automatic Cycle (Die Cast Machine)

Mold Release Spray Mold Close Pouring Injection Product Cooling
Mold Open Ejection Take Out Plunger Lubrication

3. Die cast method is one of casting method

This is a method that change air in mold cavity and molten metal with high speed before molten alloy
solidified, and harden with high pressure.
Mold Data

Die Cast

Mold

Casting Machine

Product Shape

Material

Casting Condition

Alloy Property

Gate System

Molten Metal Treatment

Melting

Chip Diameter:

70mm

Wall Thickness:

2.0mm

Product Weight:

430g

Project Area:

430cm2

Material:

ADC12

Molten Metal Temp: 680C

(hard desk drive )

4. Die Castings

Good die castings doesnt have porosities, have clean appearance and high in
dimension accuracy.
Casting Condition

Casting C/T 28sec

Low Speed Rate

High Speed Rate

High Speed Range

m/s

m/s

mm

0.20
65

3.2

67

High Speed
Acceleration
ms

Low Speed Rate

Low Speed Rate

M/s

ms

Casting
Pressure
MPa

1.5

30

5. Injection Process of Die Cast

Low
Speed

High
Speed

Intensif
y

Bubble

Low Speed
Carry molten metal that poured
in sleeve by ladle to gate.
At this time, dont make wave
on molten metal surface, and
exhaust air inside sleeve from
air vent of mold to prevent
inclusion of air in molten metal.
However if it is too slow, the
molten metal will be solidified.
(Low Speed Rate)

High Speed
Form products.

Intensify
Press and solidify the product.

High speed start from where sleeve and

runner is 100% filled with molten metal.
The condition is that the air inside sleeve
and runner is completely exhausted.
(High Speed Change Position)
(High Speed Range)
Gate becomes narrow normally so that flow
speed of molten metal is increased and get
into details as mist. It makes smooth skin.
(High Speed Rate)
Air in product area will remain inside of
product.

Give a pressure before molten metal

solidify.
(Intensify Time)
It makes porosity smaller, and
increase adhesiveness to mold.
(Casting Pressure)

6. Determine the Casting Condition

Machine/Mold/Product/Data
Condition Data
1) Machine

DC350

A) Mold Clamp Power

350ton

B) ACC Pressure

Pa = 10MPa (100kg/cm2)

C) Diameter of Injection Cylinder

125mm As = 123cm2

D) Diameter of Intensify Cylinder

180mm Ab = 255cm2

E) Tip Diameter

70mm Ap = 38.5cm2

2) Mold
F) Weight

Wc = 900g

(Product + Over Flow + Runner + Biscuit)

G) Weight

Wf = 700g

(Product + Over Flow )

H) Wall Thickness

tm = 2.0mm
(Average of Thin Areas)

NOTE
Below is applied for conversion of text.
MPa 10

I) Gate Area

Ag = 1.3cm2

1010 = 100kgf/cm2

J) Area

A = 350cm2

kN 0.1

K) Stroke

L = 337mm

L) Aluminum specific gravity

r = 2.6g/cm3

35000.1 = 350tonf

 Low Speed Rate

Speed is too high.

Low Speed Rate

Carry poured molten metal with less air inclusion and temperature
decrease to near the gate.
Speed is
appropriate.

Tip

Tip

Time
Startup of low speed shall not
have start shock and shall be
smooth.

(1) Filling Ratio of Sleeve

(Adjust it with N11 valve.)

It is ratio of molten metal in sleeve at pouring.

Filling Ratio
=
of Sleeve

Weight
100%
Tip Area Stroke Molten Metal specific gravity

(2) Low Speed Rate

Tip

Increase the low speed ratio where is less air inclusion of sleeve.
Target of Low
Speed Rate

Tip Diameter

0.7
Low Speed Rate =
Sleeve Filling Ratio

Stroke
Target of Sleeve Filling Ratio 20 ~ 50%

 EX.
Tip Diameter: 70mm

Weight: 900g

Stroke : 337mm

Tip Area = (/4) 72 = 38.5cm2 Aluminum specific gravity : 2.6g/cm3

900
1) Sleeve Filling Ratio
=

2) Low Speed Rate =

100% = 27%
38.5 33.7 2.6

0.7

70

27

= 0.21m/s

Injection Low Speed

Forward
0.21m/s

High Speed Rate

Form product, decide molten metal flow, and diffuse porosities.
1) 2)

4)
Evaluate high speed rate by mold condition.
Check gate speed.
Decide filling time.
3)
Check mold limit speed by machine ability.

(1) Filling Time

Molten metal need to be filled before it solidify in cavity.

Filling Time = 0.01 Wall Thickness Wall Thickness
(2) High
Speed Rate by Mold Condition

Weight
High Speed Rate =
Tip Area Filling Time Molten Metal specific gravity

(3) High Speed Rate by Machine Ability (Mold Limit

Speed)

If it is kg/cm2, calculate
as the value is.

(Gate Area )2 Injection Cylinder Area (Accumulator Pressure MPa 10)

Mold Limit Speed = 550

(Tip Area )

(4) Check Gate Speed

Gate Speed =

Tip Area
Gate Area

(5) High Speed

Range
High Speed Range =

High Speed Rate

20 ~ 60m/s is standard.

( Weight )
Product + Over Flow Weight
Tip Area Molten Metal specific gravity

+ 1cm
8

EX.

(( Weight )

Wall Thickness: 2mm

Product + Over Flow Weight: 700g

Gate Area : 1.3cm2

Aluminum specific gravity : 2.6g/cm3

Tip Area : 38.5cm2

Accumulator Pressure: 10MPa (100kg/cm2)

(Coefficient)
1) Filling Time = 0.01 2 2 = 0.04sec
700
2) High Speed Rate =

38.5 .0.04 2.6

= 175cm/s = 1.75m/s
Bubble

Injection Cylinder Cross Section = (/4) 12.52 = 123cm2

(Coefficient)

3) Mold Limit Speed = 550

4) Gate Speed =

38.5

(1.3)2 123 100

(38.5)3

= 332cm/s = 3.32m/s

1.75 = 52m/s

1.3

700
5) High Speed Range =

38.5 2.6

+ 1cm = 8cm = 80mm

 Casting
Pressure
(1) Casting Pressure
Intensify Cylinder Area
Casting Pressure =
Tip Area

Accumulator

Pressure

Accumulator pressure is able to be

adjusted between 9.5MPa ~ 13.5MPa
(95kgf/m2 ~ 135kgf/m2) without
nitrogen gas release.
As TOSCAST, accumulator pressure is
adjusted automatically by inputting
casting pressure.

Accumulator Pressure Drop

(2) Intensify Time

(tm)

Intensify Time = 0.01 Wall Thickness (tm) Wall Thickness

(3) Injection Power

Injection Power = Casting Pressure Project Area

(4) Mold Limit Casting Pressure

Mold Clamp Power
Mold Limit Casting Pressure =
Project Area

EX.
Die Cast Machine: DC350CL

1) Casting Pressure =

Tip Diameter: 70

Accumulator Pressure: 10MPa (100kg/cm2 )

(/4) 182
(/4) 2

10 0.9 = 59.6MPa (596kg/cm2)

Wall Thickness: 2mm

2) Intensify Time = 0.01 2 2 = 0.04

= 40ms

3) Injection Power = 59.6 350 = 2086KN = 2086 0.1= 208.6T

350 100
4) Mold Limit Casting Pressure =

= 100MPa (1000kg/cm2 )
350

7. Casting Condition Setting

1) Injection Condition Setting
Low Speed Rate (N11)
Acceleration (N12)

Low Speed Rate (C2G11)

High Speed Rate (C2G12) High Speed Range

High Speed

Intensify Time (C2G15)

Casting Pressure (ACC Pressure)

2) High Speed Range

It is important for stable displacement process of air in mold and molten metal to fill cavity with molten
metal in high speed from certain position always.
Product acceptability depend on high speed range.
Basically, high speed range starts when molten metal reach to gate area. (Gate High Speed)

3) Adjustment of High Speed Acceleration

Strewing pattern of molten metal blowout from gate depend on adjustment of startup time that low speed
reach high speed range. It is adjusted with N12 valve.
It is adjustable randomly between 10 ~ 40msec for TOSHIBA die cast machine.

4) Intensify Time
As the phrase says strike while the iron is hot, it is important to intensify filled molten metal smoothly without
burr occurrence and keep the pressure.
It is not only compensate contraction in volume by solidification, but also compress included air maximally.
Besides it makes inside structure dens.
Intensify Time is from plunger stop to casting pressurizing start.
It is required to pressurize before molten aluminium start solidifying in cavity.

5) Casting Pressure
Casting Area Casting Pressure shall not over mold clamp power.
Mold Clamp Power Casting Area Casting Pressure = Mold Open Power
Guide of Casting Pressure

General Parts, Appearance Parts 60MPa (600kgf/cm2)

Pressure Parts, Intensify Parts 90MPa (900kgf/cm2)

6) Thickness of Biscuit
Guide of Biscuit Thickness
Biscuit Thickness (mm) = 0.25 Tip Diameter (mm)
If biscuit is thin, product gravity decrease because biscuit transmit pressure to molten metal in cavity
effectively.

8. Injection Wave

Intensify Time

Low
Speed

Speed/Casting Pressure/
Displacement

High
Speed

High Speed
Acceleration

Casting
Pressure
High
Speed

Low Speed
Acceleration

Intensify
Time

Low Speed

High
Speed
Range

Time

Thickness
of Biscuit
Initial Point

Stroke

9. Die Cast Machine Specification

Die Cast Machine

(Ton f)

Injection
Cylinder
Diameter

DC 135EL

90

DC 135H

125

Pressurization
ACC
Injection (Injection
Pressurization
Cylinder
Pressure
Power
Power)
Ratio
(MPa)
(kN)
Diameter

140

2.42

9.3

143

14.6
13.2 163

16.6
DEC150MT

90

125

1.93

15

184

19

DC 200EL

90

140

2.42

13.2

204

20.8

DC 250C

110

160

2.12

13.2

266

27.1

DC 250CL, JT

115

160

1.94

13.2

266

27.1

DC 350C

115

180

2.45

13.2

337

34.4

DC 350CL-T, J-MT

125

180

2.07

13.5

340

34.7

DC 500C

135

215

2.54

13.2

480

49

DC 500CL-S, T, HT

135

215

2.53

13.2

480

49

DC 650C, CL

145

230

2.52

13.2

550

56.1

DC 800C, CL

150

240

2.56

13.2

1Mpa = 10.2kgf/cm2

1kN = 0.102Ton f

599

1kgf/cm2 = 0.098Mpa

61.1
1Ton f =

9.8kN
Die Cast Machine Specification

Pressurization cylinder Area

Pressurization Ratio =
Injection Cylinder Area

Injection
Pressurization
Cylinder

Cylinder

TOSCAST INPUT VALUE

MOLD DATA
1. MEASURE THICKNESS OF FIXED MOLD AND
MOVABLEMOLD.
FIXED MOLD
MOVABLE
MOLD

2. MEASURE DRY INJECTION STROKE.
MOLD CLOSE
INJECTION

DRY INJECTION STROKE

READ INJECTION St VALUE ON

LOW SPEED

BODY OPERATION
SCREEN.

3. MEASURE DIAMETER.
CALCULATE CROSS SECTION.

MOLD
THICKNESS

CROSS SECTION

RADIUSRADIUS3.14
4=

DIAMETER

BISCUIT THICKNESS
4. MEASURE BISCUIT THICKNESS.

5. MEASURE PRODUCT WALL THICKNESS

PRODUCT WALL THICKNESS

 WEIGHT
6. WEIGH CASTING.

(Snap off casting from

gate.)

WEIGHT

7. MEASURE AHEAD OF GATE WEIGHT (PRODUCT AND OVERFLOW)

8. FIND PROJECT AREA OF CASTING.

AREA

2
9. MEASURE THICKNESS AND WIDTH OF
GATE.
GATE THICKNESS GATE WIDTH

GATE

1. INPUT MOLD NAME

This is the file name for saving.
2. SELECT MATERIAL FROM SELECT
WINDOW.
3. SELECT PREPARER FORM SELECT WINDOW.

Less than 8 letters.

INJECTION

TOSCAST INPUT VALUE

0.7

1. LOW SPEED =

DIAMETER

LOW SPEED
RATE

SLEEVE FILLING

m/

WEIGHT
SLEEVE FILLING =

IP STROKE ALUMINUM

/cm3
2

WEIGHT PRODUCT + OVERFLOW

WEIGH

2. HIGH SPEED =

FILL TIME ALUMINUM

HIGH SPEED RATE

/cm3

m/

FILLING TIME = 0.01 WALL THICKNESS WALL THICKNESS

GATE SPEED CHECK

GATE SPEED =

TOSCAST INPUT VALUE

HIGH SPEED RATE

GATE

m/

m/

2
WEIGHT PRODUCT + OVERFLOW
WEIGH

3. HIGH SPEED =

+ 10mm

FILL TIME ALUMINUM

HIGH SPEED

/cm3
2

4. CASTING PRESSURE TIME

= 0.01 WALL THICKNESS WALL THICKNESS

CASTING TIME
ms

INTENSIFY CYLINDER
5. CASTING PRESSURE

ACCUMULATOR
PRESSURE0.9

CASTING PRESSURE
/
2

FORWARD
POSITION

6. INJECTION FORWARD LIMIT = DRY INJECTION STROKE + 10mm

LIMIT

MOLD CLOSE
1. IS INJECTION FORCE LESS THAN MOLD CLOSE
FORCE?
CASTING PRESSURE

AREA

= INJECTION FORCE

/ 2 2

MOLD CLOSE FORCE > INJECTION FORCE

INJECTION
FORCE

MOLD CLOSE
FORCE

INJECTION FORCE

MOVABLE MOLD

FIXED MOLD

MOLD CLOSE
FORCE LOAD

MACHINE TONNAGE

SETTING MOLD
CLOSE FORCE LOAD

CHECK
HIGH SPEED RARE BY MACHINE CAPACITY (LIMIT SPEED OF
MOLD)

(GATE ) 2INJECTION CYLINDER ACCUMULATOR PRESSURE

/
2

LIMIT SPEED OF
MOLD

m/

( ) 3

MOLD LIMIT CASTING

PRESSURE

MOLD LIMIT CASTING

PRESSURE

MOLD CLOSE
FORCE

POURING
1. SELECT
WINDOW.

ASSEMBLED

LADLE

TYPE

FORM

SELECT

HOW
GO?

DID

IT