TECHNICAL INFORMATION

Guidelines for Plunger Tips,

Shot Sleeves and Shot End Components

CONTENTS
Page
2 Background
2-3 Eight Common Problems
4-7 Solutions for Shot Tip Designs

7-9 Shot Tip Clearances & Beryllium Copper Materials

9-12 Coolant Volume &Temperature Considerations
13-15 Design Versatility of Shot End Components
16-18 Compressive Stress Determinations
18-19 Tip & Rod Guiding Suggestions
20-21 Shot Sleeve Design Recommendations
22 Insights for Adequate Wall Stock

23 Adequate Tip Engagement &Summary

DESIGN GUIDELINES FOR SHOT TIPS, SLEEVES,
RODS, FOR BETTER COOLING AND LONGER LIFE
BACKGROUND

Many die casters in the aluminum and magnesium die casting process experience
problems associated with hot running and/or sticking shot tips. These problems
usually lead to defective casting production, and unacceptable or costly reduction in
tip life, as well as a decrease in part production due to down time. SEMCO has
produced our Be-1OSTM and Be-20 shot tips for almost three decades. During this
time, SEMCO has seen many process problems firsthand and assisted die casters in
addressing these situations. As a result, SEMCO has published these guidelines to
help alleviate shot tip related problems.

Die casters frequently suspect shot end alignment as the initial cause for premature
plunger tips wear. Although this may not be the case with newly purchased
machines, older machines that have been operating for longer periods of time could
incur more shot end alignment problems. These problems are a result of worn shot
end components and misalignment contributed by other mechanical factors. After
the machine is properly aligned, the shot end alignment is rarely the cause of shot
tip problems.

Another common problem SEMCO has observed is improper or poorly designed shot
delivery components including the shot sleeves, shot tips, and plunger rods. These
special components, if designed in-house, may fail to recognize some of the
important aspects of the design that are regularly addr:essed by specialized
manufacturers. Specialized manufacturers and/or OEM type shot end components
consistently produce higher quality, better performing materials.

Assuming that the shot end alignment is correct and there are quality shot delivery
components, a more detailed analysis of shot related problems is required.

The following are some of the more common problems related to shot end
components and how to address these issues.

COMMON PROBLEMS

This is a summary of some problem areas in the shot process. Subsequently, these
will be discussed in detail.

1) Shot Tips: Require proper design for adequate performance. The size of the
internal cooling chamber and the wall thickness of the tip is very important.
Inadequate cooling chambers will result in higher temperatures in the shot
cycle. Proper shot tip wall thickness is critical to maximize heat dissipation
and minimize the risk of wall failure.

Page 2
 2) Shot Tip Clearance: Very critical in the shot process. The Outside Diameter
(0.0.) of the shot tip in relation to the Inside Diameter (I.D.)of the shot
sleeve is very important. Proper working clearances change with the size
of the tip, temperatures, cooling effectiveness and the type of alloy being
cast.

3) Coolant Volume: The volume of the coolant must be adequate and

properly maintained as it passes through the shot tip and plunger rod, at a
known rate of flow.

4) Coolant Temperature: Coolant (usually water) temperature is very

important. Should the water temperature be too high upon entering the
shot rod, the plunger tip willrun hotter than normal even thought the water
volume may be adequate.

5) Shot end components: Improper setup and design of shot end

components also causes problems in the shot process. The improper use
of the shot stroke spacers may result in the use of several different length
sleeves. This necessitates different plunger rod lengths and produces
longer and more costly setup/changeover times.

6) Compression stresses: The shot end components must not exceed the
compression strengths of the materials used in the shot process. Excess
force causes compression}ailures and bent plunger rods. It is important to
maintain sufficient area between the shot tip shoulder and the plunger rod
shoulder to keep stresses below the yield point of the materials.

7) Shot Tip and Rod Guiding: Should be designed to allow greater than one
inch engagement in sleeve. Anything less than one inch promotes rapid tip
wear especially coupled with a universal joint type floating rod coupling.

8) Shot Sleeve Design: Should have proper wall thickness to facilitate heat
transfer and minimize bowing and pour hole washout. Thin wall sleeves
many times fail to account for the faster cycles of autoladles or the higher
temperatures created by modern die casting practices.

SOLUTIONS

The following addresses in more detail the problems outlined above. SEMGC
has worked with die casters for years and has found a number of suggestio'\S
and guidelines that have proved useful.

?:£..:.~-
 Figure 1

END WALL
"F"

SIDE "E"
WALL

The following tabular data has been reproduced from the SDCE standards.

Table 1

,Ref,
Ref End Wall Side Wall J.D. J.D. Cooling
Tip Dia Area.. "F" , "E" , Ref Area Area %
1.75
---2.40 ~.., ~~~ .50~ ~- .38
~~ - -F 1.00
- = .78 -
~-~- ~32.5%
-:--
_.., ~~3.14-~ ~ .5(11;
-~ ~ - .5e>,
*~ ~~~ 1JOO.i8'24.8%
-- - ~w'w ~ -~-~
.-- 2.25--- ~--3.97 ~ .50 .50 125 . 1.22 30.7%
- 2.50
--~
2.75
- -4.91- - -- .63".-.&3
5.94
~-
~~--
.63-
-
~
-
~6}-"
-
-~--~--1.25
1.50
-
".."...
--1.22 --
1.76
-24.8%
296%
~
-~
0.9~~- %7.97- -~~ .6~ =-.~~~§I~ -= 1JZS-_-4.10 _~:33~9o/iM'.
-- -
3.25 - 8.29-- -- ~~--~-~
.63 .63 ,. -- -
2.00 -- -- -~ ---
3.14 -37.8%
_~..?L - M9.62- -~ .72- -~~- 15. -~ sQO -p 3.J4_- §~.6~-
3.75 11.04 .75 .75 2.25 3.97 35.9%
-:--12.56--- -~ -- - --::--
2.50
- '-"'-", --~-'r7:'-
11.91
~~ -- -_.
,
~ ~- ~- *.- ~~ --' 39.0%;
- ----
4.25
~ --14.18
-- -- .88
.? -~ .88
- -- 2.50
~~ --- 4.91
~--- 34.6%
--~'
._-~-
4.50 -.15.89- ~ .88- -. --~
.88 - - -"
2.}5 ~'" =--.---
5.94 -- 37.30/0'
- --
4.75
-"~ -- - 17.71~~--- - .88
. -- 5.00 '". -,19.62~ ~
-~
1.00
--
--
.88
~- --
1.00
~~ -
3.00
--- ~
-3 zOO-.=
7.07
"'"""""'
-~
39.9%
~"'~Jf<~ -
-~ - ~36.00jo_.
7.(17'
5.25- - - ~-
21.63- -- 1.00
-- --- 1.00
- - --- 3.25
-- 8.29
~- 38.3%
-- ~-
"""'.~.
5.50- - --23.74
-- .-~-
1.00" ~
1.00 .- ,3..50
- -- - --
9.62 _.- ---
40.5%.
5.75
1--- - 25.95
-- 1.00 ~ 1.00 ~-- 3.75 -~ 11.04 42.5%
~---
; )6.00 28.26 1.13' M 1.~3 3~75 11.04 30.0%1

Page4
I. Shot Tip Designs

Proper tip design will allow adequate cooling and strength, and will facilitate
better performance. The former SDCE Standards Committee recommended
minimum dimensions for shot tip designs. The recommendations for end wall
and side wall thickness are to promote sufficient nominal cooling and
adequate stock to resist the sizeable pressures from the molten side and
columnar forces. See Figure 1 and Table 1. -

An examination of these figures reveals aspects concerning the strength and

cooling ability of the shot tip.

The END WALL "F" dimension, based upon a tip made from beryllium copper,
indicates the minimum rec°r"!'lmended thickness necessary to withstand
standard alloy pressures and to provide adequate heat dissipation. These are
recommendations only. The "F" wall thickness may vary to facilitate better
cooling or to allow for additional machining. These guidelines are a good
starting point in tip design. Die casters that re-machine or turn down shot tips
should maintain these recommended minimums to avoid risk of tip failure. The
risk of failure increases if there is evidence of heat checking.

The SIDE WALL "E" dimensions indicate the recommended thickness

necessary to withstand the columnar forces from most standard die cast
machines. The thickness of the wall must prevent failure but must also allow
for an adequate size cooling chamber. The balance between wall thickness
(tip strength) and cooling chamber becomes very important. If the cooling
chamber is not able to dissipate the heat, the tip will expand and it will wear
prematurely. This may cause the tip to screech or stick in the shot sleeve. The
end result is more wear on all shot end components (and thus higher costs)
and lower production as a result of down time.

A common practice among die casters does not keep those factors in mind.
Many die casters design shots tips with extra stock on the 0.0. based on the
theory that a large thick walled tip can be progressively turned down to much
smaller diameters to save money.

This improper design practice results in the larger diameter size running hot
and sticky from the outset. The die caster will never achieve the optimum
performance at this diameter because the tip is not adequately cooled. This
will also increase tip, sleeve, and rod wear and will affect the ability to produce
quality parts. The cooling chamber must remain proportional to the 0.0. of the
shot tip.

SEMCO Beryllium Copper Plunger Tips are provided with the proper
relationship between front face, side wall, and cooling chamber diameter CL~
length that insures optimum cooling design for both SEMCO Beryllium Copper
Be-10STMand Be-20 alloy plunger tips. This is a result of SEMCO's yaa."'S ::f

~:'
Figure 2 shows how the water flows through the plunger rod into the tip cooling
chamber to control the temperature.

Figure 2

MOLTEN
METAL
IN
HEAT
..
&
PRESSURE

COOLANT MUST DISSIPATE HEAT

RAPIDLY TO CONTROL TIP SIZE

experience in producing plunger tips from diameters of 1 1/2" to over 7" and
lengths of 3 1/2" to 1A..long.
Example: If a 3" tip was machined with a cooling chamber of a 2" tip (1" =
.78in~, the ratio would be .78/7.07 = 11%. If the percentage is increased to
25-30%, the tip willrun much cooler, causing less sticking and flashing.

Proportional cooling chambers are essential to achieve the optimum

performance from die casting components. Note the Cooling Area Ratio in
Table 1. The ratio is calculated by dividing the 1.0. by the 0.0. and expressed
as a percentage of the cooled versus heated area. Note that the
recommended ratios range from 25% to 40%. Ifa tip is running hot, examining
the ratio of the tip design may reveal the problem. A ratio less than 25% will
produce a hot tip.

Final Tip Design Comments

Some die casters prefer not to use shot tips that have been cast with the
cooling chamber to increase the side wall thickness. They prefer tips that are
drill tapped to insert a cooling chamber. This will limit the performance of the
tip but there are other benefits of cast cooling chambers. The radius in the
cooling chamber provides additional strength. The rough interior also
facilitates turbulence in the water flow that enhances the cooling property of
the tip.

Page 6
,

Tips may also be machined from round bar stock. Bar stock is not only more
costly but die casters must also maintain tooling and personnel to machine
the tips. Additionally, the cooling chamber is often not properly undercut
which inhibits the cooling property of the tip. Machining an appropriate radius
at the deepest part of the cooling chamber is difficult, but also essential to
deliver adequate water flow to the "F" wall of the tip.

SEMCO cast tips allow the designer to establish optimized cooling chambers
for each tip size or particular applications. The cast design also eliminates the
need for machining and/or drilling the cooling chamber and thus eliminates
possible errors during these steps. SEMCO .has designed shot tips since 1976
and has shown that the cast cooling chambers reduce raw material loss,
reduce finish machining time, allowing larger cast cooling chambers that make
tips run longer. SEMCO also has designed families of castings from 2" to 5"
diameter and lengths of 4, 4 1/2, 5, and 6" long for versatility in plunger tip size
and performance.

II. Tip to Sleeve Clearances

For Beryllium Copper Plunger Tips and in particular, those with the proper
cooling chambers, a general rule exists for clearance between the shot sleeve
and plunger tips.

This clearance is suggested as an allowance of 0.001" per inch of tip diameter.

Thus, for a 2" tip the clearance is 0.002, and for a 3" tip; 0.003, etc. This is the
total clearance between the tip and sleeve. While a definite standard for
clearances does not exist, the above is a good starting point. For plunger tip
sizes above 4" diameter, the working clearances can vary, and require an
additional 0.0005" clearance. Operating temperatures of the sleeve and tip
combinations can be variable, influenced by the aluminum or magnesium
casting alloy, its temperature, and fluidity.

The area of the shot sleeve that is buried in the platen and cover die will
have metal to metal contact and can be assured to stay in a more reasonably
round (concentric) condition. Some discrepancy in clearance and
concentricity can be tolerated between the tip and sleeve in the exposed area,
since this is a zone of low pressure. But if the sleeve is "bowing" due to
thin wall construction, and/or has a hot spot under the pour hole, then
extra tip clearance may have to be developed to get beyond this spot with
minimum friction.

As before, a general starting rule works well for tips up to 3"-31/4". Starting at
3 1/2" and going up to perhaps 6" diameter tips, new ground rules must be
developed. Some tip clearances in the 4"-6" diameter range may need to be
controlled by special devices to modulate or change the temperature of the tip
coolant. In point, if a very cold tip is needed to control a friction-free size in the

Page 7
 late stages of the shot, the clearance may be excessive due to tip shrinkage in
the early (pour hole close) stage of the shot. Critical clearance applications
might require a "warm" tip to start, then changing to "cold" cooling during the
strike and solidification stage.

Some operating clues indicating the need for tip temperature control and/or
changed clearances will be the sight and sound of the tip action. Shuddering
or outright stoppage in the final stroke phase (or pullback phase) will indicate
a clearance adjustment and/or more cooling; perhaps even a lubrication
adjustment.

If the tip needs temperature control, then "relieving" the tip becomes the
proper thing to do-progressively in small amounts until the particular job runs
well. The next job, even if the tip is the same nominal size, may not be the
same. Remember that temperature affects the clearance. If the metal
temperature and shot size changes, these can affect the proper shot tip
clearance.

If the tip clearance is too excessive, flashing may occur. If the clearance has
worn, producing longitudinal grooves on the a.D. of the shot tip, metal entry
into the grooves will accelerate. This can erode a sizeable escape channel for
the entire length of the tip sealing body. These channels resemble a river and
are sometimes called "worming" or "needling." If the channel completely
breaks through on one shot to sustain flow, a sizeable amount of molten metal
at high velocity can escape toward the shot cylinder end. Washout or erosion
in the bottom of the pour hole area is also a contributing factor.

In the next section, we will discuss beryllium copper shot tip materials that are
supplied in a variety of alloy grades (Be-1OSTM, alloy 14 or 3, Be-20, and alloy
25). Alloy Be-10STMand Be-20 are Semco alloys; alloys 14 or 3 and 25 are bar
stock alloys.

Beryllium Copper Materials

Beryllium copper is a non-ferrous copper base alloy with a small addition of

beryllium, usually 0.5 or 2.0%. The alloy has high thermal conductivity close to
that of copper, but the addition of beryllium allows the alloy to be solution
annealed and treated to the hardness levels of tool steels. SEMCO developed
the Be-10STMalloy that contains 0.5% beryllium and can be heat-treated to a
hardness of 96-101 Rockwell "B". The corresponding Be-20 2.0% alloy can be
heat-treated to 36-41 Rockwell "C".

When beryllium copper is used as a plunger tips, the tip life can be extended
to 2 to 4 times that of other materials. The tip can be re-used several times
upon turning to a smaller diameter.

Page 8
Beryllium copper plunger tips also possess high thermal conductivity. SEMCO I'

Be-10STMhas thermal conductivity 10 times that of steel, and Be-20 alloy is 4

to 5 times that of steel.

The composition and hardness values of SEMCO Be-10STMand Be-20 alloys

are presented in Table II.

Table II

- SEMCO ALLOYS

Alloy Chemical Rockwell

Designation Name Composition Hardness

Be-10STM Beryllium .45-.55 B96-101

Cobalt .35-.45
Nickel 1.80-2.10
Copper BAL.

Be-20 Beryllium 1.90-2.15 C38-43

Cobalt .45-.55 .
Copper BAL.

III. Coolant Volume and Temperature

There can be cases where the tip and plunger rod coolant
(usually water) may have to be temperature-controlled in the
extreme cases. This is usually a result of water temperatures
higher than 80°F.

A most common cause is simply warm water and/or insufficient

flow and pressure, that causes tips to run hot and reduce tip life.

Many times this is caused by the reversal of the cooling

inlet/outlet hoses. This, in the absence of other factors, is the
first item to check. Typically,plunger rod cooling is accomplished
by a "percolator" pipe. The cold water flows through a central
pipe direct to the tip, then exits via a clearance surrounding the
percolator pipe. The exit channel, on an area basis, is larger than
the inlet pipe. This is to compensate for lime/scale/rust buildup
that could cause a pressure drop. This will also ensure minimal
restriction for heated water as it exits the plunger tip. If the

Page 9

--
 connection are reversed, the jet pipe cooling to the interior tip surface is
eliminated, and the system stops working. Check this elementary point first.

Figure 3

ROD

I
0
~ CENTER TUBE
FLOWAREA
EFFECTIVE
EXIT FLOW
AREA

Table 3 lists the recommended tube sizes for different diameter tips.

Table 3

Tip Size Tube Size J.D. Area

to 2" 1/4" a.D. x .030 W.T. (tubing) .028in2

2-1/4"-3" 5/16" a.D. x .030 W.T. (tubing) .049in2
3-1/4"-4" 3/8" a.D. x .030 W.T. (tubing) .078in2
4-1/4"-5" 1/4" Pipe (.264 I.D.) .104in2
5-1/4"-6" 3/8" Pipe (.492 I.D.) .190in2

A typical shot rod has a jet pipe percolator tube in the center. It is important
that the size of the tube be in proper proportion for the plunger tip being used.
The tube and pipe sizes, and their corresponding I.D. area values, should be
looked at closely in customer designs. There can be cases when "tower"
water is used in excess of 800 F temperature, and pressures below 40 psi, that
even these sizes will be marginal.

Now examine the exit center holes in the plunger rods. The area total between
the center tube (pipe) size and the center hole I.D. must be equal or larger
than the feeding tube area. Check that the center exit hole was established
for proper water flow, and not selected just to be convenient for a drill or pipe
tap size.

Page 10
Table 4 calculates the effective flow area.

Table 4

Center Exit Hole Effective

Tip Size Tube/Pipe Tube Area Diameter Flow Area. Ratio

to 2" 1/4" tube .028inZ .44 .IOOinZ 3.57

2-l/4"-3" 5/l6" tube .048inz .50 .I20inz 2.50
3-1/4"-4" 3/8" tube .078inz .56 .I36inz 1.74
4-1/4"-5" 1/4" Pipe .I04inz .68 .I4linz 1.35
5-1/4"-6" 3/8" Pipe .I90inz .87 .243inz 1.27

Note that the effective flow area is greater than the inside area of the center
flow tube. The area is the difference between the exit hole diameter and the
0.0. area of the center tube. All plunger rod designs should follow this
guideline to ensure adequate water flow to and from the shot tip.

See the previous note concerning water temperature, volume, and pressure.
Many times upon investigation of hot running sticky tips, "hot" water in excess
of 80°F is being used, sometimes in combination with low flow and pressure,
generally from recirculating or tower water systems. The'solution may be as
simple as connecting the plunger rod cooling inlet to a city water system. City
water systems usually provide water at temperature 65°F or less and at an
approximate pressure of 35 to 50 psi. Ifat times cooling is especially deficient,
add a mixing valve to use part city water and part tower water.

Finally, even when plunger rods have correct sizing relationships for the
internal passages, a seemingly small mistake can render the cooling system
marginal or ineffective.

Tapered (NPT) pipe threads are supplied on IN and OUT connection ports to
the plunger rods. A correct method to insure adequate water flow is to use
water pipe nipples for connections, then use a supply hose that will fit tightly
over the nipples. The inside diameter of the nipples (and its flow area) then
becomes the controlling restriction size. See the following Table 5.

Page II
 Table 5

Pipe Actual J.D. Actual Use Hose

Size J.D. Area a.D. Size

1/8" NPT .269" .057in2 .405 3/8" (.375)

1/4" NPT .364" .104in2 .540 1/2" (.500)
3/8" NPT .492" .190in2 .675 5/8" (.625)
1/2" NPT .622" .303in2 .840 3/4" (.750)

Review the 1.0. Area column and compare to Table 4 showing tube areas and
effective flow areas on page 9. The use of 1/8" pipe ports (1.0. area = .O57in2)
can only be partially useful for the small tip jobs less than 2" diameter. The
1/4" pipe ports (.104in2)are compatible to tip sizes through 3" size where the
largest effective flow area is listed for .136in2.

The 3/8" pipe ports (.190in2)should be used for 3 1/4" through 5" sizes where
the largest effective flow area goes to .141in2.

The 1/2" pipe ports (.303in2)should be used for the very large tips 5 1/4" - 6"
sizes where the largest effective flow area goes to .243in2-

Exact relationships do not have to exist, but they should be close. Ideally, the
inlet and outlet flow areas of the pipe nipples should be slightly larger than the
effective flow area of the plunger rod center exit hole.

Refer to the hose size recommendations to be used in conjunction with

certain pipe sizes. These hose sizes will be a tight fit over the 0.0. of the
common water pipe nipple. Even so, hose clamps should be used to prevent
leakage. In time, the hose 1.0. will stretch and tend to blow off or leak when
under pressure.

A common mistake, only being evident in marginal cases, is when an

installation for plunger rod cooling will use brass "barb" fittings. Hoses will
secure well and in some cases do not need further clamping. The problem
with a barb fitting is that the inside controlling diameter (and area) of the barb
fitting is much too small for adequate flow (for example, a typical barb fitting
with 1/4" 1.0. hose [.O49in2]).Review the figures showing that areas exceeding
.100in2 are desirable in this case. The same type of example should be
analyzed for other sizes of barb fittings and hose sizes.

It is very important when sizing the cooling capacity for shot plunger systems
to remember that the tip operates in the single most hostile point in the whole
system. Molten metal is closely adjacent and the hydraulic shot system exerts

Page 12
 .

forces to push the tip through the shot sleeve. Make the job easier by
providing correctly sized adequate cooling.

IV. Design Versatility

Shot sleeves, plunger rods, stoke adjustments, cover die thickness, and shot
- weights, et.a!.
I See Figure 4A-C - This shows a standard shot end arrangement using a 600
j ton for example. By 2" increments and use of the stroke adjustment feature,
various shot tip penetrations, cover die thickness, and shot weights are
afforded with one plunger rod design and 3 shot ram spacers. An important
point is that the pour hole starting position is a constant to autoladle position
unchanged for various setups.

See Figure 5 - This shows one variation of a customer special system that is
based on using one shot sleeve design for 2 or more jobs by a variety of split
ring flanges on the die locating side. The perceived advantage to cost saving
for sleeves is offset by requiring extra plunger rods. When the sleeve is
repositioned by split ring retainers, the pouring hole then moves from a fixed
starting point.

From a time-saving standpoint, it takes longer to change over complete shot

rods than the smaller and lighter shot rod spacers. Consider these points
when special shot end arrangements are made.

Finally, with a fixed length shot sleeve, the shot volume is a relative constant
due to the constant shot stroke that must be used. Tt1e only way to adjust
shot weights is by variable filling levels.

See Figure 5 - Sometimes, the idea to use one shot sleeve design in multiple
jobs ends up being short-sighted and more expensive in the long run.

Page13
 Figure 4A

THIN COVER DIES- LEAST SHOT WGT

19 STROKEFWD 4....

I' I

1-- r----
i-
'-

ZONSTANT
-- 5.5-1 CONSTANT ROD LGTH.
TIP POSITION

Figure 4B

MEDIUM COVER DIES- MEDIUM SHOT WGT

21

,--
STROKE FWD n r----
,
;-
'-

MIDDLE
7.5---1 SPACER

Figure 4C

THICK COVER DIES- MOST SHOT WGT

23 STROKE FULL 2

BACK l

1--9
9.5 -I

Page 14
 Figure SA

POUR POINT
FIXED MOVES
: STROKE
~

J
ONE FIXED
LENGTH SLEEVE
-~

LFFERENT
~
LENGTH RODS

Figure SB

FIXED ~
STARTINGJ
SAME AS "A" PLANE
(NOADJ.)

1--
- L-
I
a
'-
~
I MEDIUM. EXPOSED
LENGTH
CHANGES

Figure SC

l#
...
SAME AS

THICK ..
1-

Page
15
v. Compressive Stresses

Modern machine shot end forces may be greater than what some customers
are familiar with. The following table shows intensified rod forces applicable to
the machines now in SEMCO's line:

Table 6

Size Final Shot Force (tons) FiI-ialShot Force Obs)

200 20.4 40,800

400 31.8 63,600
600 39.9 79,800
900 53.5 107,000
1200 74.6 149,200
1800 109.2 218,400

One area of importance in these numbers is to consider the compressive

stress on the joint line between the shot plunger rod and the shot tip.
Compressive stresses for good rod and tip life should not go over 40,000 psi if
possible. .

High compressive stresses on a plunger rod can bend the rod causing a
misalignment and excessive tip wear problem. High stre:sses on the copper tip
material will progressively coin and deform to cause water leakage and
eventual thread breakage.

Figure 6

STUD
0.0.

\ COMPRESSIVE
STRESS AREA

Page 16

..
 If a situation requires special design, use these calculations:

1. Calculate area of rod 0.0.

2. Calculatearea of stud 0.0.

~
3. Subtract to obtain effective area under compression.

4. From machine characteristics, use the maximum thrust (in Ibs.) delivered
by the shot system.

5. Divide: Ibs. Thrust/rod effective area. When this figure is above 40,000 psi,
a risk increases for rod & tip deformation.

NOTE: The 40,000 psi limit is suggested based on steel rod materials having
yield points of 60,000-90,000 psi dependent on alloy and hardness. Some
beryllium copper shot tips have a yield strength at 40,000 psi, so they will
operate right at the limit. With stress figures at 40,000 psi and above, the shot
tips will coin in progressive compression failure creating the need to frequently
retighten the tip and prevent water leakage.

Table 7

'I
I
I
I
I

'I

2-3/4 1.25 (1.226) 2.50 (4.096) 3.680 17282 21684 29076

. I' It.
3-1/4 1.50 (1.766) 2.75 (5.936) 4.170 19136 25660 35779
.. iii .
3-3/4 1.50 (1.766) 3.50 (9.616) 7.850 10165 13630 19006 27821
.- .. I'.. : I
4-1/2 2.0 (3.141) 3.75 (11.039) 7.898 13547 18890 27652
t:'
5 2.0 (3.141) 4.00 (12.566) 9.425 11352 15830 23172
. .1. .

5-1/2 2.5 (4.906) 4.75 (17.711) 12.805 13968 19477 28511

" ...
..
.
. u ....... .. .. . .. ....

6 2.5 (4.906) 4.75 (17.711) 12.805 13968 19477 28511

Page I 7

...,I
 In Table 7, certain figures are circled to show that they are over the advised
compressive stress limit. Avoid these combinations where possible and/or
reduce shot end forces if necessary to solve those unique problems. Plunger
tip coining could occur if stresses are too high.

VI. Tip and Rod Guiding

Inadequate guiding of the shot tip and inadequate rod weight supporting is
common in some customer designs.

See Figure 8A: The machine may have a guaranteed and checked shot end
alignment between the platen sleeve hole and the shot cylinder end, but if the
intermediate items of shot sleeve, shot tip, and plunger rod are not evaluated,
each shot could occur with a relative misalignment.

Figure 8A

ROD SAG
LOOSE OR EXCESSIVE
COUPLER CLEARANCE

--11--
SMALL
ENGAGEMENT
BAD- PROMOTESTIP WEAR
AND HIGH FRICTIONSHOTS

Figure 8-A shows a typical worse case encounter. The shot tip engages by a
small amount, then a plunger rod having a loose rod coupler with excessive
clearance, will ensure that the shot tip is starting on an angle, becoming
especially bad in the first 3"-4" of stroke. In this early stroke phase, the shot
tip 0.0. bearing area must try to lift the plunger rod droop as it is moving. The
critical point is where the front edge of the tip passes the pouring hole edge.
An indication of this will be scrub marks and damage on the top leading edge
of the tip and the bottom trailing edge.

Plunger rod weights range from a low of 20 Ibs. (200 tons) to a high of about
275 Ibs. (1800 tons). A 600 ton rod weight is approximately 80-90 Ibs. If the
securing area of the shot tip is slight (1"), together with a "loose" rod coupling
for .060" drop, excessive plunger tip wear is likely.

Page 18
 Some customers when queried will state these reasons for the practice:

1. Saving a little shot sleeve steel for cost reduction.

2. Better lubrication when a large part of the sleeve body is exposed.

.,' 3. Loose floating couplers to compensate for worn sleeve holes in the platen.

"
Figure 8B
. .-- -- --.
TIGHT COUPLER CLEARANCES
.020" TOTAL-MAX.

LARGE ENGAGEMENT ROD WEIGHT SUPPORTED

1/2 TO 2/3 TIP BODY
LENGTH
GOOD- LESSTIP WEAR
AND GOODALIGNMENTFOR
LOW FRICTIONSHOTS

Following these principles can produce a well-guided and more accurate shot
alignment during the critical first stage of the shot movement. The shot tip
should fully engage in the sleeve bore using a specification of 1/2 to 2/3 the
distance of the 0.0. bearing length. Lubrication systems can be made to work
properly. The bearing stress pressure between the shot tip and the sleeve bore
is also considerably reduced. This should help facilitate making the lubrication
job easier.

On the coupling end, the maximum diametral clearance should practically be

designed at .015"-.020", to indicate a theoretical rod droop of .008"-.010".
Extra precision in this area, coupled with an accurate shot end alignment, will
allow the shot to start with the least friction and rod lift.
'0
Considering that some wear in the coupling area will eventually increase the
clearances does not justify loosening just for convenience or easier assembly.
l~
:r

Page 19

-
VII. Shot Sleeve Designs

SEMCO has encountered a large variety of customer designed shot sleeves.

Some designs are good, some are marginally passable, and some are inferior.

From the standpoint of producing a good friction-free well-aligned shot, some

of the good and bad points in a shot sleeve design are listed below:
--;

Figure 9A Figure 9Al

q

2-1/2 ~!ZAX ~I

WORST DESIGN FOR

THIN WALLS
BETTERTHAN A

Figure 9B Figure 9Bl

~.
"'-. 1-1/2 D

D--

BETTER THAN A FOR

THIN WALLS BETTER THAN B

Figure 9C Figure 9Cl

~,

1
D -

BEST FOR THIN WALLS

BEST OF ALL C

Page 20
 Figure lOA

ROD BLENDS
ct. RAISES
I
I'

.. ..
STRETCH WORST CASE LONG PROJECTION,
LONG THIN WALL, LONG TRAVEL TO PLATEN
HEAT TRAVEL HEAT SINK, TIP HAS HIGH FRICTION
ANn WFAR

Figure lOB

ct. RAISES ROD BCENDS

-<II

HEAT
.
STRETCH BAD CASE LIKE ABOVE- CAUSED
BY USE OF THIN PLATEN "INSERTS"

Figure lOC

BEST CASE THICK WALL SLEEVE,

SHORT PROJECTION, SHORT HEAT TRAVEL
TO PLATEN, ROD STAYS STRAIGHT

.
r,-
.
LOW FRICTION SHOT-LESS WEAR

SHORT
HEATTRAVEL

Page 21

...
VIII. Adequate Wall Stock

In past years, thin wall shot sleeves were common and could be tolerated with
slower cycles, operator pacing, and hand ladles. Today, with autoladles
prevalent and faster cycles, shot sleeves must have thicker walls for a variety
of reasons. As referred to earlier, the SDCE guidelines established some
minimum wall thickness for guidance. They range from a low of 3/4" per side
on smaller machines to a high of 1 1/2" per side on larger machines:

Added wall thickness in the pour hole area and the exposed shot sleeve
length has become essential to maintain even temperatures.

Metal poured into the shot sleeve from an autoladle hits the same point in the
bottom of the sleeve on each and every cycle. Also, the metal pouring
temperature is higher than used years ago. The effect is that the area under
the pour hole is subjected to severe high temperature cycles, leading to
erosion, heat check, and severe shot sleeve bore damage. A thick wall sleeve
provides an even heat transfer to carry some of the excess temperature
through the sleeve wall to the stationary platen.

Another factor is that the exposed length of the shot sleeve body has an effect
on the deformation that the sleeve goes through during the metal pouring
stage. When the shot sleeve projects a considerable distance from the platen
and coupled with a thin wall design, the sleeve will bow or bend due to the
temperature difference between the bottom half and the top half. The bottom
half of the sleeve will expand in a linear direction to more effectively move the
pouring end of the sleeve and its centerline upward. This is the mitigating
factor that causes the plunger tip to start in a relatively misaligned or binding
condition right after metal pouring.

Some experimental sleeves have been designed to minimize the bowing and
ovality problems in the casting process:

1. Water cooling in the bottom of the pour hole.

2. A strap-on water cooled jacket.

3. Air cool piping in the bottom of the pour hole.

...'

Page 22
 IX. Adequate Tip Engagement

As previously mentioned, the shot tip body should engage the open sleeve
bore 1/2 to 2/3 of the tip body length. Many design the tip engagement so the
plunger tip is only into the open sleeve 111or less. This practice is usually
based on the theory that the exposed part of the shot tip can be more easily
", , lubricated.
r
When the shot tip is engaged only a short distance, recognizing the factors of
.~
rod droop and sleeve bowing from temperature, the shot tip starts in a
relatively misaligned condition. During the initial part of the stroke to close off
the pour hole, the tip must very quickly try to compensate and align the rod
mass as the whole system moves. A more secure engagement during this
critical starting stage willgreatly reduce misalignment.

Summary: You can improve the quality of your shot process.

Technology advances in shot end components have made a significant impact

on die casting productivity. Longer plunger tip cycles because of superior
alloy composition and tighter dimensional tolerance have allowed leading die
casters to significantly reduce changeover and maintenance downtime.

With greater speed, higher pressures, less impact, more- control, and better
component alignment in the shot systems, there's no reason to tolerate many
of the problems that continue to plague the process. We hope the insight in
this manual has allowed you to not only "fix" problems when they occur, but
make the recommended process changes that act~ally circumvent their
reoccurance.

As a leading supplier of plunger tips and other shot end components. Semco
brings a unique understanding to the various factors that affect the efficiency
of the process. Careful examination and evaluation of your shot end
components is where it starts. The recommendations in this manual offer a
powerful checklist for making lasting changes to your process.

For further technical assistance or to discuss your specific problems, call us at

1-800-848-5764. We look forward to helping your casting operation achieve
maximum efficiency.
~."
...

Page 23
 tf

Semco Quality
Semco's trademarked !3E~1OSTM alloy and BE~20
alloy, have set the industry standard for long life
and quality plunger tip performance. Add tq that
total in~house control of raw materials, CNC
dimensional tolerance control and the industry's
largest tip inventory, and the reasons for Semco's
leadership become very clear.

Semco, Inc.
Fax: 740-387-6127'
.
800-848-5764 740-387-2229
Email: [email protected]
"WHEN THERE'S NO TIME
FOR DOWNTIME" TM