Position of Hi speed injection casting condition

The method of how to set position by calculation is show as below Thus , high speed filling time shall be within 0.03~0.04 sec.
The weight of casting products ahead of gate : W (g) T : high speed injection filling time
Casting weight + over flow =W L3+L1 : high speed acceleration + high speed injection stroke
613.0 V : high speed
150 L3+L1 L3+L1
T= V=
Weight 763.000 gr. V T
The volume of cast products ahead of gate : W1 (cm3) V= 0.025 0.073 0.098
3.28 m/sec.
W 763.000 0.03 0.03
W1=
Aluminum gravity 2.7 282.6 cm3 Proper gate speed
Sleeve surface area : A (cm2) A Sleeve surface area / biscuit thickness 38.49
2
3.142X(Sleeve dia) Sleeve dia: 70 (mm) Gate width 77 7.70
A= S1
4 or 7 (cm) Gate thickness 2.7 0.27
2
38.49 cm S1= 2.079
A=
A
Gate speed= VX
Hi speed injection stroke : L1 (cm) S1
W1 7.34 cm 38.49
L1 = 3.28 = 60.7 m/sec.
A 73.4 mm 2.079
Hi speed injection postion Setting of intensification pressure
Hi speed injection : L-(L1+L2+L3+L4) 1) Casting pressure
L Initial position 382 P1 injection cylinder pressure 550 kgf/cm2
L1 Hi speed injection stroke 73.4 A1 Tip section area 38.49 cm2
L2 Electricity, oil delay = 1.0 cm(10 mm) 10 mm A2 Injection cylinder area 50.27 cm2
L3 Hi speed rising = 1.50-2.50 cm(20mm) 20 mm P 50.27
550 718 kgf/cm2
L4 Biscuit thickness = 2.0-2.50 cm(20mm) for sleeve dia. 60.0 20 mm 38.49
Hi speed injection position = (L1+L2+L3+L4) 2) Casting area
Die locking force 350000
A=
= 259 mm casting pressure 718 487.22 cm2 casting area
 MOTHERSON AUTO COMPONENT PVT LTD

Part Name F Cyl Hanon Customer

Project No. 08-TS-002 Alloy ADC 12

Die Number F Cyl Hanon

No Items Units Design Actual Proposed -1

1 Clamping Force Ton 250 350 250

2 Projected Area cm2 270 585 270

3 Casting Wall Thickness mm 2.7 2.7 2.7

4 Casting Weight gr. 488 613 464 including all cavities

5 Overflow + Chill vent Wt gr. 29 150 50

6 Runner + biscuit Wt. gr. 373 458 371

7 Shot Weight. gr. 890 1221 885

8 Biscuit Thickness cm 2 2 2

9 Yield % 54.8% 50.2% 52.4%

10 Active Shot Sleeve Length cm 37.5 38.2 37.5

11 Shot Sleeve Diameter cm 6 7 6

12 Shot Sleeve Capacity cm3 1060.3 1470.1 1060.3

13 Metal Filling Ratio ％ 35.1 34.8 34.9

14 Slow-shot Length (S1) cm 28.4 25 28.4

15 Fast-shot Length cm 7.1 7.75 7.1

16 Fast-shot Ratio ％ 100 100 100 Should be 100%, more than 100 means fast sh

17 Slow-shot Velocity m/sec 0.2 0.2 0.2

18 Fast-Shot Velocity m/sec 2 2.8 2.2

19 Gate-Area cm2 1.21 1.925 1.456

20 Gas-ventilation (Act) cm2 0.12 0.624 0.5

21 Gas-ventilation (Req) cm2 0.80 0.98 0.57

22 Gas Ventilation % 15.0% 63.7% 88.4%

23 Metal-Velocity (Gate) m/sec 46.7 56.0 42.7

24 Gate Thickness mm 2.7 2.7 2.7

25 Metal density g/cm3 2.57 2.57 2.57

26 J number for Atomized 4970 6767 4263

27 J number req. 525 525 525

28 Filling Time (Req) sec 0.043 0.043 0.043

29 Filling Time (Act) sec 0.038 0.030 0.035

30 Casting-Pressure Mpa 95 72 95

31 Die-Clamping Force Ton 257 421 257

32 Spare-Force Ratio ％ -2.6 -20.3 -2.6

33 Intensification Cyl. Dia cm 12 8 12

34 Intensification Pressure Max Mpa 25 25 25

35 Intensification Pressure Min Mpa 23 23 23

36 Intensification Pressure to be used Mpa 23.8 55.1 23.8

37 Flow rate Required cc/sec 4602.9 6793.1 4576.2

38 Flow rate Actual cc/sec 5652.0 10770.2 6217.2

 Position of Hi speed injection casting condition
The method of how to set position by calculation is show as below Thus , high speed filling time shall be within 0.03~0.04 sec.
The weight of casting products ahead of gate : W (g) T : high speed injection filling time
Casting weight + over flow =W L3+L1 : high speed acceleration + high speed injection stroke
655.0 V : high speed
122 L3+L1 L3+L1
T= V=
Weight 777.000 gr. V T
The volume of cast products ahead of gate : W1 (cm3) V= 0.025 0.078 0.103
2.93 m/sec.
W 777.000 0.035 0.035
W1=
Aluminum gravity 2.6 298.8 cm3 Proper gate speed
Sleeve surface area : A (cm )
2
A Sleeve surface area / biscuit thickness 38.49
2
3.142X(Sleeve dia) Sleeve dia: 70 (mm) Gate width 64 6.40
A= S1
4 or 7 (cm) Gate thickness 3 0.3
2
38.49 cm S1= 1.92
A=
A
Gate speed= VX
Hi speed injection stroke : L1 (cm) S1
W1 7.76 cm 38.49
L1 = 2.93 = 58.8 m/sec.
A 77.6 mm 1.92
Hi speed injection postion Setting of intensification pressure
Hi speed injection : L-(L1+L2+L3+L4) 1) Casting pressure
L Initial position 371 P1 injection cylinder pressure 550 kgf/cm2
L1 Hi speed injection stroke 77.6 A1 Tip section area 38.49 cm2
L2 Electricity, oil delay = 1.0 cm(10 mm) 10 mm A2 Injection cylinder area 50.27 cm2
L3 Hi speed rising = 1.50-2.50 cm(20mm) 20 mm P 50.27
550 718 kgf/cm2
L4 Biscuit thickness = 2.0-2.50 cm(20mm) for sleeve dia. 60.0 20 mm 38.49
(L1+L2+L3+L4) 2) Casting area
Die locking force 350000
A=
Hi speed injection position = 243 mm casting pressure 718 487.22 cm2 casting area
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DESIGN DATA SHEET
Part Name PORCH HOUSING UFI Customer ASK

Project No. 08-TS-002 Alloy ADC 12

Die Number F Cyl Hanon

No Items Units Design Actual Proposed -1

1 Clamping Force Ton 250 350 250

2 Projected Area cm2 270 838 270

3 Casting Wall Thickness mm 2.7 2.7 2.7

4 Casting Weight gr. 488 655 464 including all cavities

5 Overflow + Chill vent Wt gr. 29 122 50

6 Runner + biscuit Wt. gr. 373 516 371

7 Shot Weight. gr. 890 1293 885

8 Biscuit Thickness cm 2 2 2

9 Yield % 54.8% 50.7% 52.4%

10 Active Shot Sleeve Length cm 37.5 37.1 37.5

11 Shot Sleeve Diameter cm 6 7 6

12 Shot Sleeve Capacity cm3 1060.3 1427.8 1060.3

13 Metal Filling Ratio ％ 35.1 37.9 34.9

14 Slow-shot Length (S1) cm 28.4 50 28.4

15 Fast-shot Length cm 7.1 7.75 7.1

16 Fast-shot Ratio ％ 100 99 100 Should be 100%, more than 100 means fast sh

17 Slow-shot Velocity m/sec 0.2 0.2 0.2

18 Fast-Shot Velocity m/sec 2 2.8 2.2

19 Gate-Area cm2 1.21 1.925 1.456

20 Gas-ventilation (Act) cm2 0.12 0.624 0.5

21 Gas-ventilation (Req) cm2 0.80 0.98 0.57

22 Gas Ventilation % 15.0% 63.7% 88.4%

23 Metal-Velocity (Gate) m/sec 46.7 56.0 42.7

24 Gate Thickness mm 2.7 3.0 2.7

25 Metal density g/cm3 2.57 2.60 2.57

26 J number for Atomized 4970 7607 4263

27 J number req. 525 525 525

28 Filling Time (Req) sec 0.043 0.043 0.043

29 Filling Time (Act) sec 0.038 0.030 0.035

30 Casting-Pressure Mpa 95 72 95

31 Die-Clamping Force Ton 257 603 257

32 Spare-Force Ratio ％ -2.6 -72.4 -2.6

33 Intensification Cyl. Dia cm 12 8 12

34 Intensification Pressure Max Mpa 25 25 25

35 Intensification Pressure Min Mpa 23 23 23

36 Intensification Pressure to be used Mpa 23.8 55.1 23.8

37 Flow rate Required cc/sec 4602.9 6917.7 4576.2

38 Flow rate Actual cc/sec 5652.0 10770.2 6217.2