53-63

International Conference on Advancements and Futuristic Trends in Mechanical and Materials Engineering (October 5-7, 2012)

Punjab Technical University, Jalandhar-Kapurthala Highway, Kapurthala, Punjab-144601 (INDIA) 53

Study of Design of Gating System for a Die-Casting Die : A Review

Chandan Deep Singh1, Rajdeep Singh

2

Department of Mechanical Engineering

University College of Engineering, Punjabi University, Patiala

Patiala – 147 002, Punjab (India)

Authors E-mail address: [email protected],

[email protected]

1Corresponding Author

Tel.: 1+9181469-21111, 2+9184277-25500

Abstract

In the era of mechanization, every new dawn witnesses the launch of enterprising products

and technologies. This has been made possible due to adoption of improved design and manufacturing processes by the manufacturing companies. Modern design and manufacturing

processes are quite different from the traditional ones. The traditional ones were manual,

involved lot of paperwork and traditional machine tools. Now the things have changed a lot

with the introduction of computer systems, NC machine tools and the advent of information

technology in design and manufacturing processes. Today design sections have acquired an

all new look due to hi-tech computer workstations with 3-D design software support like

CATIA, Pro. E. etc. NC, CNC and DNC machine tools have re-invented the outlook of shop

floor. This new look is the result of development in the field of CAD and CAM. CAD/CAM

is the term that stands for computer-aided design (CAD) and computer-aided manufacturing

(CAM). CAD deals with generating and managing the design information and CAM is

responsible for planning, managing and controlling the manufacturing activities.

Keywords: die-casting, die design, CAD file, gating system

Introduction

Although CAD and CAM have been significantly developed over the last three

decades, they have traditionally been treated as separate activities. Many

designers use CAD with little

understanding of CAM. This, sometimes,

results in design of non-machinable

components or use of expensive tools and

difficult operations to machine complex

geometries.[Rad M.T., 2006] In many

cases, design has to be modified several

times, resulting in increased lead times and

cost. Therefore, great savings in machining

times and costs can be achieved if

designers can solve machining problems of

the products at the design stage. This can

only be achieved through these fully integrated CAD/CAM systems [Lin & Tai,

1996].

In compliance with the need of design

manufacturing integration, this section explains the idea in detail and gives insight

into the integration process. Design-manufacturing integration involves the

generation of manufacturing information and data from the design data of a product.

Attempts for integration of CAD/CAM

have been made by many researchers

[Madan J. et. al, 2007 & Suleman S. &

Keen T.C., 1997 ]. There are some systems

available that are capable of generating

manufacturing data from the CAD model.

But human intervention is required at

some steps. The main focus of present

CAD/CAM integration is to generate the

manufacturing data i.e. NC codes for NC

and CNC machines. Besides the generation

of CAM data base, we can also integrate the other functions such as process

planning, factory management and robotic control.



The benefits that can be derived from the

integration of CAD/CAM are many. Some

of the benefits are: shorter lead times,

improved productivity, fewer design

errors, better design analysis, greater

accuracy in design calculations, standardization of design, reduced data

redundancy, scheduling of tools and components, better product planning and

control, application in product forecasting etc.

Die-casting Process

Die-casting process is an example of

permanent mold casting. In die-casting

process molten metal is forced into the die

cavity at pressures ranging from 0.7MPa to

700MPa and finally ejected out after

solidification of the metal

[http://www.brockmetal.co.uk/papers/].

The metal, typically a non-ferrous alloy

such as aluminum or zinc, is melted in the

furnace and then injected into the dies in

the die-casting machine. The die-casting method is especially suited for applications

where a large quantity of small-to-medium-sized part is needed with good

detail, a fine surface quality, and dimensional consistency. This level of

versatility has placed die casting among the highest volume products made in the

metalworking industry

[http://www.themetalcasting.com/].

A die-casting die consists of two halves

named as core half and cavity half. Cavity

half is the fixed one while core part is

movable. Injection of the metal is done

using a gating system which is provided in

the cavity half of the die. The following

paragraphs give a brief idea about stages in

die-casting process, die-casting machines

and the die-casting die. There are five

main stages in die-casting process which are:

Main Stages in Die-casting Process

The five main stages in die-casting process

are explained as below:

� Clamping

� Injection

� Cooling

� Ejection

� Trimming

i. Clamping The first step is the preparation and

clamping of the two halves of the die. Each die half is first cleaned from the

previous injection and then lubricated to facilitate the ejection of the next part. After

lubrication, the two die halves, which are

attached inside the die-casting machine,

are closed and securely clamped together. [

http://www.custompartnet.com/wu/die-

casting]

ii. Injection

The molten metal, which is maintained at a

particular temperature in the furnace, is

transferred into a chamber from where it

can be injected into the die. The method of

transferring the molten metal depends

upon the type of die-casting machine,

whether a hot chamber or cold chamber machine is being used. The difference in

hot chamber or cold chamber machines has been discussed in the next section.

iii. Cooling The molten metal that is injected into the

die will begin to cool and solidify once it enters the die cavity. When the entire

cavity is filled and the molten metal

solidifies, the final shape of the casting is

formed.

iv. Ejection

After the predetermined cooling time has

passed, the die halves can be opened and

an ejection mechanism can push the

casting out of the die cavity. Once the

casting is ejected, the die can be closed

again for the next injection.

v. Trimming

During cooling, the material in the

channels of the die will solidify and would remain attached to the casting. This excess

material, along with any flash that has occurred, must be trimmed from the



casting either manually via cutting or

sawing, or using a trimming press.

Die-casting Machines

There are two main types of die-casting

machines –

� Hot chamber machines � Cold chamber machines

i. Hot chamber machines

These machines are used for alloys with low melting temperatures, such as Zinc,

Tin, and Lead. The molten metal is contained in the holding pot which is

placed into furnace. The molten metal

flows through shot chamber into the goose

neck and finally injected through the

nozzle into the die with the push of

plunger. Figure 1.1 shows the important

parts of hot chamber die-casting machine.

Figure 1.1 Hot chamber die-casting

machine [http://www.chinyen-

engineering.com]

ii. Cold chamber machine

Cold chamber machines are used for alloys

with high melting temperatures, such as, Aluminum, Brass, and Magnesium. The

metal is poured from the ladle into the shot chamber through a pouring hole. The

plunger forces the metal through shot chamber into the die. Figure 1.2 shows the

important parts of cold chamber die-casting machine.

Figure 1.2 Cold chamber die-casting

machine [http://www.chinyen-

engineering.com]

Die-casting Die

A die-casting die consists of two halves termed as cavity (cover die) and core

(ejector die). The cavity half is fixed and the core half is movable. The core half is

moved towards the cavity half to assemble the die. Molten metal is poured into the

space left between the two halves termed as cavity. Figure 1.3 shows the various

parts of a die with shot sleeve and plunger.

Figure 1.3 various parts of die [Zahi M.,

et. Al, 2009]

Design-Manufacturing Integration of

Die-casting Process.

Die-casting processes involve extensive use of CAD tools in part and die design.

The normal process is to prepare a CAD model of the part and use this CAD model



for designing and making the CAD model

of the die. Designing of die-casting die

requires lot of knowledge and expertise on

the behalf of the die designer. Design –

manufacturing integration can be realized

if we develop such a system that is capable

of generating die design from the 3-D model of the part itself. The system would

take 3-D model of the part as input, recognize various features of the part

model and determine different aspects of die such as, parting direction, parting

surface, gate runner design, cavity layout etc.

Figure 1.4 shows the important stages of

the die-casting process. Out of these

stages, die design is the most cumbersome

and sustained. Die design requires

optimization of interacting parameters at

various steps of the die design process.

The processing theory defines a step-by-

step analytical procedure to design the

energy exchange functions necessary to

make a useful piece part. The results are

the specifications for the die design and

the process control set points. Cooling and heating channels plus the heat flow paths

must be designed to focus the correct amount of energy through the cavity

surface to achieve the required heat flux. Hence, the die design is derived from the

defined required final condition of the solidification pattern.

Figure 1.4 Flow chart for die-casting

process

The design of the die includes the following aspects

� mechanical aspect: material

selection, insert seams, and clearance space;

� in the thermal exchange: location, size, length of the cooling=heating

channels, and the flow rate of the

medium used; and

� in the fluid flow arena: the location

and size of the gating and venting,

as well as configuration of the

metal feed system. This term is

also used to define the net shape

produced from this process.

The following section throws some light

on the die-casting die design process that

could be beneficial in understanding the

principles of die design process and formulating the objectives for the present

work. The succeeding section describes about the die-casting die design.

Die-casting Die Design

Die-casting die design is an intricate

process that requires balancing of the

conflicting parameters. The principal

parameters taken into account are: shape

and size of the part, material of the part,

type and capacity of the machine, lot size,

and tolerances required. Based on the

above parameters, features like: design of

cavity, number of cavities, gating and

runner system, parting design, cooling

design etc. are determined or calculated.

There are no set rules for the designing

procedure of a die-casting die but some

researchers proposed seven major steps of die-casting die design which are as

follows:

Part Design

Die design

NC codes generation

Die manufacturing

Die Casting of the part

Casting



� Setting shrinkage

� Determining the cavity number and

layout

� Designing the gating system

� Designing the die-base

� Parting design

� Designing the moving core mechanism

� Designing the cooling system

i. Setting shrinkage. As the molten metal contracts

during solidification, the original die-casting part geometry must be

scaled by a certain factor to reflect

the material shrinkage.

ii. Determining the cavity number and

layout.

Cavity number is the number of

cavities to be machined in a die-

casting die. It is determined based

on the part shape and dimension,

machine type, machine size

limitation, machine clamping force,

machine pumping capacity, etc.

Once the number of cavities is finalized, then their layout pattern

in the die is decided to reduce the variations in the properties of the

castings hence produced.

iii. Designing the gating system. The gating system is the feeding

system of the die that facilitates the

flow of molten metal in the die.

Flow paths and filling conditions

are analyzed at this stage. The type,

size and location of the gate, runner

and overflow are determined in

accordance with the part geometry

and cavity layout to achieve proper

filling in the die cavity.

iv. Designing the die-base.

Die base (Die-set) is an assembly

of upper and lower die shoes, guide pins and bushings, and punch and

die retainers. Once the number of cavities and cavity layout are

decided, a suitable die-base is

selected to accomplish the

proposed layout. The criterion

generally used in establishing the

overall size of the die-base is that

the ejector plate must completely

cover or contain all of the cavity area within its bounds.

v. Parting design.

It refers to the determination of parting direction, parting line and

parting surface of the die halves. The parting surface along the

selected parting lines is created and

it eventually splits the containing

box into two halves, a core block

and a cavity block, in which the

negative impression of the die-

casting part is formed.

vi. Designing the moving core

mechanism.

Components of the die which have

motion in a direction other than the

main parting direction are called

moving cores or side cores. If the die-casting part has any undercut,

which will block the die halves from opening, moving cores and

angled pins should be designed to facilitate the die opening and the

removal of die-casting from the die.

vii. Designing the cooling system.

The cooling system is an essential feature

of a die-casting die, which is composed of

a set of waterlines drilled within the dies

and inserts that conduct the heat away

from the die cavity. The cooling system

should be positioned and sized properly so

as to achieve rapid and uniform cooling

without interfering with the ejection

system and moving core mechanism.

Die Design Process

From the above discussion, we conclude that once cavity number and layout



decisions have been taken, the very next

steps are gating system design and parting

design. The decisions regarding gating

design and parting design further effect the

decision of core and cavity generation,

side core design, die base design etc.

Figure 1.5 Die Design Process [2]

Figure 1.5 shows the flow chart for die

design process that has been already

discussed in the previous paragraphs.

However, the decisions regarding gating design, parting design and side core design

are taken by the die-casting expert based on his knowledge and experience. It is

very monotonous and protracted process. It has been felt that efforts could be made to

increase level of automation in three stages

of die-casting die design process i.e.

parting line design, gating system design

and side core design. These three steps

have been briefly explained in the

following paragraphs.

In this section, literature review is

presented on topics related to gating system design for die-casting. Systems for

computer-aided design for other manufacturing processes have been

reported (Zhou et al., 2009; Pehlivan et al., 2009), but not much work has been done

for die-casting die design, especially for

computer-aided design of gating systems.

Some of the literature related to plastic

injection molding design was also studied

because of similarities of the process to

die-casting. Research gaps have been

presented at the end of literature review.

Abdalla et. al (2011) This paper

presents a knowledge-based system to

enhance creative conceptual design.

Market globalisation and technology

advances require fast adaptation to customer needs by being creative and

competent. Current practices in design constituted the basis for the developed

Creative Design Tools (CDTs) system architecture. The developed system

provides users with and integrated and flexible creative design environment to

enhance their creative conceptual thinking.

Such design environment requires the

integration of many components namely:

design process, creative tools and design

knowledge within a highly collaborative

interactive human-computer interface. The

CDT system was implemented as a web

application, which was integrated with

various creative methods.

Choi et al. (2002) developed a die

design system for the die-casting process

which was an attempt to automate die

design. Generation process and die design system using 3D geometry handlings were

integrated with the technology of process planning. However, the optimization of the



gate runner system was not considered in

this research.

Kwong (2001) made an attempt to

develop a case-based system for process

design (CBSPD) of injection moulding,

which aims to derive a process solution for

injection moulding quickly and easily without relying on the experienced

moulding personnel, but such effort is missing in case of die-casting.

Khalgui et. al (2011) The paper deals with reconfigurable embedded

control systems following component-based technologies and/or Architecture

Description Languages (ADL). A Control

Component is defined as a software unit of

the system which is assumed to be a

network of components with precedence

constraints. We define an agent-based

architecture to handle automatic

reconfigurations under well-defined

conditions by creating, deleting or

updating components to dynamically bring

the whole system into safe and optimal

behaviors. To cover all reconfiguration

forms, we model the agent by nested state

machines according to the formalism Net Condition/Event Systems (NCES), and

apply a model checking to verify properties of NCES according to the

temporal logic "Computation Tree Logic" (CTL). The goal is to check the agent's

reactivity after any environment's evolution. Several complex networks can

implement the system such that each one is

executed at a given time when a

corresponding reconfiguration scenario is

automatically applied by the agent. To

check the correctness of each one of them,

we apply in several steps a refinement-

based approach that automatically

specifies feasible Control Components

according to NCES. The model checker

SESA is automatically applied in each step

to verify deadlock properties of new

generated components, and is manually

used to verify CTL-based properties according to user requirements. We

implement the proposed agent by three modules that allow interpretations of

environment's evolutions, decisions of

useful reconfiguration scenarios before

their real applications.

Lee et al. (2002a) presented a

semi-automated die-casting die design

system. It described a prototype system

structured by several functional modules as specific add-on applications on a

commercial CAD system for die-casting die design. These modules are: data

initialization, cavity layout, gating system and die base. However, user experience

was required at various stages of the die design process.

Lee and Lin (2006) illustrated the

process of optimizing the multi-cavity

injection mold parameters through network

approach. Finite element simulation was

performed on different runner and gating

systems with different volumes, gate

diameters, runner diameters and cavities an

inputs. Limited numbers of cavity designs

were taken for study. Only circular gate

and runners were taken into account.

Placement of the gating system was not

taken into account. Also, the issues of non-

identical cavities were also addressed. Shehata and Abd-Elhamid (2005)

presented a die-design computer program, which can be can be used to estimate the

die overall dimensions including sizes of sprue, runners and in-gates. The system

can be used to select casting machine characteristics along-with preparing design

of a die. However, a feature library is not

included and CAD models of gating

system cannot be generated.

Ferreira et al. (2007) developed a

methodology for advanced die-casting

manufacturing using a hot-chamber

process. This methodology involves virtual

prototyping, rapid prototyping, P-Q²

analysis and a Numerical Control (NC)

connected to transducers to control in real-

time the die-casting manufacturing

parameters. This approach optimizes the

die-casting manufacturing technology parameters reducing the lead-time of die-

casting designs, but design of a gating system was not addressed.



Lee et al. (2007) aimed at developing a

design system that helped to realize

automatic generation of the gating

system’s geometries by applying

parametric design. Parameterized solid

models of gating elements are pre-

constructed and stored in the system database. User experience is required at

various stages of this system. Also, system application is limited to parts with simple

shapes. Lee et al. (2004) presented a method

of gating system design for die-casting. The parametric models of the gating

system were created. The system reduces

the need of designing the gating system

from scratch for a part as the pre-

constructed gating system can be modified.

System application is limited to parts with

simple shapes. The database of the gating

system needs to be enlarged.

Lin (2002) employed FEM and neutral

network techniques to find the accurate

location of injection gate for a die-casting.

FEM software was used to analyze the

effect of various gate locations on the

warping of the casting. The system reduces the reliance on human skill to find the

location of the injection gate. The optimization of the gate runner system was

however not considered. Lin and Tai (1996) proposed a runner

optimization design study. In the die-casting test stage, the runner part is

generally corrected, which leads to

increased processing time and cost. To

overcome this, several experiments were

carried out in this study. For a runner part,

different insert runner blocks were made

and a die-casting test was designed.

Reddy et al. (1994) reported the

development of a software package for

providing intelligent assistance in several

tasks involved in the design of die-casting

dies. These typically include material

selection, parting line location, die layout,

gating system etc. Algorithms have been developed for addition of shrinkage

allowance and automatic generation of parting line based on maximum projected

area, section thickness. System application

is limited to parts with simple shapes.

Sulaiman and Keen (1997)

performed flow analysis along the runner

gate system for a pressure die using a

program written in FORTRAN. The

analysis was performed to find out the pressure needed during injection of the

metal and to note the effect of branch angle of runner gate system. The results

were good and define some relation between the branch angle and the die

pressure. The system was limited to the simulation of the gating system.

Woon Yong Khai (2003) presented a

research work of a computer-aided die

design system for die-casting. The

proposed system consisted of eight

modules, through these modules; die

designers were able to create a complete

die-casting die from a product part model.

The aim of this research was four-fold: (1)

integrating different stages of die design

process, (2) facilitating the editing and

customizing of die-casting die design

during or after the design process, (3)

semi-automates several die-casting die design process, (4) increasing

standardization. However, the feature library in this was insufficient. The

calculation of parameters of gates, runners and overflow was also user dependent.

Zabel et.al (2011) The layout of temperature control systems for moulds is

decisive for the performance and stability

of the production process. A design and

optimisation approach for temperature

control systems is introduced, coping with

geometric constraints and complex thermal

dependencies and allowing a significant

reduction of manufacturing costs. Five-

axis milling processes are increasingly

used for the production of moulds in order

to achieve high surface qualities and low

manufacturing times. The CAM-

programming required for the milling of

free-formed surfaces in this field is complex and error-prone. An approach is

shown, which automatically generates



five-axis NC-paths from existing error-free

three-axis paths.

Zahi et al. (2009) proposed a non-

dominated sorting algorithm using runner

and molding conditions as design

parameters for gate-runner for injection

moulding design. So a weighted sum approach was employed to select the

suitable design parameters. The choice of the weighted functions is left to the

designer.

Summary of Related Literature

Table 2.1 Summary of related literature

S.

No

.

Title Aim Limitatio

ns

1. Computer

Aided Design of

Die Casting

Dies by Reddy et.al

(1994)

Reports

the developme

nt of a software

package for

providing intelligenc

e involved

in the

design of

die casting

dies

Can not

handle complex

shapes

2. Developme

nt of a semi

–

automated

die casting

die design

system by

Wu et.al

(2002)

A

prototype

system for

die casting

die design

on CAD

system for

design.

User

experienc

e required

at various

steps

3. Feature

based

parametric design of

gating system for

die casting

The PQ2

technique

and feature

based

approach

are

User

knowledg

e required at various

steps

die by Wu

et.al (2002) combined

for achieving

the automatic

generation of the

geometries 4. Developme

nt of

Windows

based

Computer

aided die

design

system for

die casting

by Wong

Yoon Khai

(2003)

In this

thesis, die

casting die

design

system has

been

developed

Insufficie

nt feature

library

5. Semi –

automated

parametric

design of gating

system for die casting

die by Wu et.al (2007)

Aim of

this work

is to

develop a design

system that helps to

realize automatic

generation of gating

system

User

experienc

e required

at various steps

Conclusions

Most of the literature available on gating

system design aims at optimizing the gate-

runner parameters and properties of molten

metal being injected into the die for

minimizing the wrap or simulation of flow

of molten metal through the gate and

runners. A system is, thus, required that

could work on the following shortcomings

of the present gating system design.

� Calculating Gating system parameters with minimum user interaction.

� Minimizing user dependent knowledge.

� Reducing time consumption



After going through the literature survey,

some of the identified research gaps are

mentioned below.

� Issue of automated determination

of gating system parameters has

not been addressed. � Feature library of gating systems

needs to be enriched. � Automated generation of CAD

model of elements of the gating system has not been attempted

In present times, the industry is much

more dependent on user knowledge as gate

velocity is selected by the user based on

his knowledge and experience. Further, the

machine and die are matched by the user.

This process is quite a tedious one and

involves wastage of MET (Money,

Energy, Time)

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