CONTENTS
CONTENTS
CONTENTS
Chapter 1. Introduction
Section 1.2. Designed/Undesigned Scrap/Cost
breakeven
profits
point
%
maximum
20
profits
23
}
}
0
invesment
cost
{
no
100
0 78 80
~65-75
scrap %
scrap
0
100
%
Chapter 1. Introduction
Section 1.4. Historical Background
Chapter 1. Introduction
Section 1.5. Numerical Simulations
Chapter 1. Introduction
Section 1.6. Integral Models
Chapter 1. Introduction
Chapter 2. Basic Fluid Mechanics
U
Section 2.2. What is fluid? Shear streass
Chapter 2. Basic Fluid Mechanics
Chapter 3. Dimensional Analysis
Chapter 3. Dimensional Analysis
D1
2
D
Section 3.2. The processes in die casting
initial
stage
hydralic
jump
H
later
stage
bubles
air
entrainment
Chapter 3. Dimensional Analysis
Section 3.2. The processes in die casting
Shot
Sleeve
heat transfer
to the air
process 1
heat transfer
to the sleeve
process 2
Solidification
layer
(liquid)
liquid metal
(solid)
shot sleeve (steel)
insulation
y
Temperature
y
´
l
Temperature
Chapter 3. Dimensional Analysis
Section 3.2. The processes in die casting
liquid
metal
air streaks
Chapter 3. Dimensional Analysis
pressure
Section 3.2. The processes in die casting
Chapter 3. Dimensional Analysis
Section 3.3. Special topics
Chapter 3. Dimensional Analysis
Section 3.4. Estimates of the time scales in die casting
Chapter 3. Dimensional Analysis
Section 3.4. Estimates of the time scales in die casting
Chapter 3. Dimensional Analysis
Section 3.4. Estimates of the time scales in die casting
Chapter 3. Dimensional Analysis
Section 3.5. Similarity applied to Die cavity
Chapter 3. Dimensional Analysis
Section 3.5. Similarity applied to Die cavity
Chapter 3. Dimensional Analysis
Section 3.6. Summary of dimensionless numbers
Chapter 3. Dimensional Analysis
Section 3.8. Questions
Chapter 3. Dimensional Analysis
12.00
11.00
10.00 "
9.00
8.00 "
"
7.00
6.00
5.00
"
"
4.00
"
3.00
2.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00
Time [sec]
almost
still
flow
Transition
thin
zone
boundary
layer
plus
solidification
U1
U1
U2
U2
Re10^3
Section 3.8. Questions
cooling
liquid
D
H
equilibrioum
level
H
K
M
L
Chapter 3. Dimensional Analysis
D
t
Chapter 4. Fundamentals of Pipe Flow
1
0.1
0.01
0.001
Air
Crude Oil
0.0001
Hydrogen
1e-05
Mercury
Water
1e-06
1e-07
Velocity[m/sec]
1.2
1.0
0.8
0.6
0.4
0.2
0.0
100 1000 10000
Reynolds Number
Head Loss [meter]
0.00
0.00
0.50
1.00
2.00
4.00
8.00
0.02
0.06
0.12
0.25
0.03
0.01
Loss Coefficient
Section 4.3. A simple flow in a straight conduit
Chapter 4. Fundamentals of Pipe Flow
Section 4.4. Typical Components in the Runner andVent Systems
cross section
¸
R
Chapter 4. Fundamentals of Pipe Flow
Section 4.5. Putting it all to Together
Chapter 4. Fundamentals of Pipe Flow
Chapter 5. Flow in Open Channels
g
Flow
y
"
x
d
Section 5.1. Introduction
Y
EL
specific
energy line
Y2
2
specific
thrust line
Y3
3
Y
YC
Y1
1
e, f
Chapter 5. Flow in Open Channels
Chapter 6. Runner Design
vents
vents
Mold
i
j
K
º
a
b
Biscuit
Section 6.1. Introduction
¸
1
¸2
Chapter 6. Runner Design
Section 6.1. Introduction
Chapter 6. Runner Design
Chapter 7. pQ2 Diagram Calculations
Section 7.2. The common pQ2 diagram
gate
mold
3
gate
runner
2
Shot sleeve
1
Chapter 7. pQ2 Diagram Calculations
plunger location
liquid metal reaches
to the venting system
starging filling the cavity
liquid metal pressure at the plunger tip
or the hydralic pressure
cavity
filling
Time
{
Section 7.2. The common pQ2 diagram
Chapter 7. pQ2 Diagram Calculations
P
2
max
smaller
plunger
2
2
2 A CD
Pmax
2
3
1
Q =
Á
2
Q
max
Section 7.2. The common pQ2 diagram
P Q
max
max
1
<"
2
2
<"D
D
P
P
P
max
Q
max
D
1
Chapter 7. pQ2 Diagram Calculations
Section 7.3. The validity of the common diagram
P
A
1
Chapter 7. pQ2 Diagram Calculations
Pbar
A3
Section 7.3. The validity of the common diagram
P1 Q
1
<"
2
<"DP
DP2
1
<"
DP
P1
u3
Q
D1
Chapter 7. pQ2 Diagram Calculations
P1
2
Á
Qmax
2
2
2 A CD
3
Pmax
Section 7.4. The reformed pQ2 diagram
Chapter 7. pQ2 Diagram Calculations
Section 7.4. The reformed pQ2 diagram
Chapter 7. pQ2 Diagram Calculations
KF
K0
A3
Section 7.4. The reformed pQ2 diagram
Chapter 7. pQ2 Diagram Calculations
gate
mold
3
area
0.01 [m]
gravity
A-A
0.008 [m]
flow direction
L
0.01438 [m]
A A
A2
2
runner
shot
1
entrance
sleeve
Section 7.4. The reformed pQ2 diagram
Chapter 7. pQ2 Diagram Calculations
U3
common model
realistic velocity
A3
Section 7.4. The reformed pQ2 diagram
pressure
efficiency
power
P
power
·
Q
Chapter 7. pQ2 Diagram Calculations
1
0.8
0.6
P
4
0.4
P= 1 - Q
2
P= 1 - Q
0.2 P= 1 - Q
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Q
Section 7.4. The reformed pQ2 diagram
atmospheric
PB
2
DR pressure
P1 D1
DB PB1
rode
plunger
hydraulic
piston
Chapter 7. pQ2 Diagram Calculations
Section 7.4. The reformed pQ2 diagram
liquid
the moving part of
metal out
the control volume
UP atmospheric
pressure
air flow
in
PB
2
PB1
friction is neglected
Chapter 7. pQ2 Diagram Calculations
Section 7.4. The reformed pQ2 diagram
U3
common model
realistic velocity
A1
possible max
Chapter 7. pQ2 Diagram Calculations
Section 7.6. The Intensification Consideration
Chapter 7. pQ2 Diagram Calculations
Chapter 8. Critical Slow Plunger Velocity
1
vp
vw
2
H
h1
v1
h2
P1
P2
L(t)
Section 8.2. The common models
initial height
Chapter 8. Critical Slow Plunger Velocity
1
vw-vp
v=0
2
2R
v1
h1
vw
h2
P1
P2
L(t)
Section 8.2. The common models
Chapter 8. Critical Slow Plunger Velocity
Section 8.3. The validity of the common models
Chapter 8. Critical Slow Plunger Velocity
Section 8.4. The Reformed Model
16.00
..
14.40 momentum
..
.
..
.
12.80 energy
..
.
..
.
..........
.
..
11.20 Miller
..
..
..
9.60 Karni
..
..
..
Fr
8.00 Garber ..
..
.
..
6.40
...
...
...
4.80
..
...
.
...
.
....
3.20
.
...
.
....
.
.
.....
.
.
.
.
1.60 .
.
.
.
.
.
.
.
.
.
.
.
. .........
.
.
.
.
.
.
.
. ...... .
. . . .
................. . ................
0.00
0.00 0.17 0.33 0.49 0.66 0.83 0.99 1.16 1.32 1.49 1.65
h
2
R
Chapter 8. Critical Slow Plunger Velocity
Section 8.5. Summary
Chapter 8. Critical Slow Plunger Velocity
maximum
shrinkage
porosity
porosity
wall thickness
Chapter 9. Venting System Design
Section 9.2. The common models
Chapter 9. Venting System Design
Section 9.4. The Analysis
Chapter 9. Venting System Design
Section 9.5. Results and Discussion
Chapter 9. Venting System Design
Section 9.5. Results and Discussion
Chapter 9. Venting System Design
Chapter 10. Clamping Force Calculations
Chapter A. What The Establishment s Scientists Say
Section A.2. Referee 1 (from hand written notes)
Chapter A. What The Establishment s Scientists Say
Section A.3. Referee 2
Chapter A. What The Establishment s Scientists Say
Section A.4. Referee 3
Chapter A. What The Establishment s Scientists Say
Section A.4. Referee 3
Chapter A. What The Establishment s Scientists Say
Section A.4. Referee 3
Chapter A. What The Establishment s Scientists Say
Chapter B. My Relationship with Die Casting Establishment
Chapter B. My Relationship with Die Casting Establishment
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