Effects of Fan Gates’ Design Parameters on Flow Behavior in a High Pressure Die Casting Process

Abstract

Gas porosity and surface defects are common problems found in High Pressure Die CastingProcesses (HPDC). Flow pattern of liquid metal is one the main factors contributing to those problems. Toprevent such problems, distributed flow pattern from ingate to overflow is required. Mainly, ingate positionand gate design are factors controlling the flow pattern.

Gating system design for HPDC processes is based on the mass flow rate conservation law. Thereare 2 main variables in fan gate design, including flow angle and the ratio of runner’s cross section areato the ingate’s cross section area. In this research, the effects of these factors to the liquid metal flowbehaviors are investigate using casting process simulation software. Results from the study are used todesign gating system for the part’s production. Beside the defect reduction problem, the study also showsthat by applying the gating design principle, a better casting yield can be achieved. This results in lowermaterial and melting energy cost.

Keywords : High Pressure Die Casting / Fan Gate / Distributed Flow / Gating System Design