High Pressure Die Casting(HPDC) Process Development Calculator

By Technical Data-E

🏭 High Pressure Die Casting Process Design & Validation

Engineering Guide: This toolkit provides essential calculations for Die Casting process development based on NADCA (North American Die Casting Association) standards. Thermal constants and density values automatically adjust based on the selected alloy. Input your part geometry to optimize process variables and validate machine compatibility using standard formulas.

NADCA Compliant v2.0 Extended
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📐 Part & Cavity Parameters

Define the basic part geometry and material properties. These parameters form the foundation for all subsequent calculations.

Typical range: 50-2000 cm² depending on machine size
Thin: <1.5mm | Medium: 1.5-3mm | Thick: >3mm
Decorative: 400-600 bar | Functional: 600-800 bar | Pressure-tight: 800-1200 bar
2

🔄 Runner & Overflow System

The runner system delivers metal from the biscuit to the gates. Overflow wells capture first metal and provide backpressure.

NADCA recommends 15-30% for most applications
Typically 10-20% of cavity area
3

⚙️ Machine Parameters

Die casting machine specifications that define the PQ² machine line. These determine the maximum available pressure and flow rate.

Machine Line Formula: P = Pmax × (1 - Q²/Qmax²) Pressure-Flow relationship of the injection system
Common sizes: 50, 60, 70, 80, 90, 100 mm
Modern machines: 6-10 m/s
4

🎯 Pressure Settings

Metal pressure determines part density and surface quality. Higher pressure reduces porosity but increases die wear.

Clamping Force Formula: Fclamp = Pmetal × Atotal × Ks K_s = Safety factor (1.1-1.2)
Decorative: 300-500 | Functional: 500-800 | Pressure-tight: 800-1000+ bar
NADCA recommends 1.10-1.20
5

🚪 Gate Design

Gates control metal entry into the cavity. Gate velocity is critical - too slow causes cold shuts, too fast causes erosion.

Gate Velocity: vgate = Q / (Agate × 100) Q = Flow rate (cm³/s), A_gate = Gate area (cm²)
Die Resistance (Bernoulli): R = ρ / (2 × Cd² × Ag² × 10⁹) Used to calculate operating point on PQ² diagram
NADCA recommends 0.5-0.7 (typical: 0.6)

Recommended Gate Velocities by Material

Material Min (m/s) Max (m/s) Notes
Aluminum3060Lower end for thick walls
Magnesium4090Higher due to rapid solidification
Zinc2550Lower due to higher density

6 🌡️ Thermal Parameters (Fill Time)
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Temperature settings for NADCA fill time calculation. Metal must fill the cavity before freezing at critical locations.

NADCA Maximum Fill Time: tmax = K × [(Ti - Tf + S×Z) / (Tf - Td)] × T K = Heat transfer constant | T_i = Metal temp | T_f = Flow stop temp | T_d = Die temp | S = % Solids | Z = °C per % solids | T = Wall thickness
Aluminum: 640-680°C | Magnesium: 640-680°C | Zinc: 390-430°C
Aluminum: 180-250°C | Magnesium: 200-280°C | Zinc: 150-200°C
Typical: 20-30% for good surface finish

7 💨 Shot Profile Optimization
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Optimize the three-phase shot profile: Slow Shot → Fast Shot → Intensification. Proper slow shot prevents air entrapment.

Critical Slow Shot Velocity (Garber): vcritical = c × √(g × D) × (1 - Fill%/100) c ≈ 0.579 for >50% fill | g = 9810 mm/s² | D = Plunger diameter | Fill% = Sleeve fill ratio
Typical: 15-30mm depending on plunger size

8 💨 Venting & Vacuum System
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Air must be evacuated from the cavity during fill. Insufficient venting causes gas porosity and incomplete fill.

Vent Area (Compressible Flow): Avent = ṁair / (ρair × vsonic × Cd) Empirical: A_vent ≈ 30-50% of gate area

9 ❄️ Thermal Management (Cooling)
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Cooling channels remove heat from the die. Proper thermal management ensures consistent cycle times and part quality.

Heat Load per Shot: Q = m × [Cp × ΔT + Lf] C_p = Specific heat | L_f = Latent heat of fusion
Reynolds Number (Turbulent Flow Required): Re = ρvD/μ > 4000 Turbulent flow ensures efficient heat transfer
Common sizes: 8, 10, 12 mm
Recommended: 1.5-3.0 m/s for turbulent flow

10 🔩 Slide Core (Optional)
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Calculate locking force required for angular pin actuated slide cores.

Slide Locking Force: Flock = Fback / (cos(θ) - μ × sin(θ)) θ = Wedge angle | μ = Friction coefficient (~0.15)
Typical: 15-25° (lower = more mechanical advantage)

🔬 Advanced Settings
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