BIG FLANGE

SMAC MANESAR
VISHAL RAJPUT

TONNAGE
Casting M/C Cap.
Projected Area Projected M/C Cap.
add_30% Pressure M/C Cap. Kgf TON with
mm2 Area CM2 TON
kgf /cm2 safety factor

51700 10340 620.4 1100 682440 682.44 818.928

GATE AREA
WEIGHT OF CASTING
Gate velocity
VOLUME filling time Gate area Gate area
runner +over total weight CM3 (sec.) cm2 mm2
Casting weight grm flow grm grm cm/sec.

560 501 1061 408.1 8000 0.04 1.28 128

PLUNGER DIA 250T casting capacity

VOLUME 2ND FACE Filling time Plunger dia Plunger area Biscuit Plunger dia shot pressure projected Net shot
Tip dia mm shot vol cm3
CM3 FORCE cm/sec Sec. cm cm2 height calulations kfg/cm2 cast area cm2 Weight kfg

408.1 345 0.04 6.00 28.3 20.0 390.2 50 1207 207 625 1.62

60 838 300 901 2.34

70 616 405 1226 3.2
GATE SPEED

VOLUME Gate area VOLUME Gate area

Filling time Gate Filling time Gate
CM3 cm2 (sec.) Speed m/sec cm2 (sec.) Speed m/sec
CM3

408.1 180.00 0.04 0.57 408.1 0.49 0.06 138.80

 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
560.0 V : high speed
138 L3+L1 L3+L1
T= V=
Weight 698.000 gr. V T
The volume of cast products ahead of gate : W1 (cm3) V= 0.025 0.095 0.120
6.00 m/sec.
W 698.000 0.02 0.02
W1=
Aluminum gravity 2.6 268.5 cm3 Proper gate speed
Sleeve surface area : A (cm2) A Sleeve surface area / biscuit thickness 28.28
2
3.142X(Sleeve dia) Sleeve dia: 60 (mm) Gate width 16 1.60
A= S1
4 or 6 (cm) Gate thickness 0.8 0.08
2
28.28 cm S1= 0.128
A=
A
Gate speed= VX
Hi speed injection stroke : L1 (cm) S1
W1 9.49 cm 28.28
L1 = 6.00 = 1324.8 m/sec.
A 94.9 mm 0.128
Hi speed injection postion Setting of intensification pressure
Hi speed injection : L-(L1+L2+L3+L4) 1) Casting pressure
L Initial position 458 mm by defult P1 injection cylinder pressure 260 kgf/cm2
L1 Hi speed injection stroke 94.9 A1 Tip section area 28.28 cm2
L2 Electricity, oil delay = 1.0 cm(10 mm) 10 mm A2 Injection cylinder area 78.55 cm2
L3 Hi speed rising = 1.50-2.50 cm(20mm) 20 mm P 78.55
260 722 kgf/cm2
L4 Biscuit thickness = 2.0-2.50 cm(20mm) for sleeve dia. 60.0 20 mm 28.28
Hi speed injection position = 274 (L1+L2+L3+L4) 2) Casting area
Die locking force 500000
A=
= 129 mm casting pressure 722 692.31 cm2 casting area
 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
705.0 V : high speed
1 L3+L1 L3+L1
T= V=
Weight 706.000 gr. V T
The volume of cast products ahead of gate : W1 (cm3) V= 0.025 0.096 0.121
3.03 m/sec.
W 706.000 0.04 0.04
W1=
Aluminum gravity 2.6 271.5 cm3 Proper gate speed
Sleeve surface area : A (cm2) A Sleeve surface area / biscuit thickness 28.28
2
3.142X(Sleeve dia) Sleeve dia: 60 (mm) Gate width 360 36.00
A= S1
4 or 6 (cm) Gate thickness 3 0.3
2
28.28 cm S1= 10.8
A=
A
Gate speed= VX
Hi speed injection stroke : L1 (cm) S1
W1 9.60 cm 28.28
L1 = 3.03 = 7.9 m/sec.
A 96.0 mm 10.8
Hi speed injection postion Setting of intensification pressure
Hi speed injection : L-(L1+L2+L3+L4) 1) Casting pressure
L Initial position 470 mm by defult P1 injection cylinder pressure 280 kgf/cm2
L1 Hi speed injection stroke 96.0 A1 Tip section area 28.28 cm2
L2 Electricity, oil delay = 1.0 cm(10 mm) 10 mm A2 Injection cylinder area 132.75 cm2
L3 Hi speed rising = 1.50-2.50 cm(20mm) 20 mm P 132.75
280 1314 kgf/cm2
L4 Biscuit thickness = 2.0-2.50 cm(20mm) for sleeve dia. 60.0 20 mm 28.28
Hi speed injection position = 281 (L1+L2+L3+L4) 2) Casting area
Die locking force 500000
A=
= 320 mm casting pressure 1314 380.39 cm2 casting area
 BIG FLANGE
SMAC MANESAR
VISHAL RAJPUT

TONNAGE
Casting M/C Cap.
Projected Area Projected M/C Cap.
add_30% Pressure M/C Cap. Kgf TON with
mm2 Area CM2 TON
kgf /cm2 safety factor

50000 10000 600 900 540000 540 648

GATE AREA
WEIGHT OF CASTING
Gate velocity
VOLUME filling time Gate area Gate area
runner +over total weight CM3 (sec.) cm2 mm2
Casting weight grm flow grm grm cm/sec.

412 570 982 377.7 8000 0.04 1.18 118

PLUNGER DIA 250T casting capacity

VOLUME 2ND FACE Filling time Plunger dia Plunger area Biscuit Plunger dia shot pressure projected Net shot
Tip dia mm shot vol cm3
CM3 FORCE cm/sec Sec. cm cm2 height calulations kfg/cm2 cast area cm2 Weight kfg

377.7 345 0.04 7.00 38.5 38.5 531.2 50 1207 207 625 1.62

60 838 300 901 2.34

70 616 405 1226 3.2
GATE SPEED

VOLUME Gate area VOLUME Gate area

Filling time Gate Filling time Gate
CM3 cm2 (sec.) Speed m/sec cm2 (sec.) Speed m/sec
CM3

377.7 0.49 0.04 192.70 377.7 0.49 0.06 128.47