On-Line User Help Manual HotFlo!

Runners, Gates and Feed System Data

In this module, you develop and specify all the dimensions of the metal feed system to enable
the casting to be made with the desired characteristics, to enable the die drawing to clearly
detail all the critical dimensions of the gates and runners.

Index and Quick Links to Help Topics on this page

Overview of the
Data Entry Data Entry
Methodology
Feed System Building Gated Runner Data
Hot Chamber Data
Blocks continued..
Fan Gates Gate Land Select Hot or Cold Sprue
Tapered Tangential
  Hot Sprue Exit Area
Runner Gates
Shock Absorber Runner Dimensions Suggested HotFlo! Series
Runner Extension into
  Chosen HotFlo! Series
Shock Absorber
Gated Runner Set to Size Above ! Sprue Runner Data
Segments A1, A2, A3, A4 Angle of Runner to Gate Select Sprue Runner Shape
Distance of Runner from
Feed Runners Runner Exit Area
Land
Tapered Feed Systems Runner Length Sprue Runner Taper
Exit and Entry
Delta Depth No of Identical Sprue Runners
Dimensions
Joining Runners Set to Size Below Sprue Runner Exit Width
Runner Shape Runner Depth Sprue Runner Entry Width
Data Entry Runner Width Sprue Hole Diameter
Required Runner
Section 1: Fan Gates Sprue Post Diameter
Diameter
Runner Width
Fan Gate - Design Details Clearance, Sprue hole to Post
Reduction Angle
Section 2: Tapered Runner Entry Area Sprue Hole Length
Tangential Runner
Gates
Runner Definitions Runner Mass Nozzle Bore Location Clearance
Shock Absorber Data Feed Runner Data Reverse Draft Angle in Nozzle
Will Shock Absorbers be
Select Runner Shape Internal Land in Nozzle
used ?
Runner Extension Shape Runner Exit Area Runner Dimensions in Sprue Post
Gated Runner Data Runner Taper Sprue Hole Diameter at Entry
Select Runner Shape Length Minor Bore Hole Diameter
Distance from Gate End No of Identical Runners Draft Angle of Sprue Hole
Available Gate Length Runner Dimensions Sprue Runner Mass
No of Gate Channels   Sprue Cone Mass
Length of each Gate
  Total Sprue & Runner Mass
Channel
Gating & Runner
Gate Depth Dimensions for Cold Chamber Data
Toolmaking
Desired Flow Angle from
  Length of Biscuit Desired
Gate
Actual Gate Area    
Effective Gate Area    
Shock Absorber Diameter    

Overview of the Methodology

We start with a blank page, and we need to specify all the dimensions of the total metal feed
system from the very end of the runners all the way back to the hot chamber and nozzle or the
cold chamber shot sleeve.

The methodology used by DC–CALC starts at the very end of the runner, and works backwards
from that point. This is in the opposite direction of the flow of the molten metal, but this
important point is the key to the methodology. By starting downstream, we can define the
metal speed and direction at each part of the feed system, and thereby create a casting with
the required characteristics.

The metal feed system is critical to the Die Casting process, and therefore must be given
adequate attention.

However, we also want to get a quick result, so DC–CALC has been designed to make the
process as efficient as possible. Firstly, it assumes that you want to make either a single cavity
die, or else a die with multiple identical cavities. This means that you only have to specify the
gated runners once. All the other gated runners will be identical, and they can be simply
joined together with feed runners all the way back to the nozzle or shot sleeve.

If you wish to make a ‘family die’, which has multiple different cavities, you can still use DC–
CALC to help with the basic specifications, but the details for each cavity will have to be
specified with a manual calculation. In effect, you treat a ‘family’ of parts as if it was a single
cavity.

Definition of the Feed System Building Blocks

It is useful to think of a Die Casting metal feed system as being constructed of a number of
standard 'Building Blocks' which can be joined together to create the total system. At all times,
it is important to keep in mind the end result we want to achieve in terms of the casting
properties, as well as the physical constraints of a mass of moving metal.

The main buiding blocks are:

Fan Gates

Tapered Tangential Runner Gates

Shock Absorbers
Gated Runners

Feed Runners

Sprue runners

Fan Gates

A Fan Gate is created when a feed runner, (either trapezoidal

or circular in cross section) is blended smoothly into a thin
wide gate into the edge of the casting. To avoid air
entrapment and high pressure losses fan gates should be
carefully designed so that the cross-sectional area of the
runner decreases continuously towards the gate.

DC–CALC enables you to quickly design and specify the

dimensions of all forms of fan gates.

In the early days of pressure Die Casting, nearly all castings were made with fan gates of which
there are four main forms: -

Fan gate with linear width

Here the sides (width) are straight lines from the feed runner to
the gate land. To maintain a smooth converging flow path, the
depth in the fan gate runner must be machined curved.

Fan gate with linear depth

Here the depth from the feed runner to the gate land proceeds
in a straight line (linear) but the sides must be curved to ensure
a smoothly varying area.

Paddle gate

Here a section of the fan gate runner nearest the gate land is
made with 'parallel sides'. A paddle gate can be made with
either linear width or linear depth.

The name derrives from the fact that it looks a little like the
shape of a paddle used in a canoe or boat.

Chisel gate

Here the runner and the gate are the same width. The metal
flows along the runner, which then steps down through the gate
land and the gate, into the cavity. It looks similar to the shape of
a woodworking chisel.

The schematic illustration to

the left shows a 'chisel gate'.
In this case the runner is
trapezoidal in cross section,
but it could just as easily be
circular.

Flow Angle

The Flow Angle is the angle at which the metal flows into
the cavity . It is measured relative to a line drawn normal
(at a right angle (90 degrees)) to the gate. So with a zero
flow angle, the metal flows directly across the cavity from
the gate. With a high flow angle, it flows out to the sides.

In a fan gate, as illustrated to the right, the metal sprays

into the cavity at a range of diverging flow angles, wide at
the edges and straight ahead in the middle.

It is also possible to design a fan gate so that nearly all the metal flows into the cavity at a low
flow angle by adding a segment of runner near the gate which has parallel sides, a paddle gate.

Advantages of Fan Gates

Low flow angles possible

Small fan gates very effective at directing metal into critical areas
Chisel gates are good for thick walled parts.

Shortcomings of Fan Gates

Large ratio of runner mass to gate area gives low yields

Significant metal pressure losses
High heat losses
High potential for air entrapment if not carefully dimensioned

In seeking a way around the shortcomings of fan gates, the CSIRO Research Team in
Melbourne, Australia, developed the Tapered Tangential Runner Gate which has several
distinct advantages. See below.

In many dies, the best way of gating the cavity is by using a combination of both gating
systems:-

- tapered tangential runner gates for controlled flow angles on long casting edges

- fan gates in short critical regions of the cavity.

See also: Design Details for Fan Gates

Tapered Tangential Runner Gates

These are created by making the feed runner

branch into one or more tapered runners
which travel along an edge of the casting,
from which a gate is cut.
The flow angle of the metal into the cavity
can be precisely controlled by careful
specification of the runner dimensions and is
invariant to machine settings.

Advantages of Tapered Tangential Runner Gates

Low metal pressure loss = high gate velocity

Low metal heat loss to the die
Controlled flow angles
Low runner mass = high casting yields
Long gates easily fed

Shortcomings of Tapered Tangential Runner Gates

Low flow angles difficult to achieve

The 'delta region' between two branching runners

The elements of a Tapered Tangential Runner System are described below.

Shock Absorber

Small circular pockets, which trap a bubble of air in the centre

and absorb the pressure shock when the runner system
suddenly becomes full. This helps prevent a spurt of metal
rushing into the cavity before the main metal stream.

Shock absorbers are not always necessary, but DC–CALC enables you to specify them in detail.
It is a reasonable tactic to design the die to accommodate them, but to perform the first trials
without them. If they are found to be required, machine them in at a later time.

Runner Extension into Shock Absorber

This is the small segment of runner, which connects the end of the gated runner to the shock
absorber. It is usually not tapered.

Gated Runner

This is a tapered tangential runner which has a long thin gate, or a series of short gates leading
to the cavity ( known as a "comb gate").

For each cavity, gated runners can have either one branch, or two branches, referred to as
Branch A and Branch B.
Segments A1, A2, A3, A4

In each gated runner branch, DC–CALC allows you to have up to four different segments, each
with a different flow angle into the gate.

Mostly, you would only use one flow angle per cavity, sometimes two, and very rarely would
you require four. The sketch above shows one branch of a gated runner with three segments
and three different flow angles.

Feed Runners

You can define a whole network of feed runners, depending on how many cavities there are in
the die, and how they are placed in relationship to the hot chamber nozzle or cold chamber
shot sleeve.

Feed runners should always be joined with

smooth bends to minimise turbulence and
pressure losses. The sketches here are
included to illustrate the many different
ways in which feed runners can be
combined: branches of 2, branches of 3,
branches of 5, or no branches at all.

In any die you can define up to eight different sized feed runners, but you can have any
number of each size. This leads to a very large number of combinations.

Tapered Feed Systems

The metal feed system should be designed so that the total area of the feed system decreases
as the metal moves from the nozzle, or shot sleeve, to the gate.

This minimises air entrapment and pressure losses and will increase your probability of
making a high quality casting.
Since DC–CALC starts at the end of the runner and works backwards in this design procedure,
we ensure that the metal feed system area always increases towards the source.

Exit and Entry Dimensions

To simplify the process of specifying the total feed system, DC–CALC establishes two key
parameters for each runner – the Exit area and the Entry area. (Since we are working
backwards from the end of the runner, we always start at the Exit!).

Joining Runners

Runners are joined together observing 3 simple rules:-

The Exit Area of a runner equals the Entry Area of the previous downstream runner.

The Entry Area of a runner is greater than (or sometimes equal to) its Exit Area.

Where 2 or more branch runners come together, the Exit Area of the upstream feed
runner is greater than or equal to the sum of the Entry Areas of the branches.

Runner Shape

DC–CALC expects the runner shape to be one of two kinds – 'Trapezoidal' or 'Circular' (T or C).
See: 'Circular versus Trapezoidal Runners'

Once you specify the shape, DC–CALC quickly calculates the dimensions. For Trapezoidal
Shapes, you enter a depth and it will calculate the width so as to equal the required Area. For
Circular Shapes, it will calculate the diameter.

Data Entry

Section 1: Fan Gates

Fan Gate Design Details

See also: Introduction to Fan Gates

Fan Gate Identifier

You can define up to 4 different Fan-
gate sizes per cavity. Identify each
size/type with your own description,
number, letter or location.

The illustration to the right shows

the main sections of a fan-gate
runner. The gate land is usually
from 1 to 3 mm wide. (0.040" to
0.120"). In this example the is no
"parallel" side to the runner just
before the gate land, so the flow
angle into the cavity will be greater
at the edges.

The Fan-gate shown on the right has

a short section where the sides of
the runner are "parallel" just before
they connect to the gate land. This
has the effect of forcing the metal to
flow into the cavity at a right angle
to the gate. ie a zero flow angle. The
length of parallel runner needs to be
proportional to the width of the gate.

Number of identical Fan-gates per cavity

For each identified Fan-gate, you can have as many as required feeding into the cavity. A
typical example is to have say 10 small chisel gates feeding into the edge of a casting to achieve
a zero flow angle. Alternatively, two small fan gates might feed into a thick wall section. Yet
again, one small fan gate might be used into the 'delta region' between two tangential runner
gates.

Taper in the runner

This refers to the percent increase in the runner, from the 'parallel' section (if any) to the entry
to the Fan-gate runner. Because you have to force the high speed molten metal stream to
change from the direction along the feed runner out to each side at the same time squeezing
down in thickness, you need to allow a generous percentage of taper. A typical amount would
be 50%, but 100% is quite common. The larger the amont of taper, the lower the pressure
losses, the greater the speed of metal through the gate and the less air will be mixed into the
metal stream.
Linear Depth or Linear Width

To ensure a smooth flow of

metal without air entrapment,
the Fan-gate runner must
increase in area away from
the gate.

If you make the Depth a

straight line (Linear) as in the
top illustration right, the sides
(Width) will be curved.

Conversely, if the Width is

linear, the depth will be
curved.

It is more common for the

Depth to be chosen as linear.

The equations for all

dimensions are shown in the
illustration.

DC-CALC automatically
calculates all these runner
dimensions for you.

At the gate

In this section of the worksheet, you need to enter a few basic dimensions so that DC-CALC can
complete all the dimensional specifications. All 'Distances' are measured from the gate. Enter
the Width of the gate and the Depth of the gate.

At the entry to the gate land, the width is always the same as the gate width, but the depth is
usually greater to create a smooth entry. A depth increase from 20% to 50% is quite common.
The 'Distance from the gate' defines the gate land, and 1 to 3 mm is quite common (0.040" to
0.120").

At the entry to the parallel section, you need to define the distance from the gate where the
parallel section begins. For example, if the gate land was 1.5mm (0.060")and the parallel
section was 5mm (0.200") then the 'Dist. from gate' would be 6.5mm (0.260"). You must also
define the Depth, which would usually be greater than the depth at the entry to the gate land.
At the entry to the Fan-gate runner, you define the distance to the gate and the Width of the
feed runner at this point. Have a look at the calculated Depth of the runner at this point. Make
sure it is not too shallow (high heat losses) or too deep in relation to the width (extraction or
ejection problems). A ratio of 1 to 1 is a good target. Change the Width until the calculated
Depth is appropriate.

Fan-gate runner mass

DC-CALC displays the mass of the identified Fan-gate runner, both individually and for the
total if there are multiple runners per cavity.

Angle of runner to gate

For a Fan-gate, the runner usually is at a right angle to the gate (90 degrees). If you require the
runner to be at some angle other than 90 degrees, specify it here. This will have the effect of
changing the average Flow Angle of the metal into the cavity. For example, if the runner is at
80 degrees (or equivalently 100 degrees) then the effect on the flow angle will be to increase it
by 10 degrees.

DC-CALC displays both the estimated average flow angle from the Fan-gate and the total flow
angle including the effect of an angled runner. Also displayed is the actual gate area and the
effective gate angle due to the flow angle.

The definition of all Fan-gate dimensions are illustrated below.

At the Runner Points 1 to 9, DC-CALC displays the Width, Depth and 'Dist. from gate' which is
required to create a smooth runner with the taper specified above. These dimensions must be
added to the tool drawing so that the toolmaker can create a Fan-gate which will achieve the
metal flow characteristics required for a high quality casting.

Section 2: Tapered Tangential Runner Gates

This section is where you specify all the dimensions for tapered tangential runner gates. For a
description of the methodology and definitions of relevent feed system building blocks, see
Introduction to Tapered Runner Gates.

Runner Definitions for Each Cavity

A code is assigned to each part of the feed system to help you identify it in other parts of the
worksheet.

Defined Runner Elements Branch A Branch B

Shock Absorber AS BS

Runner Extension AE BE

Gated Runner, Segment 1 A1 B1

Gated Runner, Segment 2 A2 B2

Gated Runner, Segment 3 A3 B3

Gated Runner, Segment 4 A4 B4

Shock Absorber Data

Will Shock Absorbers be used? (Y/N)

You need to specify either Y, Yes or N, No. See "Shock Absorbers".

If you enter N for No, no text will appear in the lines below. If you enter Y for Yes, you will see
additional text as described below.

Runner Extension Shape ‘C’ or ‘T’

Enter 'T' if you wish to use a Trapezoidal shaped extension runner and ‘C’ for Circular.

See definition of "Runner Extension" above.

See: "Circular versus Trapezoidal Runners"

Enter all other data regarding the Shock Absorbers, as requested in the text, using the units of
measure indicated.

Shock Absorber Diameter is the diameter cut into the face of the die, typically 10 to 20 mm
(0.400" to 0.750").

Shock Absorber Depth is the depth into the die, typically 3 to 10 mm (0.120" to 0.400").

Runner Width and Runner Depth or Runner Diameter, refer to the dimensions of the
Runner Extension.

Runner Extension Length is the distance from the end of the gate to the entry to the shock
absorber.

Runner Area is the calculated cross sectional area of the Runner Extension.

Mass shows the calculated metal mass contained in each shock absorber, runner extension
and the total. Keeping this value as small as possible will minimise metal and energy waste.

Gated Runner Data

See definitions: "Gated Runner"

Select Runner Shape

'T'=Trapezoidal, 'C'=Circular

See: "Circular versus Trapezoidal Runners"

Distance from Gate End to End of Segment

You can define up to 4 segments in each gated runner branch. DC-CALC requires you to define
each gated runner segment measured from the same starting point 0, called the ‘Gate End’.
For example, the data for the runner sketched above (in millimeters) is:-

Segment A1 A2 A3 A4
Distance from Gate-End to end of segment 10 25 50 63

Available Gate Length

DC-CALC calculates the length, within this segment, that is available to have a gate cut. There
will be some dies where you may want to cut a gate channel in only part of the available
runner length. This is known as a ‘comb gate'. You would use this when the depth of the gate
becomes so small that atomisation of the metal does not take place and unsatisfactory filling
results.Use the Feasibility worksheet of DC-CALC to determine if atomised flow will occur.

Number of Gate Channels

Length of Each Gate Channel

If you want to use a comb gate in any segment, these two cells are how you specify this to DC-
CALC.

For a normal, fully gated runner you would enter 1 for the 'Number of Gate Channels' and set
the length to the total available gate length for the segment. For Example, you might want to
cut a comb gate in segment A3, and could enter

No. of Gate Channels 4

Length of Each Gate Channel 3mm (0.120")

Gate Depth

Enter the depth of the gate, in each segment. Here you could choose different depths in each
segment if you require.

Note that if you want to cut the gate into each die half, you should enter here the sum of the
gate depths in both die halves.

Desired Flow Angle from the Gate

The Flow Angle is measured from a line at 90 degrees to the gate. Be

aware of this, because if you measure it from the gate you will end up
with incorrect results. The flow angle of the metal is one of the most
important elements of high pressure Die Casting die design. It is
effected by the gate area and the runner area.
The ability to specify the Flow Angle is a most
important design tool. A low flow angle (say 30°
-35° ) will direct more of the metal stream to the
centre of the casting. A high Flow Angle (say 35°
-45° ) will direct more to the end of the casting.

You can specify a different Flow Angle for each segment if you wish. This is illustrated on the
diagram above. The segment nearer the shock absorber is using a higher flow angle than the
segment closer to the feed runner.

It is a good idea to draw a sketch of the cavity and the gate and add arrows to indicate the
metal flow at the required Flow Angle for each segment.

It is not necessary for the runner to be a straight line. It should follow the contour of the edge
of the casting.

To the far right of this line on the worksheet, after the last data input cell for Segment B4, are
two data display cells ‘Average’ Flow Angle and ‘Target Flow Angle’.

The ‘Target’ Flow Angle is the value you entered into the 'Feasibility' worksheet. Because Flow
Angle reduces the effective gate area, it has an effect on the ability of the machine to fill the
cavity.

The ‘Average’ Flow Angle, is calculated from the various Flow Angles you enter into segments
A1 to B4. If you find that the average is not the same as the Target, you should go back to the
'Feasibility' worksheet, enter the new Average Flow Angle into the appropriate cell and double
check that the fill time and gate velocity are still acceptable.

Actual Gate Area

Effective Gate Area

This data is the net result of all the data you have entered in the 'Gated Runner Data' section so
far.

Whether you have designed a continuous gated runner, a comb gate, a single segment or 8
segments, a common Flow Angle or 8 different Flow Angles, the net results these will have on
the actual and effective gate areas are displayed here.

The last column ‘Target’ comes from the 'Feasibility' worksheet and if your Total Area (in the
second last column) is significantly different to the ‘Target’, you should return to the Feasibility
Worksheet and change the gate depth or length so that it equals the Total.

This is part of the design feedback loop, which is required to refine your parameters.

Gate Land
This is the width of the small parallel cross section through the gate. It represents the
separation of the cavity from the Runner or the ‘Delta’ zone.

Runner Width, Depth or Diameter at End of Gate

The runner dimensions must be specified at the end of the gate since this is the starting point
for the calculations. Keep these dimensions as small as possible to reduce runner mass. If
Shock Absorbers have already been specified, then these dimensions should be set to the same
dimensions of the Runner Extension. (See under: Shock Absorbers).

Set to Size Above!

For Circular Runners, this cell should be set to the same value of the cell above to avoid
possible problems with self-referencing equations.

Angle of Runner to Gate

This allows for the possibility that you might not

want to have the runner parallel to the gate, but
approaching at an angle.

One reason you might consider designing such a feature is to assist in reducing the Flow Angle.

To get a very low Flow Angle (say 20° ), and to avoid the runners becoming excessively large in
area (and therefore mass), having the runner at an angle to the gate will help. The runner is
joined to the gate through a thin region called a ‘delta’ region.

Distance of Runner from the Land

For normal runners which are parallel to the gate, this would be set to zero.

But for Runners at an Angle to the gate, as

described above, you have the option to have the
exit (end) of the runner some distance from the
land which may help in placement of runner
extensions and shock absorbers.

Entry

DC-CALC will calculate and display the distance of the runner from the land at subsequent
segments (Entry points).
Runner Length

This calculation is only used for Runners at an Angle to the Gate (described above), in order to
calculate the runner mass accurately.

Delta Depth

At any segment where the Runner diverges from

the Gate land, you make a thin channel between
them, and this is referred to as a ‘Delta’ region.

Typically it occurs in the small triangular space

where two tapered tangential runners diverge.

   

However, it is also required when you

design a runner to be cut at an ‘Angle to
the Gate’, as shown to the left.

If you have a Delta region in your design enter its average depth into this cell, in millimetres. It
is usual to cut the Delta region so it tapers slightly, decreasing in cross section towards the gate.

Set to Size Below

For Circular Runners, this cell should be set to the same value of the cell below to avoid
possible problems with self-referencing equations.

Runner Depth

For Trapezoidal Shaped Runners, enter the preferred depth of the runner at the Entry of each
segment.

Runner Width (at half depth)

For Trapezoidal Runners, DC-CALC will display the required width of the runner at the Entry
of each segment.

If the width is not practical, change the depth, above, until you obtain a satisfactory result.

With trapezoidal runners, by definition, their 'width' varies with depth. So, as standard
practice, it is always specified at the halfway depth position. The width will be greater above
this point, and smaller by exactly the same amount below it. For this reason we can still
multiply the width (at half depth) by the depth to get the cross sectional area of a trapezoidal
runner.

Required Runner Diameter

For Circular Runners, DC-CALC will display the required diameter at the Entry to each
segment.

Runner Width Reduction Angle

This is the calculated angle between the two side walls of the runner, created by the tapering
of the runner.

Runner Entry Area

This is the area at the Entry of each runner segment, it is used in the Feed Runner design,
described below.

Runner Mass

DC-CALC calculates the mass of the runner and delta zone to help you assess the amount of
wasted material you are designing.

Feed Runner Data

By definition, a feed runner does not have a gate. Here you create and enter information about
the feed runner in the die, be it a simple, single feed runner or a whole network of different
sized runners. They are designated FR1, FR2, FR3.....

A feed runner can be straight or curved, but DC-CALC is only concerned with the dimensions
at the Exit and Entry.

Select Runner Shape

Enter 'T' for Trapezoidal and 'C' for circular.

Runner Exit Area (Cell formula)

Because there are so many different ways you can join a network of feed runners, the data
entry into these cells is designed to allow you many possibilities.

The data in this cell tells DC-CALC the Exit Area of the feed runner, as a formula which relates
to other downstream runners.

The Exit Area of a feed runner is the sum of the Areas of the downstream Runners it has to
feed.
You can have up to 8 different sized feed runners, but you can have as many of each size as
you require.

Step 1 : Join a Fan-gate Runner or Gated Runner to a Feed Runner.

The Feed Runner FR1 (or Sprue Runner) needs to have its Exit Area set to the same, as, or
greater than, the area of the Fan-gate Runner, Gated Runner, or othe Feed Runners, that it
feeds.

Look at the row ‘Runner Entry Area’ in the Gated Runner Data Section above.

Select the last segment of Gated Runner Branch A, which has a non-zero 'Runner Entry Area'
displayed. Note its Column Letter Header at the top of the screen, and its Row Number at the
left edge of the screen.

(For example, if there is only one segment in the gated runner, A1, and its Column is D and its
row is 118, its cell reference is D118).

Do the same for Branch B.

Return to ‘Runner Exit Area' (cell formula) for FR1 and enter the formula for the area:-

=(Area of Last Segment of Branch A) +

(Area of Last Segment of Branch B)

Examples:

=D118 + H118 (or D214 + H214)

=E118 + J118 (or E214 + J214)

=(E118 + J118) x 1.05

This last example says that the Exit Area equals (the Entry Area E118 plus the Entry Area J118)
plus 5%.

Step 2 Join the Feed Runners Together

If for example, two feed runners branch from one larger feed runner which leads to the metal
source, use the same cell formula technique, described above, to combine the Exit and Entry
areas. If there are two identical runners joining to a single upstream feed runner, then you
must specify that in the Cell formula. For example=2*E118

Continue this process until you arrive back at the hot chamber sprue or the cold chamber shot
sleeve.

Quick Reference
As a quick reference, the Exit Areas for the various Runner types in DC-CALC Version 2.8, can
be found at the Rows and Columns listed below:

Metric Non-Metric Multi-Lingual

 
Version Version Version
F30 or L30 F30 or L30 F52 or L52
Fan-gate Runners
F54 or L54 F54 or L54 F97 or L97
Tapered tangential Runners Row 118, D to K Row 118, D to K Row 214, D to K
Feed Runners Row 138, D to K Row 138, D to K Row 244, D to K

Runner Taper

This is the % change in the area of the feed runner, along its length, which is necessary to
create a fully tapered runner system to minimise pressure losses and entrapped air in the
molten metal.

Because the DC-CALC process starts at the gate and works BACKWARDS, the taper in any
length of feed runner makes the Entry larger than the Exit by the % entered into this cell.

Length

Enter the length of this Feed Runner.

Number of Identical Runners

Because you can have multiple (identical) cavities in the die, and different ways of joining up
the Feed Runners, here you enter the total number of each identical feed runner in the die.
This data is used to calculate the mass of the runner system you are designing. It is not used to
calculate the exit area of the feed runners. You have to do that by entering it into the Cell
formula for the runner area.

Runner (Entry/Depth, Width, Diameter) and Area and Mass

Based on the above input data, DC-CALC will display the calculated dimensions, and area, for
the Entry of each Feed Runner, and its mass.

Hot Chamber Data

Enter this section only if you are designing a feed system for a traditional Hot Chamber
machine, where the molten metal comes through a sprue hole in the back of the die.

If it is a multi-slide machine with the metal injected into the parting line of the die, you can
specify all elements as Feed Runners in the section above.
Select Hot Sprue or Cold Sprue ‘H’ or ‘C’

‘H’ refers to the HotFlo! hot sprue system. ‘C’ refers to a traditional cold sprue with a conical
sprue post with runners cut into the sides.

Hot Sprue Exit Area (Cell formula)

This line will appear if you have entered 'H' for Hot Sprue system in the line above.

Here you must enter a spreadsheet cell formula similar to the way described in Runner Exit
Area (Cell formula) above.

Enter a formula to relate the area of the appropriate Feed Runners (FR1, FR2, .....FR8) to the
HotFlo! sprue exit.

For example, if you were proposing to use a HotFlo! sprue with a Mono Tip Style (single
runner outlet), and you wanted to connect it to Feed Runner FR4, you would enter :

=G81

where G81 is the spreadsheet cell reference for the Entry Area of FR4.

If you are using a Duo Tip Style (two runner outlets), you need to be aware that the Runner
Entry Area of the Feed Runners FR1, FR2,.... is, in each case the area of a single runner.
Therefore you may need to enter a factor in the cell formula to specify the correct runner area.

For example, if you were connecting to two identical copies of Feed Runner FR4, you would
enter :

=2*G81

Suggested HotFlo! Series from Feasibility Analysis

DC-CALC arrives at this suggestion using the data you entered in the 'Feasibility' worksheet. Is
based on the rule of thumb that the sprue area usually needs to be twice the gate area. It does
so in order to arrive at a quick feasibility suggestion of the HotFlo! Series you are likely to
require, without doing the full runner design. However, once you reach this point in DC-CALC,
you have now specified the runner system in detail. You now need to review the rule of thumb
suggestion to see if it is satisfactory.

Is the 'Hot Sprue Exit Area' less than or equal to the area of the 'Suggested Series from
Feasibility Analysis' ?

If not, you can either choose a larger HotFlo! sprue kit ( see below), or revise your runner
design to make it smaller.
Revising the runner design means going back over some of the assumptions you made along
the way. You can change them in DC-CALC to see how much effect they will have on the sprue
area. (Remember to make a copy of the DC-CALC file, or take a note of the values before you
change them.) Some of the data you should review is :

Flow Angle : a greater Flow Angle will reduce runner and sprue size.

Taper : by reducing the amount of taper in the feed runners, it will decrease the required
sprue area.

Number of Cavities : Less cavities require a smaller sprue area.

Chosen HotFlo! Series

If the area of the 'Suggested Series from Feasibility Analysis' is smaller than the 'Hot Sprue Exit
Area' (above), and you have reviewed the runner design as described in the paragraph above,
without success, then you can specify here a HotFlo! Series with a larger exit area.

If the area of the suggested Series is adequate, enter the suggested Series number.

Sprue Runner Data

This appears if you specified 'C' in 'Select Hot Sprue or Cold Sprue' above.

A cold sprue means that the metal in the sprue hole will solidifiy and must be extracted with
each shot. The lines below will appear in DC-CALC to enable you to fully design and specify
the cold sprue system. It will also calculate the mass of metal in the sprue system to enable you
to judge the savings that could be made by going to a HotFlo! sprue system.

A Sprue Runner is cut into the sprue post (and sometimes the sprue
bush also) to create a runner channel to join with the feed runners at
the die face.

DC-CALC allows you to design a traditional cold sprue with up to four

Sprue Runners, designated SR1, SR2, SR3 and SR4.

Select Sprue Runner Shape ‘T’ or ‘C’?

This is only required if you are designing a traditional cold sprue with runners cut into the
sprue post.

Enter ‘T’ for Trapezoidal shape sprue runners or ‘C’ for Circular.

Runner Exit Area (Cell formula)

Similar to the technique in ‘Feed Runners’ above, enter the formula for the sum of the Feed
Runner Areas to which each Sprue Runner will join.

Sprue Runner Taper to Nozzle

How much larger, entered as a %, will the entry to each Sprue Runner be, compared to its exit.

Number of Identical Sprue Runners

You have the option to create more than one copy of each Sprue Runner SR1, SR2, SR3, SR4. For
example, a sprue post with 2 identical sprue runners cut into each side could be designed as
SR1, with 2 copies, to speed up the data entry.

Sprue Runner Exit Width

Sprue Runner Entry Width

Enter the width of each Sprue Runner at its exit and entry. This gives you the option to taper
the width of the sprue runner to match the conical shape of the sprue post. If you make it
thinner at the top, it will also be deeper at the top, and vice versa. DC-CALC displays the depths
under ‘Runner Dimensions in Sprue Post’ described below.

Sprue Hole Diameter at Base

The diameter of the sprue hole in the fixed die half, at the
parting line.

   

Sprue Post Diameter at Base

The diameter of the sprue post at the parting line.

It must be smaller than the sprue hole at the parting line, and usually it is made at least 1mm
(0.040") smaller to create a thin conical shell of die cast metal around the post. Whilst this
conical shell of material is not desirable from a metal flow point of view, it provides
mechanical strength to the solidified sprue on ejection.

Clearance, Sprue Hole to Post

DC-CALC assumes you will create a constant clearance between the sprue hole and post, and
displays it here.

Sprue Hole Length

Here you enter the length of the sprue hole from the parting line to the
nozzle seat.

Usually it will be the same, or very similar to the thickness of the fixed
die.

This data is used to calculate the mass of the sprue.

Nozzle Bore Location Clearance

To allow for some possible misalignment between the machine

nozzle bore and the sprue hole, the hole in the nozzle is usually
made smaller. This ensures that the ‘pip’ on the end of the
sprue will part cleanly on die opening. This is where you
specify the amount of that clearance.

Enter the required amount of clearance on each side of the

nozzle. If you enter 1mm (0.040") clearance, the sprue hole will
be made 2mm (0.080") greater in diameter.

Note: For dies with a HotFlo!hot sprue system installed, this requirement is not required, and
the bore in the nozzle is made the same size as the sprue entry hole.

Reverse Draft Angle in Nozzle Bore

A small reverse taper is usually machined into the bore in the

nozzle, right at the tip, illustrated as Angle A on the sketch to
the right. Although undesirable from a metal flow point of view
(because it creates an expanding flow path with high
turbulence), it is usually required so that the ‘pip’ of solidified
metal at the tip does not snap off and block the nozzle, but is
extracted cleanly with the sprue. This data is used to calculate
the required sprue hole diameter.

Here you specify the angle per side, in degrees. A 1° angle

entered here will result in a 2° included angle.
Internal Land in Nozzle Bore

This dimension refers to the length of the reverse draft angle in

the nozzle bore described above, before it opens out into the
main nozzle bore. It is shown as dimension B on the sketch to
the right.

Enter the value.

DC-CALC uses this dimension to calculate the minor diameter you will require to machine in
the nozzle tip before adding the reverse taper. This will ensure that the point of greatest
restriction in the nozzle will be large enough to feed the runner system you have just designed.

Much of the data required for the sprue and nozzle tip design are rather tedious to have to
specify, but if you do not do so, you run the risk of inadvertently ending up with a constricting
condition in the nozzle.

This is quite often the cause of inadequate or inconsistent casting quality. Of course, you could
consider eliminating all these sprue-nozzle restrictions altogether by specifying a HotFlo! hot
sprue system.

Runner Dimensions in Sprue Post

DC-CALC displays all the data regarding the Sprue Runners SR1, SR2, SR3, SR4.

Note 1: The ‘Depth’ refers to the depth that the runner must be machined into the post itself.
The actual depth of the flow path, as experienced by the flowing metal, is greater than this by
the amount of the ‘Clearance: Sprue Hole to Post’. See above.

Note 2: ‘Width at ½ depth’ refers to the fact that Trapezoidal

runners have tapered sides, (often with different angles on each
side), and so their width must always be measured at the position
of half the depth.

Sprue Hole Diameter at Entry

DC-CALC displays the diameter you will have to machine at the point of the nozzle seat in
order to satisfy –

A non-restricted metal flow path

Required nozzle location clearance

Required reverse taper angle

Minor Bore Hole Diameter in Nozzle

This is the hole you have to drill in the nozzle before machining the reverse taper angle. See
‘Internal Land in Nozzle Bore’.

Draft Angle of Sprue Hole

DC-CALC calculates the draft angle of the sprue hole as a result of the previously specified Exit
and Entry diameters and length.

Sprue Runner Mass

DC-CALC displays the mass of the runners cut into the sprue post.

Sprue Cone Mass

The mass of the conical shell which results from the clearance between the sprue post and
sprue hole.

Total Sprue and Runner Mass

DC-CALCdisplays the total mass of the sprue and runner mass that you have just designed,
including:

Shock absorbers

Gated Runners

Feed Runners

Sprue Runners

Sprue Cone

If you think there is too much wasted metal in the sprue and runners compared to the part
weight, you should consider redesigning it using a HotFlo! hot sprue system.

Cold Chamber Data

Length of Biscuit Desired

For Cold Chamber machines, enter the desired final length of the solidified biscuit in the end of
the shot sleeve.

DC-CALC will then display the Biscuit Mass and the Total Runner and Biscuit Mass of the
designed feed system.
Runner and Gating Dimensions for Toolmaking

The last part of the worksheet contains a summary of all the important aspects of the gating
and runner system that you have just finished designing. You can print out these next few
pages, and, combined with a few sketches, they can be used to complete the detailed drawing
of the die.

Feasibility DC-CALC HotFlo! Home Page Production & Costs

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