Contents

• I. BASIC SCIENCE
  • 1. Introduction
    • 1.1 The importance of reducing production costs
    • 1.2 Designed/Undesigned Scrap/Cost
    • 1.3 Linking the Production Cost to the Product Design
    • 1.4 Historical Background
    • 1.5 Numerical Simulations
    • 1.6 ``Integral'' Models
    • 1.7 Conclusion
  • 2. Basic Fluid Mechanics
    • 2.1 Introduction
    • 2.2 What is fluid? Shear streass
      • 2.2.1 Thermodynamics and mechanics concepts
      • 2.2.2 Control Volume, c.v.
      • 2.2.3 Energy Equation
      • 2.2.4 Momentum Equaton
      • 2.2.5 Compressible flow
  • 3. Dimensional Analysis
    • 3.1 Introduction
    • 3.2 The processes in die casting
      • 3.2.1 Filling the shot sleeve
      • 3.2.2 Shot sleeve
      • 3.2.3 Runner system
      • 3.2.4 Die cavity
      • 3.2.5 Intensification period and after
    • 3.3 Special topics
      • 3.3.1 Is the flow in die casting is turbulent?
      • 3.3.2 Dissipation effect on the temperature rise
      • 3.3.3 Gravity effects
    • 3.4 Estimates of the time scales in die casting
      • 3.4.1 Utilizing semi dimensional analysis for characteristic time
      • 3.4.2 The ratios of various time scales
    • 3.5 Similarity applied to Die cavity
      • 3.5.1 Governing equations
      • 3.5.2 Design of Experiments
    • 3.6 Summary of dimensionless numbers
    • 3.7 Summary
    • 3.8 Questions
  • 4. Fundamentals of Pipe Flow
    • 4.1 Introduction
    • 4.2 Universality of the loss coefficients
    • 4.3 A simple flow in a straight conduit
      • 4.3.1 Examples of the calculations
    • 4.4 Typical Components in the Runner andVent Systems
      • 4.4.1 bend
      • 4.4.2 Y connection
      • 4.4.3 Expansion/Contraction
    • 4.5 Putting it all to Together
      • 4.5.1 Series Connection
      • 4.5.2 Parallel Connection
  • 5. Flow in Open Channels
    • 5.1 Introduction
    • 5.2 Typical diagrams
    • 5.3 Hydraulic Jump
  
  
• II. DIE CASTING DESIGN
  • 6. Runner Design
    • 6.1 Introduction
      • 6.1.1 Backward Design
      • 6.1.2 Connecting runner seqments
      • 6.1.3 Resistance
  • 7. Diagram Calculations
    • 7.1 Introduction
    • 7.2 The ``common'' diagram
    • 7.3 The validity of the ``common'' diagram
      • 7.3.1 Is the ``common'' model valid?
      • 7.3.2 Are the trends reasonable?
      • 7.3.3 Variations of the Gate area,
    • 7.4 The reformed diagram
      • 7.4.1 The reform model
      • 7.4.2 Examining the solution
      • 7.4.3 Poor design effects
      • 7.4.4 Transient effects
    • 7.5 Design Process
    • 7.6 The Intensification Consideration
    • 7.7 Summary
    • 7.8 Questions
  • 8. Critical Slow Plunger Velocity
    • 8.1 Introduction
    • 8.2 The ``common'' models
      • 8.2.1 Garber's model
      • 8.2.2 Brevick's Model
      • 8.2.3 Brevick's circular model
      • 8.2.4 Miller's square model
    • 8.3 The validity of the ``common'' models
      • 8.3.1 Garber's model
      • 8.3.2 Brevick's models
      • 8.3.3 Miller's model
      • 8.3.4 EKK's model (numerical model)
    • 8.4 The Reformed Model
      • 8.4.1 The reformed model
      • 8.4.2 Design process
    • 8.5 Summary
    • 8.6 Questions
  • 9. Venting System Design
    • 9.1 Introduction
    • 9.2 The ``common'' models
      • 9.2.1 Early (etc.) model
      • 9.2.2 Miller's model
    • 9.3 General Discussion
    • 9.4 The Analysis
    • 9.5 Results and Discussion
    • 9.6 Summary
    • 9.7 Questions
  • 10. Clamping Force Calculations
  
  
• III. MORE INFO: Appendixes