Determine Optimally Sized Gates While
Taking into Consideration PQ2 Analysis
This series provides an approach to gating design based on NADCA sponsored research that integrates considerations from PQ² analysis with traditional views of cavity layout and runner geometry design. The work flow presented emphasizes sizing gates to maximize the process operating window allowing the maximum range for process adjustments without gate modification. Included is instruction on how to use the fill time prediction equation (gating equation) that has a solid basis in heat transfer analysis. This result is important for determining optimally sized gates and its use will be explained and illustrated.
Part 1 - Introduction and Basic Principles - The first session will review the objectives of this webinar series and present several key concepts including: relationship between part quality requirements and process requirements; gating’s influence on quality; implications for total gate area versus multiple gates; fundamental relationships between cavity volume, gate speed, and cavity volumetric fill rate; gate speed and metal pressure relationships using Bernoulli’s principle.
Date: March 27, 2023
Part 2 - PQ² , the Operating Window, Machine Constraints, Relationship to Gates - The session will introduce the PQ² diagram with an emphasis on using quality requirements to size gates and then to evaluate the limitations, if any, that the machine places on the operating window. Procedures to use aspects of PQ² to select the gate area to maximize the operating window are illustrated followed by consideration of plunger selection (or evaluation) and the effect on the operating window is shown.
Date: March 28, 2023
Part 3 - Calculations - In this session uses the ideas introduced in the first two sessions to calculate total gate area requirements by first introducing and demonstrating how to calculate the optimum gate area by computing the maximum fill time. This leads directly to calculation of the gate area that maximizes the operating window. The standard atomization calculation to check gate dimensions is illustrated. The use of the NADCA web app to complete these calculations is also briefly illustrated.
Date: April 5, 2023
Part 4 - Designing Runners, Overflows and Vents. Design Verification - This session addresses construction of the detailed geometry of runners and gates. Cavity layout is briefly discussed followed by main runner geometry construction, with consideration both of heat loss and fluid flow. Procedures to construct tangential and fan gates are introduced along with guidelines for constructing overflows and vents. Use of the NADCA web app to complete these calculations is illustrated. The session concludes with a very brief introduction to the importance of simulation for design evaluation and verification.
Date: April 6, 2023
Part 5 - Practical Example for Aluminum Die Casting - Walk through the PQ² and Gating process with a sample die casting geometry made of aluminum A380 alloy. A look at how to create the PQ² graph and basic design of the gating and runner system. The NADCA PQ² and Gating apps will be used to confirm the calculations.
Date: April 11, 2023
Part 6 - Practical Example for Zinc Die Casting - Walk through the PQ² and Gating process with a sample die casting geometry made of Zamak 3 alloy. A look at how to create the PQ² graph and basic design of the gating and runner system. The NADCA PQ² and Gating apps will be used to confirm the calculations.
Date: April 12, 2023
Register for the Series
Register for a Webinar:
Part 1 - Introduction and Basic Principles
Part 2 - PQ² , the Operating Window, Machine Constraints, Relationship to Gates
Part 3 - Calculations
Part 4 - Designing Runners, Overflows and Vents. Design Verification
Part 5 - Practical Example for Aluminum Die Casting
Part 6 - Practical Example for Zinc Die Casting
These webinars will take place at 12pm CDT on the dates listed. The cost per webinar is $69 for Corporate Members, $99 for Individual Members or $119 for Non-Members. Please note that registering for a webinar grants you access to the live broadcast on the given date. No recordings or pdfs of the presentation will be issued.