Fundamentals of Die Casting Design

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	9. TERMINATION
	10. FUTURE REVISIONS OF THIS LICENSE
	ADDENDUM: How to use this License for your documents
CONTRIBUTORS LIST
	How to contribute to this book
	Credits
		Steven from artofproblemsolving.com
		Tousher Yang
		Steve Spurgeon
		Irene Tan
		Your name here
		Typo corrections and other "minor" contributions
Prologue For The POTTO Project
	Preface
	Why Volunteer?
	What Has been So Far
Prologue For This Book
	Version 0.1 January 12, 2009
		pages 213 size 1.5M
	Version 0.0.3 October 9, 1999
		pages 178 size 3.2M
Introduction
	The Importance of Reducing Production Costs
	Designed/Undesigned Scrap/Cost
	Linking the Production Cost to the Product Design
	Historical Background
	Numerical Simulations
	``Integral'' Models
	Summary
Basic Fluid Mechanics
	Introduction
	What is fluid? Shear stress
		What is Fluid?
		What is Shear Stress?
	Thermodynamics and mechanics concepts
		Thermodynamics
		Basic Definitions
		Momentum Equation
		Compressible flow
		Speed of Sound
		Choked Flow
Dimensional Analysis
	How The Dimensional Analysis Work
	Introduction
	The Die Casting Process Stages
		Filling the Shot Sleeve
		Plunger Slow Moving Part
		Runner system
		Die Cavity
		Intensification Period
	Special Topics
		Is the Flow in Die Casting Turbulent?
		Dissipation effect on the temperature rise
		Gravity effects
	Estimates of the time scales in die casting
		Utilizing semi dimensional analysis for characteristic time
		The ratios of various time scales
	Similarity applied to Die cavity
		Governing equations
		Design of Experiments
	Summary of dimensionless numbers
	Summary
	Questions
Fundamentals of Pipe Flow
	Introduction
	Universality of the loss coefficients
	A simple flow in a straight conduit
		Examples of the calculations
	Typical Components in the Runner andVent Systems
		bend
		Y connection
		Expansion/Contraction
	Putting it all to Together
		Series Connection
		Parallel Connection
Flow in Open Channels
	Introduction
	Typical diagrams
	Hydraulic Jump
Runner Design
	Introduction
		Backward Design
		Connecting runner segments
		Resistance
pQ+0.65ex2  Diagram Calculations
	Introduction
	The ``common'' pQ+0.65ex2  diagram
	The validity of the ``common'' diagram
		Is the ``Common'' Model Valid?
		Are the Trends Reasonable?
		Variations of the Gate area, A3
	The reformed pQ+0.65ex2  diagram
		The reform model
		Examining the solution
		Poor design effects
		Transient effects
	Design Process
	The Intensification Consideration
	Summary
	Questions
Critical Slow Plunger Velocity
	Introduction
	The ``common'' models
		Garber's model
		Brevick's Model
		Brevick's circular model
		Miller's square model
	The validity of the ``common'' models
		Garber's model
		Brevick's models
		Miller's model
		EKK's model (numerical model)
	The Reformed Model
		The reformed model
		Design process
	Summary
	Questions
Venting System Design
	Introduction
	The ``common'' models
		Early (etc.) model
		Miller's model
	General Discussion
	The Analysis
	Results and Discussion
	Summary
	Questions
Density change effects
Clamping Force Calculations
Analysis of Die Casting Economy
	Introduction
	The ``common'' model, Miller's approach
	The validity of Miller's price model
	The combined Cost of the Controlled Components
	Die Casting Machine Capital Costs
	Operational Cost of the Die Casting Machine
	Runner Cost (Scrap Cost)
	Start–up and Mold Manufacturing Cost
	Personnel Cost
	Uncontrolled components
	Minimizing Cost of Single Operation
	Introduction to Economics
		Marginal Profits
	Summary
	Question
Fanno Flow
	Introduction
	Fanno Model
	Non–Dimensionalization of the Equations
	The Mechanics and Why the Flow is Choked?
	The Working Equations
	Examples of Fanno Flow
	Supersonic Branch
	Maximum Length for the Supersonic Flow
	Working Conditions
		Variations of The Tube Length (4fLD) Effects
		The Pressure Ratio, P2 P1, effects
		Entrance Mach number, M1, effects
	Practical Examples for Subsonic Flow
		Subsonic Fanno Flow for Given 4fLD and Pressure Ratio
		Subsonic Fanno Flow for a Given M1 and Pressure Ratio
	The Approximation of the Fanno Flow by Isothermal Flow
	More Examples of Fanno Flow
	The Table for Fanno Flow
	Appendix – Reynolds Number Effects
What The Establishment's Scientists Say
	Summary of Referee positions
	Referee 1 (from hand written notes)
	Referee 2
	Referee 3
My Relationship with Die Casting Establishment