PROCEDURETIE BAR LOAD CALCULATIONSELECT THE MACHINE ON WHICH LOAD IS TO BE CALCULATEDFEED THE TOTALPROJECTED AREAFEED THE CO-ORDINATE OF CENTROID WITH REF. FROM M/C CEN. AS SHOWN IN FIG.DON'T TOUCH COLOURED FONTS250T TOSHIBA'!A1250T ZITAI'!A1350T TOSHIBA'!A1500T ZITAI'!A1500T TOSHIBA'!A1650T TOSHIBA'!A1800T TOSHIBA'!A1

250T TOSHIBA'!A1350T TOSHIBA'!A1500T TOSHIBA'!A1650T TOSHIBA'!A1800T TOSHIBA'!A1250T ZITAI'!A1500T ZITAI'!A1

tonnagePROJECTED AREA OF COMPONENT240SQCMPROJECTED AREA OF RUNNER110SQCMPROJECTED AREA OF OVERFLOW10SQCMPROJECTED AREA OF BISCUIT40SQCMTOTAL PROJECTED AREA400SQCMINJECTION PRESSURE800SQCMREQUIRED M/C TONNAGE320TONSELECTED M/C TONNAGE350TON

250T TOSHIBATOTAL PROJECTED AREA570sqcmINJECTION PRESSURE800Kg/sqcmCALCULATED TONNAGE456T121.3844990548113.2241965974SELECTED M/C250TC.D. BETWEEN TIE BAR690mmCENTROID CO-ORDINATE(X)-12mmCENTROID CO-ORDINATE(Y)10mmF1+F2235.9304347826TF1/F20.9436619718F2121.3844990548TNOT OKF1114.5459357278TNOT OKF3+F4220.0695652174TF4/F30.9436619718F3113.2241965974TNOT OKF4106.84536862TNOT OK114.5459357278106.84536862

350T TOSHIBATOTAL PROJECTED AREA580sqcmINJECTION PRESSURE700Kg/sqcmCALCULATED TONNAGE406T81.6564395294SELECTED M/C800TC.D. BETWEEN TIE BAR850mm105.6289722353CENTROID CO-ORDINATE(X)54.4mmCENTROID CO-ORDINATE(Y)-32.9mmF1+F2177.016TF1/F21.1678143331F281.6564395294TOKF195.3595604706TOKF3+F4228.984TF4/F31.1678143331F3105.6289722353TOKF4123.3550277647TOK95.3595604706123.3550277647

420T ZITAI TOTAL PROJECTED AREA420sqcmINJECTION PRESSURE800Kg/sqcmCALCULATED TONNAGE336T82.933191259192.4371313215SELECTED M/C420TC.D. BETWEEN TIE BAR775mmCENTROID CO-ORDINATE(X)21mmCENTROID CO-ORDINATE(Y)17mmF1+F2158.895483871TF1/F20.9159456119F282.9331912591TOKF175.9622926119TOKF3+F4177.104516129TF4/F30.9159456119F392.4371313215TOKF484.6673848075TOK75.962292611984.6673848075

FORPRINTTOTAL PROJECTED AREA420sqcmINJECTION PRESSURE700Kg/sqcmCALCULATED TONNAGE294TSELECTED M/C350TC.D. BETWEEN TIE BAR775mmCENTROID CO-ORDINATE(X)21mmCENTROID CO-ORDINATE(Y)42mmF1+F2139.0335483871TF1/F20.8044237485F277.0514955255TOKF161.9820528616TOKF3+F4154.9664516129TF4/F30.8044237485F385.8814077003TOKF469.0850439126TOKTOTAL PROJECTED AREA420sqcmINJECTION PRESSURE800Kg/sqcmCALCULATED TONNAGE336TSELECTED M/C420TC.D. BETWEEN TIE BAR775mmCENTROID CO-ORDINATE(X)21mmCENTROID CO-ORDINATE(Y)17mmF1+F2158.895483871TF1/F20.9159456119F282.9331912591TOKF175.9622926119TOKF3+F4177.104516129TF4/F30.9159456119F392.4371313215TOKF484.6673848075TOK

MP1250 T ZITAI500 T ZITAI800 T ZITAIMACHINE CENTER125mmMACHINE CENTER175mmMACHINE CENTER250mmC.D. BETWEEN TIE BAR630mmC.D. BETWEEN TIE BAR810mmC.D. BETWEEN TIE BAR1040mmPLUNGER STROKE425mmPLUNGER STROKE600mmPLUNGER STROKE750mmPLUNGER TIP PROTRUSION195mmPLUNGER TIP PROTRUSION250mmPLUNGER TIP PROTRUSION350mmPLUNGER SPEED MAX6M/secPLUNGER SPEED MAX4.5M/secPLUNGER SPEED MAX4.5M/secWORKING PRESSURE140Kg/cm2WORKING PRESSURE140Kg/cm2WORKING PRESSURE150Kg/cm2HYDRAULIC CYL. DIA158.25mmHYDRAULIC CYL. DIA219.5mmHYDRAULIC CYL. DIA234.7mm350 T TOSHIBA500 T TOSHIBA800 T TOSHIBAMACHINE CENTER125mmMACHINE CENTER175mmMACHINE CENTER250mmC.D. BETWEEN TIE BAR775mmC.D. BETWEEN TIE BAR900mmC.D. BETWEEN TIE BAR1110mmPLUNGER STROKE380mmPLUNGER STROKE580mmPLUNGER STROKE750mmPLUNGER TIP PROTRUSION165mmPLUNGER TIP PROTRUSION250mmPLUNGER TIP PROTRUSION350mmPLUNGER SPEED MAX5M/secPLUNGER SPEED MAX5M/secPLUNGER SPEED MAX5M/secWORKING PRESSURE140Kg/cm2WORKING PRESSURE140Kg/cm2WORKING PRESSURE150Kg/cm2HYDRAULIC CYL. DIA175.7mmHYDRAULIC CYL. DIA210.9mmHYDRAULIC CYL. DIA227.3mm420 T ZITAI560 T ZITAI500 T UBEMACHINE CENTER150mmMACHINE CENTER175mmMACHINE CENTER175mmC.D. BETWEEN TIE BAR775mmC.D. BETWEEN TIE BAR900mmC.D. BETWEEN TIE BAR800mmPLUNGER STROKE515mmPLUNGER STROKE600mmPLUNGER STROKE580mmPLUNGER TIP PROTRUSION195mmPLUNGER TIP PROTRUSION250mmPLUNGER TIP PROTRUSION230mmPLUNGER SPEED MAX4.5M/secPLUNGER SPEED MAX4.5M/secPLUNGER SPEED MAX4.5M/secWORKING PRESSURE140Kg/cm2WORKING PRESSURE140Kg/cm2WORKING PRESSURE140Kg/cm2HYDRAULIC CYL. DIA183.4mmHYDRAULIC CYL. DIA195.9mmHYDRAULIC CYL. DIAmmMASTER SHEET

MASTER SHEET

MSHEETRICO SOFTECH LIMITEDDESIGN CALCULATION SHEETDATECUSTOMERPART NAMEPART NO.DRG. NO. NO. OF CAVITYINPUT AREAOUTPUT AREACONSTANTS AREAMACHINE POWERMIN GATE VELOCITYMAX GATE VELOCITYTH. FILL RATEDIE LINE (GATE AREA)PROJECTED AREA OF COMPONENT394Cm2TOTAL PROJECTED AREA692.00Kg/Cm2INJECTION PRESSURE700Kg/Cm20171.4678899083034.40366972480111.4678899083116.3293267713000PROJECTED AREA OF RUNNER236Cm2REQUIRED M/C TONNAGE484.40TonEMPIRICALLY DERIVED CONSTANT(FOR FILL TIME)0.0346Sec/mm370.56250380.562534.4036697248380.5625111.4678899083116.3293267713171.4678899083126.329326771372.9357798165PROJECTED AREA OF OVERFLOW23Cm2SELECTED M/C TONNAGE500TonTEMP. OF MOLTEN METAL AS IT ENTER THE DIE6600C252.6586535426145.871559633PROJECTED AREA OF BISCUIT39Cm2FILLING TIME41.2Milli-secMIN. FLOW TEMP. OF THE METAL5750CP. AREA OF SLIDE (HYD. CYL.)0Cm2SHOT WEIGHT1620gmTEMP. OF DIE CAVITY SURFACE JUST BEFORE METAL ENTERS2100CP. AREA OF SLIDE (ANGLE PIN.)0Cm2ACTIVE SLEEVE LENGTH325mm% SOLID FRACTION ALLOWABLEAT THE END OF FILLING20%CASTING WALL THICKNESS2.7mmSLEEVE MASS3375.30375gmUNIT CONVERSION FACTOR (FOR FILL TIME)3.80C/%CALCULATION AREAPLUNGER DIA70mmFILLING RATIO48.0%DENSITY OF MOLTEN METAL(Al)2.7gm/cm3CAL OF LOAD ON TIE BARSPRUE BUSH LENGTH135mmSLOW SHOT SPEED(PHASE 1)0.08M/secCURVE FITTED CONSTANT CCC(FOR SLOW SHOT SPEED)0.579M0.5/secDIFFUSER CONE HT.25mmFLOW RATE TH10785.6Cm3/secWORKING PRESSURE (P)(FOR BORE DIA OF CYL.)140Kg/cm 2F1+F2235.9496774194TBUISCUIT THICKNESS20mmFLOW RATE MAX19250Cm3/secDIA OF PISTON ROD(FOR BORE DIA OF CYL)4.5cmF1/F20.9254658385COMP. WEIGHT1100gmVENT AREA0.54Cm 2ACCELERATION DUE TO GRAVITY981Cm/sec2F3+F4248.4503225806TRUNNER WEIGHT220gmGATE AREA269.64mm 2OKCOEFFICIENT OF DISCHARGE OF GATING SYSTEM0.5F4/F30.9254658385OVERFLOW WEIGHT100gmFAST SHOT SPEED (PHASE 2)2.80M/secOKCAL FOR BORE DIA OF CYL.BISCUIT WEIGHT200gmMETAL PRESSURE MIN GATE VELOCITY34.40Kg/Cm2NOT OKAPPLIED FORCE3150NCENTROID CO-ORDINATE(X)10mmMETAL PRESSURE MAX GATE VELOCITY111.47Kg/Cm2OKAPPLIED FORCE (F)315KgCENTROID CO-ORDINATE(Y)15mmMETAL PRESSURE MAX M/C POWER882.01Kg/Cm2WORKING AREA (AW)2.25cm 2PROJECTED AREA OF SLIDE (AP)250mm 2LOAD ON TIE BAR BL(F1)113.4TonBORE DIA OF CYLINDER4.8079353197cmSURFACE AREA OF SLIDE (AS)1500mm 2LOAD ON TIE BAR TL(F2)122.5TonP.A OF SLIDE (WL NOT PROVIDED)100mm 2LOAD ON TIE BAR TR(F3)129.0TonGATE VELOCITY MIN (FOR P-Q2 )25M/secLOAD ON TIE BAR BR(F4)119.4TonAV. RUNNER THICKNESS1cmGATE VELOCITY MAX (FOR P-Q2 )45M/secBORE DIA OF CYL.48.1mmOFLOW LENGTH35mmGATE VELOCITY40M/secBORE DIA OF CYL. ( INCL S.F.)60mmOFLOW WIDTH20mmBORE DIA (WLOCK NOT PROVIDED)25.2mmOFLOW DEPTH10mmBORE DIA (WLOCK NP)(INCL S.F.)32mmNO. OF OFLOW6START OF PHASE II169.0mmBISCUIT WT.(APPROX.)216.9054642857gmEND OF PHASE II40.4mmRUNNER WEIGHT637.2gmMACHINE PARAMETEROFLOW WEIGHT113.4gmMACHINE CENTER125mmC.D. BETWEEN TIE BAR775mmCAL FOR BORE DIA OF CYL.(W.L.N.P.)PLUNGER STROKE380mmAPPLIED FORCE700KgPLUNGER TIP PROTRUSION165mmWORKING AREA (AW)5cm 2PLUNGER SPEED MAX5M/secBORE DIA OF CYLINDER2.5237723256cmWORKING PRESSURE140Kg/cm2TAN50.0874886635HYDRAULIC CYL. DIA175.7mmTAN150.2679491924

SPRUE BUSH LENGTH+PLUNGER STROKE-PLUNGER TIP PROTRUSION-DIFFUSER CONE HTPLUNGER DIADENSITY OF MOLTEN METALACTIVE SLEEVE LENGTHSHOT WT./SLEEVE MASS

MSHEET171.467889908334.4036697248111.467889908300034.4036697248111.4678899083171.467889908372.9357798165145.871559633

MACHINE POWERMIN GATE VELOCITYMAX GATE VELOCITYTH FILL TIMEDIE LINEFLOW RATE(CM3/SEC)METAL PRESSURE(Kg/CM2)PQ2 DIAGRAM

BORE DIACALCULATION FOR BORE DIA OF HYDRAULIC CYLINDERPROJECTED AREA OF SLIDE (AP)2616mm 2SURFACE AREA OF SLIDE (AS)8307mm 2APPLIED FORCE9232.4874426606NAPPLIED FORCE (F)923.2487442661KgWORKING PRESSURE (P)140Kg/cm 2WORKING AREA (AW)6.5946338876cm 2DIA OF PISTON ROD3.6cmBORE DIA OF CYLINDER4.6217753624cm46.2177536236mmBORE DIA AFTER CONSIDERING58SAFETY FACTORCONSIDERING LOCKING FORCE FOR SLIDE

COMP P. AREA+RUNNER P. AREA+OFLOW P. AREA+BISCUIT P. AREA+SLIDE P. AREA*TAN 5 (HYD. CYL.)+SLIDE P. AREA*TAN 15 (ANGLE PIN)TOTAL P.A.*INJECTION PRESSURECOMP WEIGHT+RUNNER WEIGHT+OFLOW WEIGHT+BISCUIT WEIGHTPLUNGER DIAFILLING RATIOCURVE FITTED CONSTT.SLOW SHOT SPEED(PHASE I)COMP. WT.OFLOW WT.DENSITY OF MOLTEN METALFILLING TIMEGATE VELOCITYPLUNGER DIAGATE AREAGATE VELOCITYREQ. M/C TONNAGECENTROID (X)CENTROID (Y)C.D. BETWEEN TIE BARREQ. M/C TONNAGECENTROID (X)CENTROID (Y)C.D. BETWEEN TIE BARREQ. M/C TONNAGECENTROID (X)CENTROID (Y)C.D. BETWEEN TIE BARREQ. M/C TONNAGECENTROID (X)CENTROID (Y)C.D. BETWEEN TIE BARPROJECTED AREA OF SLIDESURFACE AREA OF SLIDEWORKING PRESSUREDIA OF PISTON RODBORE DIA OF CYLINDERCOMP. WT.OFLOW WT.DENSITY OF MOLTEN METALFILLING TIMEFLOW RATEVELOCITY OF AIRP.AREA OF SLIDE (WLOCK NOT PROVIDED)WORKING PRESSUREBORE DIA (W LOCK NOT PROVIDED)PLUNGER SPEED MAXPLUNGER DIAGATE VELOCITY MIN. DENSITY OF MOLTEN METALACCELERATION DUE TO GRAVITYDISCHARGE COEFFICIENT OF GATING SYSTEMGATE VELOCITY MIN. DENSITY OF MOLTEN METALACCELERATION DUE TO GRAVITYDISCHARGE COEFFICIENT OF GATING SYSTEMHYD. PRESSUREHYD. CYL. DIAPLUNGER DIATOTAL PROJECTED AREAM/C TONNAGETOTAL PROJECTED AREAM/C TONNAGETOTAL PROJECTED AREAM/C TONNAGETOTAL PROJECTED AREAM/C TONNAGETOTAL PROJECTED AREAM/C TONNAGETOTAL PROJECTED AREAM/C TONNAGEFILLING TIMEP-Q2 DIAGRAMSLEEVE MASSFILLING RATIOSLOW SHOT SPEED(PHASE I)FAST SHOT SPEED(PHASE II)FLOW RATE MAXP-Q2 DIAGRAMACTIVE SLEEVE LENGTHSLEEVE MASSFILLING RATIOACTIVE SLEEVE LENGTHSLEEVE MASSFILLING RATIOACTIVE SLEEVE LENGTHSLEEVE MASSFILLING RATIOSELECTED M/C TONNAGESHOT WT.FILLING RATIOFLOW RATE TH.VENT AREAP-Q2 DIAGRAMSELECTED M/C TONNAGESHOT WT.FILLING RATIOSELECTED M/C TONNAGESHOT WT.FILLING RATIOFILL RATE TH.VENT AREASELECTED M/C TONNAGESHOT WT.FILLING RATIOLOAD ON TIE BARSELECTED M/C TONNAGELOAD ON TIE BARSELECTED M/C TONNAGEBORE DIA OF CYLINDERBORE DIA OF CYLINDERBORE DIA OF CYLINDER(WLOCK NOT PROVIDED)METAL PRESSURE AT MIN GATE VELOCITYP-Q2 DIAGRAMMETAL PRESSURE AT MIN GATE VELOCITYP-Q2 DIAGRAMM/C TONNAGEFILLING TIMEFILLING TIMEFILLING TIMEFILLING TIMEFILLING TIMEFILLING TIMESLEEVE MASSFILLING RATIOGATE AREASLOW SHOT SPEEDFAST SHOT SPEEDFLOW RATE THFLOW RATE MAXMETAL PRESSURE MINMETAL PRESSURE MAXBORE DIA OF CYLINDERBORE DIA OF CYLINDERMETAL PRESSURE AT MIN GATE VELOCITYMETAL PRESSURE AT MAX. GATE VELOCITYMETAL PRESSURE AT MIN GATE VELOCITYMETAL PRESSURE AT MAX. GATE VELOCITYrsl:PLEASE DON'T TOUCH RED COLOUR FONTS.rsl:F = AS 2 x0.35/APrsl:AW = F/P

GATE AREAGATE AREA CALCULATIONCOMP. WEIGHT821.5gmOVERFLOW WEIGHT100gmCASTING WALL THICKNESS7mmFILLING TIME65M-secGATE VELOCITY30M/secDENSITY2.7gm/cm3GATE AREA175.0237416904TABLE FOR GATE AREA CALCULATIONWALL THKFILLING TIMEGATE VELOCITYmmmilli-secM/Sec2.54542.53.06541.453.58840.384.011239

800T TOSHIBATOTAL PROJECTED AREA580sqcmINJECTION PRESSURE800Kg/sqcmCALCULATED TONNAGE464T98.4275242594119.8196829478SELECTED M/C800TC.D. BETWEEN TIE BAR1110mmCENTROID CO-ORDINATE(X)54.4mmCENTROID CO-ORDINATE(Y)-32.9mmF1+F2209.2598198198TF1/F21.1260294963F298.4275242594TOKF1110.8322955604TOKF3+F4254.7401801802TF4/F31.1260294963F3119.8196829478TOKF4134.9204972324TOK110.8322955604134.9204972324

FILLRATIOFILLING RATIO FOR 800 TSPRUE BUSH LENGTH200mmPLUNGER STROKE750mmPLUNGER TIP PROTRUSION350mmDIFFUSER HT.15mmBUISCUIT15mmACTIVE SLEEVE LENGTH585mmPLUNGER DIA90mmSLEEVE MASS10043.25075gmSHOT WEIGHT2400gmFILLING RATIO23.8966452172%FILLING RATIO FOR 400 TSPRUE BUSH LENGTH190mmPLUNGER STROKE400mmPLUNGER TIP PROTRUSION120mmDIFFUSER HT.75mmBUISCUIT15mmACTIVE SLEEVE LENGTH380mmPLUNGER DIA70mmSLEEVE MASS (gm)3946.509gmSHOT WEIGHT(gm)1320gmFILLING RATIO33.4472821423%

FIX BLOCK+PLUNGER STROKE-PLUNGER TIP PROTRUSION-DIFFUSER HT.-BUISCUITPI/4xdxdxLx2.7/1000SHOT WT./SLEEVE MASSFIX BLOCK+PLUNGER STROKE-PLUNGER TIP PROTRUSION-DIFFUSER HT.-BUISCUITPI/4xdxdxLx2.7/1000SHOT WT./SLEEVE MASSPLEASE DON'T TOUCHRED COLOUR FONTS.

FSHOTSPEEDPLUNGER DIA60MMPLUNGER AREA(AP)2828.5714285714SQMMGATE AREA175SQMMGATE VELOCITY30M/SECFAST SHOT VELOSITY1.8560606061M/SEC

SSHOTSPEEDCONSTANT K0.579MFILL RATIO19%0.190.81PLUNGER DIA0.07M0.2645751311SLOW SHOT VELOCITY0.1240830907M/SEC

FILLTIMEEMPIRICALLY DERIVED CONSTANT0.0346SEC/MMTEMP. OF MOLTEN METAL660DEG SECMIN. FLOW TEMP.575DEG SECTEMP. OF DIE CAVITY SURFACE210DEG SEC% SOLID FRACTION AT THE END OF FILLING20%UNIT CONVERSION FACTOR3.8CASTING WALL THICKNESS2MMFILLING TIME0.0305238356SEC30.5238356164MSEC

FILLRATIO (2)FILLING RATIO FOR 800 TFIX BLOCK270mmPLUNGER STROKE750mmPLUNGER TIP PROTRUSION350mmDIFFUSER HT.40mmBUISCUIT20mmACTIVE SLEEVE LENGTH630mmPLUNGER DIA80mmSLEEVE MASS8545.824gmSHOT WEIGHT2300gmFILLING RATIO26.9137300277%FILLING RATIO FOR 420 TFIX BLOCK140mmPLUNGER STROKE515mmSTART OF PHASE II460.4435008257MMPLUNGER TIP PROTRUSION195mmSLOW SHOT SPEED0.2M/SECDIFFUSER HT.30mmTIME2.3022175041SECBUISCUIT0mmACTIVE SLEEVE LENGTH430mmPLUNGER DIA70mmSLEEVE MASS (gm)4465.7865gmSHOT WEIGHT(gm)1250gmFILLING RATIO27.9905902353%

FIX BLOCK+PLUNGER STROKE-PLUNGER TIP PROTRUSION-DIFFUSER HT.-BUISCUITPI/4xdxdxLx2.7/1000SHOT WT./SLEEVE MASSFIX BLOCK+PLUNGER STROKE-PLUNGER TIP PROTRUSION-DIFFUSER HT.-BUISCUITPI/4xdxdxLx2.7/1000SHOT WT./SLEEVE MASSPLEASE DON'T TOUCHRED COLOUR FONTS.

MBD000D5733.unknown

MBD01FA4DA6.unknown

MBD031F1B66.unknown

MBD00C103D1.unknown

MBD00C14831.unknown

MBD006BE7EF.unknown