“Cast projection area” in die casting is the area of the mold cavity projected onto the parting surface. This area is calculated by projecting the three-dimensional casting onto a flat surface, specifically, onto the parting surface of the mold.

The projection area plays a crucial role in the design phase, as it determines the opening force generated by the molten metal against the mold walls.

The projection area  includes the area of the actual casting, the area  of the sprue and runner system, etc. The area of die casting  is a key parameter in the die casting process because it influences the filling and solidification process of the casting. In addition, the projection area  is also used to calculate the clamping force required by the die casting machine, which is usually formulated as: Clamping force = Total projection area × Injection pressure.

Projection area is an important concept in die casting design, which directly affects the quality and productivity of castings.

Significance of die casting projection area

Die casting projection area in die casting process has important significance, mainly reflected in the following aspects:

• Selection of the basis of die-casting machine: the casting area is one of the important parameters for selecting the tonnage of die-casting machine. By calculating the projection area of the part, can determine the required die casting machine tonnage, so as to choose the appropriate die casting equipment.
• Mould design and manufacturing: area of project is one of the key factors in mold design. It affects the layout and design of mold cavities, pouring system and overflow system. The size of the casting area  directly determines the shape and volume of the mold, which in turn affects the cooling requirements, material flow and structural integrity of the mold for long-term use.
• Clamping force estimation: The projection area is used to evaluate the required clamping force, which is critical to ensure stability during the die casting process. In practice, the castiing area  usually needs to be multiplied by a factor (e.g. 1.2 to 1.5 times) to account for the effects of the pouring system and other factors.
• Calculation of process parameters: The projection area  is also used to calculate other important parameters in the die casting process, such as the specific pressure of the shot and the main expansion force. These parameters are essential to ensure the quality and dimensional accuracy of the casting.
• Economy and production efficiency: projection area  also affects the economy and production efficiency of die casting process. For example, in the squeeze casting process, by adjusting the pressure can significantly change the die casting area of the part, thus improving productivity and reducing costs.

In short, die casting area in die casting process plays a vital role, it not only affects the choice of equipment and mold design, but also directly related to the setting of process parameters and production economy. Therefore, in the die casting process, accurate calculation and reasonable application of projection area is very important.

How to calculate cast projection area?

The method of calculating the projection area  of die casting mainly involves the following steps:

• Determine the projection area of the casting: this is the basis for calculating the total casting area . The projection area  of the casting can be determined by measuring the projection of the casting on a flat surface. Image processing software such as ImageJ, Adobe Photoshop or GIMP can be used to measure the area in the image.
• Calculate the projection area of the casting system: The projection area  of the casting system is usually taken as 15% to 30% of the area  of the casting. For specific calculations, the projection area  of the casting can be multiplied by a factor (e.g. 0.15 to 0.3) to get the projection area  of the pouring system.
• Calculation of the projection area of the cake: The casting area  of the cake can be calculated from the diameter of the punch by the formula πd²/4, where d is the diameter of the punch.
• Calculate the projection area of the overflow system: the projection area  of the overflow system is usually taken as 10% to 20% of the area  of the casting. For specific calculation, the projection area  of the casting can be multiplied by a coefficient (such as 0.1 to 0.2) to get the casting area  of the overflow system.
• Calculation of the total projection area : add the projection area  of the casting, the projection area  of the pouring system, the projection area  of the cake and the area  of the overflow system to get the total projection area .

Cast projection area on the selection of Haichen die casting machine

Projection area is an important consideration when choosing a Haichen die casting machine. The “projected area” in die casting refers to the area of the mold cavity projected onto the parting surface. The projected area plays a crucial role in the design phase, as it determines the opening force generated by the molten metal against the mold walls.

Therefore, at the design stage of the die casting mold, it will be necessary to keep enough safe outer dimensions. Then, according to the confirmed external dimensions of the mold, we can choose a die casting machine model with sufficient capacity of the mold hole to form a complete production line.

When choosing Haichen die-casting machine, the choice of projection area mainly depends on the type of die-casting machine used and the application scene. For example, if a cold chamber die casting machine is used, such as the Brilliance C series cold chamber die casting machine, this model is suitable for aluminum production, and its hydraulic and electrical systems use components from well-known European, American and Japanese manufacturers, with reasonable product structure design and safe and reliable operation performance. In addition, Brilliance also provides hot and cold chamber die casting machines ranging from 30 tons to 1,600 tons, which allows us to choose the right model according to specific needs.

Therefore, when choosing a Brilliance die casting machine, the relationship between the projected area and the type of die casting machine, the type of material and the production demand should be considered to ensure that the selected equipment can meet the production efficiency and quality requirements.

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