DETERMINATION OF NUMBER OF CAVITIES

As discussed in section 1, using a multi-cavity die would save cost and improve the
production efficiency. However, increasing the number of cavities requires a larger die, hence
a larger machine, which will result in higher investments in the die and machine. We need to
make balance between these factors by using optimal number of cavities.
The number of cavities is affected by several factors, such as the delivery requirements,
the allowable production cost, capacity of the selected machine and part geometric shape. The
first two are dependent on the dynamic market conditions, and the designer must review the
delivery and cost issues based on the latest information available. Machine parameters like
clamping (locking) force, the maximum flow rate and the machine size restrict the number of
cavities which can be used on it. The part shape (or undercut features) also put limit on the
maximum number of cavities that can be arranged in mould base and their orientation.
Therefore, the number of cavities is selected which must be economically acceptable,
technically permissible and geometrically feasible. Following paragraphs describe the
procedure to find number of cavities based on different criteria. This criterion has been used
in the first module of the system to find suitable number of cavities. Information flow
diagram of this module is given in section 3.2.

3.1 Criterion for Selecting Number of Cavities

3.1.1 Number of cavities based on delivery date [ Ndel ]
The number of cavities must ensure that the order can be fulfilled within the available time
period. Based on time period for die casting, the minimum number of cavities for meeting the
delivery date can be determined using the following relation [17].
K t
r cycle L

N
del = (3.1)
tm
Where, Kr = Rejection factor (1.05), tcycle = Cycle time of every product (sec),
L = Lot size of the product, tm = Time available for production (sec).

3.1.2 Number of cavities based on cost [ Ncos t ]

The optimum number of cavities to be used in the die casting die can be determined for a
particular die casting task by first calculating the most economical number of cavities and
then analyzing the physical constraints of the equipment to ensure that the economical
number of cavities is practical. Dewhurst and Blum [4] proposed a formula to calculate the
economically optimum number of cavities, which is given as follow:
L (b t + C r t p )
N m+1cos t d m t o (3.2)
=
m(Cd + Ct )

Where, L = Lot Size, bd = Minimum casting machine rate ($/hr),

 tm = Die casting machine cycle time (hr), Crt = Trim press and operator
rate ($/hr), Tpo = trimming cycle time (hr), Cd = Cost of single-cavity die
casting die ($),
CT = Cost of single aperture trim die ($), m = Multi-cavity die cost exponent (0.7).

3.1.3 Number of cavities based on machine parameters [ Nmac ]

The capacity of a diecasting machine is also limited by its parameters. Number of cavities is
therefore dependent upon the constraints of the diecasting machine like clamping (locking)
force, the maximum flow rate and the machine size. Following paragraphs discuss
determination of number of cavities based on various machine constraints.

3.1.3.1 Number of cavities based on the clamping force [ Ncf ]

The force applied by the machine is required to hold the die halves together and must
therefore exceed the force generated within the die [9]. Thus, the maximum number of
cavities can be calculated as follows:
FC
N
cf = (3.3)
K AP PM
Where, FC = Maximum clamping force (N), AP = Projected area of each cavity, its
overflow and
runner (mm2) PM = Maximum metal pressure (M Pa), K = Factor of safety against flashing
(1.75)
The system takes AP as 1.75 times the projected area of individual cavity to accommodate
overflow and runner area [2].

3.1.3.2 Number of cavities based on the maximum flow rate [ N fr ]

Flow rate represents the power of the shot system of the die casting machine. It describes the
volume of molten metal that is pushed into the cavity per second by the shot system. The
flow rate required by a die should not exceed the power that the machine can provide [8].
Based on this principle, the maximum number of cavities can be determined as follows.
V
S
N fr = (3.4)
V
Where, VS = Volume of molten metal that is pushed into the cavity by shot system
(mm3),
V = Volume of each cavity, its overflow and runner (mm3).

The system takes V as (1+2/h) times the Volume of each cavity to accommodate overflow and
runner volume [2].
Where, h = Average wall thickness (mm).

3.1.3.3 Number of cavities based on the machine size [ Nms ]

The distance between the tie bars of the machine decides the maximum size of the die that
can be used. When choosing the number of cavities, one should assure that all cavity inserts
be contained within the die and that adequate margins be provided. Assuming that the cavities
are arranged in a rectangular array in the die, the maximum number of cavities will be [7]:
L
die
L W
mar die Lmar
Nms = (int) (int ) (3.5)
L
ins + 0.5Ldis W
ins + 0.5Ldis
Where,
Ldie and Wdie are the allowable maximum length and width of the die
used (mm), Lins and Wins are the length and width of the cavity inserts
(mm),
Lmar = Minimum margin between the edges of the die and inserts (mm),
Ldis = Minimum distance between the cavity inserts (mm), and
int = Mathematic function to round off the given numeral to an integer.

Therefore, number of cavities based on machine parameters can be taken as:

[ Nmac ] = Minimum of ( Ncf , N fr and Nms )

3.1.4 Number of cavities based on the part geometry features [ Ngeo ]

Maximum number of cavities are not only limited by the machine constraints itself but also
on the number of side-pulls (or side-cores) and their location. This factor is also considered in
the proposed system. The system finds the maximum number of cavities applicable to a given
design by applying a well practiced rule. The rule states that moulds having side-cores on
four sides are limited to single-cavity dies, while cavities with undercut on three sides are
limited to two-cavity dies. Cavities containing undercut on two sides are restricted to either
two- or four-cavity dies, depending on the angle between undercuts as shown in figure 3.

3.2 Determination of Number of Cavities

The system takes part CAD file as input and extracts part geometric information such as
projected area, volume, wall thickness, longest part depth and envelope size. Some other
details like lot size, cycle time, total production time and data related to diecasting process
cost are taken interactively. Figure 4 shows the information flow diagram for determining the
number of cavities based on delivery date, economical, technical and geometrical aspects.
The system selects diecasting machine from the machine database. A representative machine
database is shown in table 1. It first checks longest part depth against die opening size or
clamp stroke by using simple rule proposed by Blum [1]. The rule states that Ls > 2D + 120
mm, where Ls is clamp stroke and D is depth of the longest hollow feature in the cavity. This
selected machine is then used to determine minimum number of cavities (Nmac) which
ensure that selected machine is technically permissible. If the selected number of cavities
(Nmac) is economically acceptable, technically permissible and geometrically feasible, Nmac
is selected as the number of cavities, else next machine from machine database with higher
capacity is selected to fulfill the condition. If the number of cavities determined by machine
parameters is more than the maximum number of cavities possible due to geometrical
constraints, which also satisfies the delivery date and cost considerations; number of cavities
using geometrical constraints is selected as Nmac in that case.