Die Casting Method

8/18/2019 Die Casting Method

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HOUSING FOR LIGHT FITTING IN

TRAIN BY DIE CASTING METHOD

ENROLLMENT NO.:- 150490728006

Prepared By : Misal Gandhi

Branch : M.E. (Production)

Guided By : Mr. Hardik Naik


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OBJECTIVE

Within 2 minute faster casting product

Higher Production Rate

Less Human Errors

Faster Products due to Semi –

Automatic DieCasting Process

Highly Customer Satisfaction of Quality Product


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INDUSTRY PROFILE

Nandratan Foundry manufactures ferrous and

nonferrous castings (as cast or with machining),

Plant based in Sarigam, Gujarat and 160 kms

from Mumbai casting and fabrication.


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INDUSTRY PRODUCTS

Ferrous Castings

• Ductile iron (SGCI) castings like valve bodies,

spools, flanges, links, levers, water connection

kits, boxes, dampers, oil seals, housings to name

a few.

Nonferrous Castings

• Aluminum base product like gear cases, housing

for light fittings, venturies, housing for

automobile components, electrical motor housing,

transmission line components etc.


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PLANT LAYOUTS- EQUIPMENTS

Plant & Machinery

• Foundry

• 150 kW medium frequency induction furnace

with 250 kg crucible• 3 oil fired pit furnaces

• 2 coke fired pit furnaces

• Molding machine

Fettling Shop

• Shot blasting machine

• Swing frame grinders


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PLANT LAYOUTS- EQUIPMENTS

Machine Shop

• Heavy duty lathes

• Milling machines

• Drilling machines

•

Tapping machines• Facing machines

Fabrication Shop

• Heat treatment furnace

• Rolling mill• Hydraulic & pneumatic power presses

• Shearing machines

• Pedestal grinders

• Welding equipments


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INTRODUCTION

Die casting is a manufacturing process that can

produce geometrically complex metal parts through

the use of reusable molds, called dies.

The die casting process involves the use of a furnace,

metal, die casting machine, and die. The metal, typically a nonferrous alloy such as

aluminum or zinc, is melted in the furnace and then

injected into the dies in the die casting machine.

There are two main types of die casting machines hotchamber machines (used for alloys with low melting

temperatures, such as zinc) and cold chamber

machines (used for alloys with high melting

temperatures, such as aluminum).


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DIE CASTING HOT CHAMBER MACHINE


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DIE CASTING COLD CHAMBER MACHINE


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DIE – CASTING M/C USED IN INDUSTRY


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PRODUCT PROCESS CYCLE

Clamping

Injection

Cooling Ejection

Trimming

Pouring

Clamping

Cooling Ejection

Removal ofCore

Trimming

General PPC In Industry PPC


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EQUIPMENTS

Cold chamber die casting machine Cold

• Open holding pot – It place in to furnace

• Plunger – Powered by Hydraulic or Manually

• Induction Furnace

• Grinding Machine

• Cutting Machine


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DIE CASTING W ALL THICKNESS


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MACHINE SPECIFICATION

Both hot chamber and cold chamber die casting

machines are typically characterized by the

tonnage of the clamp force they provide. The

required clamp force is determined by the

projected area of the parts in the die and thepressure with which the molten metal is injected.

Also, certain materials that require high injection

pressures may require higher tonnage machines.


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MATERIAL

Die casting typically makes use of nonferrous

alloys. The four most common alloys that are die

cast are shown below, along with brief

descriptions of their properties.

Aluminum alloys

• Low density

• Good corrosion resistance

•

High thermal and electrical conductivity• High dimensional stability

• Relatively easy to cast

• Requires use of a cold chamber machine


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1.Wall thickness: 2.Corner:

Incorrect Incorrect

Non-uniform wall thickness. Sharp corner.

Correct Correct

Uniform wall thickness. Rounded corner.

DESIGN RULES


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3.Draft: 4.Undercuts:Incorrect Incorrect

No draft angle. Die cannot separate.

Correct Correct

With draft angle. Die easily separet.


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Flash- Due to injection pressure too high& clamp force too low.

Hot tearing- Due to non-uniform cooling

rate.Bubbles- Due to very high injection

temperature & non-uniform cooling rate.

Unfilled sections- Due to slow injection& low pouring temperature.

Ejector marks- Due to very shortcooling time & high ejection force.

POSSIBLE DEFECTS


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Very high rate of production is achieved.

Close dimensional tolerances of + 0.025 mm is

possible.

Surface finish of o.8 microns can be obtained.

Very thin sections of 0.50 mm can be cast.

Longer die-life is obtained.

Less floor space is required.

Unit cost is minimum.

A DVANTAGES OF DIE CASTING


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Only economical for nonferrous alloys.

Not economical for small runs.

Heavy castings cannot be cast.Cost of die and die casting equipment is high.

Die casting usually contain some porosity due

to the entrapped air.

DISADVANTAGES OF DIE CASTING


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CONCLUSION

By using this casting method we can get complex

casting shapes at Higher production at minimum

time in less effort.


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THANK YOU

Documents

Die Casting Method