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 hot chamber 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).
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 hot chamber 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).
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 hot chamber 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).
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 hot chamber 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).
Prepared By : Misal Gandhi Branch : M.E. (Production) Guided By : Mr. Hardik Naik
CONTENTS Objective Introduction Industry Profile Process Cycle Equipments Machine Specification Suitable Material Advantages-Disadvantages & Application Video Conclusion Future Scope
OBJECTIVE Within 2 minute faster casting product Higher Production Rate Less Human Errors Faster Products due to Semi Automatic Die Casting Process Highly Customer Satisfaction of Quality Product
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.
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.
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
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 hot chamber 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).
DIE CASTING HOT CHAMBER MACHINE
DIE CASTING COLD CHAMBER MACHINE
DIE CASTING M/C USED IN INDUSTRY
PRODUCT PROCESS CYCLE
General PPC
Clamping Injection Cooling Ejection Trimming
In Industry PPC
Pouring Clamping Cooling Ejection Removal of Core Trimming
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
DIE CASTING WALL THICKNESS
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 the pressure with which the molten metal is injected. Also, certain materials that require high injection pressures may require higher tonnage machines.
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
DESIGN RULES
1.Wall thickness: Incorrect
Non-uniform wall thickness.
Correct
Uniform wall thickness.
2.Corner: Incorrect
Sharp corner.
Correct
Rounded corner.
3.Draft: Incorrect
No draft angle.
Correct
With draft angle.
4.Undercuts: Incorrect
Die cannot separate.
Correct
Die easily separet.
POSSIBLE DEFECTS 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 short cooling time & high ejection force.
ADVANTAGES OF DIE Very
CASTING
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.
DISADVANTAGES OF DIE Only
CASTING
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.
CONCLUSION
By using this casting method we can get complex
casting shapes at Higher production at minimum time in less effort.
