Die Casting

Presentation Pressure break off plaster cast Sam Mande Deepak Ch Veera Pratap Vamsi raj J (BUB0912011) (BUB0912016) (BUB0912013) (BUB0912010) M. Sc. (Engg. ) in Engineering Manufacturing and Management Module Leader Dr N S Mahesh M. S. Ramaiah aim of innovational Stu flunks 1 History Casting since about 4000 BC Ancient Greece bronze statue casting 450BC Iron works in proto(prenominal) Europe, e. g. cast iron potfulnons from England 1543 2 M. S. Ramaiah give slightons of groundbreaking Stu exhales Introduction Die casting is a genuinely commonly use type of changeless molding offshoot in which surface discharge and tolerance of b junior-grade over cast parts is good that post-processing kitty be eliminated in many an(prenominal) cases. Die casting molds argon expensive and require much judgment of conviction to manufacture they ar generally called conks. Die casting is done for heights volume with high details, and value added economicalally priced cast parts. M. S. Ramaiah instill of locomote Stu weakens 3 Die Casting Process 1. Die is ready to convey 2. Die is closed, run coat is fill up in the domiciliate . The break up fomentes the molten coat in to the die 4. Die cavity is filled with molten metal in few micro seconds 4 M. S. Ramaiah civilize of Advanced Studies Die Casting Process 5. The metal than solidifies 6. The component casted is ejected from the die 7. The die is cleaned and sprayed with releasing agents 8. Die is ready for the next cycle 5 M. S. Ramaiah shoal of Advanced Studies Die casting process In Die-Casting the metal is injected in to the mold under high wardrobe 10-210 Mpa (1,450-30500 psi) Casting can produce very complex geometry parts with internal cavities and hol offset sections. It is economical, with very little wastage, the extra metals in each casting is run awayed and re utilize The clamping pressure exerted on the die is Rated in Clamping piles The capacity varies from 400 tons to 4000 to ns. M. S. Ramaiah School of Advanced Studies 6 Die Casting Process weedyly of the die castings are made from non-ferrous metals, oddly zinc, copper, aluminum, magnesium, lead, and tin based alloys, although ferrous metal die castings are possible The die casting method is especially suited for employments where a large quantity of tenuous to strength sized parts are needed with good detail , a fine surface quality and dimensional tolerance There are two common types of die casting hot- domiciliate process and cold-chamber process Example Pressure die casting M. S. Ramaiah School of Advanced Studies 7 Cold chamber process The essential feature of this process is the unconditional holding and pellet units In the cold chamber process metal is transferred by ladle, manually or automatically, to the shot sleeve Actuation of the injection piston forces the metal into the die.This is a single-shot operation This procedure minimizes the clutch age between the hot metal an d the injector components, this extend their operating life M. S. Ramaiah School of Advanced Studies 8 Cold chamber process igneous melt is pressurised with high-speed injection is likely to enter air in the metal, which can cause porosity in the castings The cold chamber process is used for the production of aluminium, copper base alloys and steel castings Next to zinc, aluminium is the most widely used die-casting alloy The mould has sections, which include the cover or hot side and the movable or cartridge ejector side M. S. Ramaiah School of Advanced Studies 9 The die may also have spare moveable segments called slides or pulls, which are used to create features such as undercuts or holes which are parallel to the parting line Available car capacity ranges 300 to 4000 T clamping pressure M. S. Ramaiah School of Advanced Studies 10 Cold- bedchamber Die Casting Process Operating Sequence of the ColdChamber Die Casting ProcessThe die is closed and the molten metal is ladle d into the cold-chamber shot sleeve. The plunger pushes the molten metal into the die cavity where it is held under pressure until solidification. Ejector pins push the casting out of the ejector die and the plunger returns to its original incline The die opens and the plunger advances, to ensure that the casting remains in the ejector die. Cores, if any, retract. M. S. Ramaiah School of Advanced Studies 11 Applications Fuel Pumps Carburetor Parts Valve Covers Handles M. S. Ramaiah School of Advanced Studies 2 Hot Chamber Process Hot chamber process is the process where the metal is maintained at an appropriate temperature in a holding furnace adjacent to the machine The injection mechanism is fit(p) within the holding furnace and a part of it is therefore in unending contact with the molten metal Pressure is transmitted to the metal by the injection piston through the gooseneck and into the die On the return concussion metal is drawn into the gooseneck for the next shot M. S. Ramaiah School of Advanced Studies 13 Hot Chamber Process In this process there is minimum contact between air and the metal to be injected Due to the contact between the metal and parts of the injection system hot chamber is restricted to zinc-base alloys The Zinc alloys are mostly used in the die casting process They have physical, mechanical and casting properties Applications limited to low melting point metals that do not chemically attack bill and other mechanical components M. S. Ramaiah School of Advanced Studies 14 Hot Chamber Process The main advantage of this process includes fast cycle quantify of approximately 15 cycles per minute Due to this process, hot chamber machines are used with Casting metals likes zinc, tin, lead, and magnesium M. S. Ramaiah School of Advanced Studies 15 Hot Chamber Die Casting Process M. S. Ramaiah School of Advanced Studies 16 Advantages Economical for large production quantities More accuracy Surface finish is good Thin se ctions are possible Fast cooling leads small grain size and also good strength to casting dimensional control is achieved Due to thin walls, weight is reduced M. S. Ramaiah School of Advanced Studies 17Disadvantages High tooling costs Size restrictions of castings Volume restrictions Generally limited to metals with low metal points Part geometry must allow removal from die M. S. Ramaiah School of Advanced Studies 18 Applicability Excellent for large and complicated shapes, particularly with internal features Can produce net shape or near net shape components Used where mechanical properties are not heavy Used where solid state processing is difficult or uneconomic M. S. Ramaiah School of Advanced Studies 19 Conclusion Depending on the field of application Die casting plays a crucial role in fulfilling the exigency accordingly &depending on the size and shape of component and material used the appropriate process should be selected Mainly by controlling and maintainin g the various(a) parameters such as material, machine, cycle time and impression(mould)the effectiveness can be improved and its directly reflects in M. S. Ramaiah School of Advanced Studies 20 simplification maintenance cost Quality of component is improved Rejection rate is less Wastage of material is less Life of machine and mould is improved By following these parameters overall process will be effective & which leads to economic effectiveness M. S. Ramaiah School of Advanced Studies 21 Reference 1 Unknown. , pressure die casting process, www. wikipedia. com, 2 Unknown, Advantages of PDC, www. dynecast. com, 3 Unknown. , cold chamber die casting, www. diecastetechnology. blogspot. com , 4 Unknown. , Hot chamber die casting, www. duecasting. com 4 Module notes ENGMATLS. Dr Ns mahesh MSRSAS Bangalore. , M. S. Ramaiah School of Advanced Studies 22 THANK YOU M. S. Ramaiah School of Advanced Studies 23