Die Casting

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  • Topic: Die casting, Zinc, Casting
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  • Published : March 20, 2013
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Pressure Die Casting

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 School of Advanced Studies

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History
Casting since about 4000 BC…

Ancient Greece; bronze statue casting 450BC

Iron works in early Europe, e.g. cast iron cannons from England 1543 2

M. S. Ramaiah School of Advanced Studies

Introduction
• Die casting is a very commonly used type of permanent molding process in which surface finish and tolerance of die cast parts is good that post-processing can be eliminated in many cases.

• Die casting molds are expensive and require much time to manufacture they are generally called dies. • Die casting is done for high volume with high details, and value added economically priced cast parts.

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Die Casting Process

1.Die is ready to start

2.Die is closed, molten metal is filled in the chamber

3.The ram pushes the molten metal in to the die

4.Die cavity is filled with molten metal in few micro seconds 4

M. S. Ramaiah School 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 School of Advanced Studies

Die casting process
• In Die-Casting the metal is injected in to the mold under high pressure 10-210 Mpa (1,450-30500 psi)

• Casting can produce very complex geometry parts with internal cavities and hollow sections. • It is economical, with very little wastage, the extra metals in each casting is melted and reused • The clamping pressure exerted on the die is Rated in “Clamping

tons”
• The capacity varies from 400 tons to 4000 tons.
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Die Casting Process
• Most of the die castings are made from non-ferrous metals, particularly zinc, copper, aluminum, magnesium, lead, and tin based

alloys, although ferrous metal die castings are possible
• The die casting method is especially suited for applications where a large quantity of small to medium sized parts are needed with good detail , a fine surface quality and dimensional tolerance • There are two common types of die casting: hot- chamber process and cold-chamber process • Example: Pressure die casting M. S. Ramaiah School of Advanced Studies

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Cold chamber process
• The essential feature of this process is the independent holding and

injection 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 contact time between the hot metal and the injector components, this extend their operating life

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Cold chamber process
• Hot 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 ejector side

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• The die may also have additional 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 machine capacity ranges 300 to 4000 T clamping pressure

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Cold-Chamber Die Casting Process

Operating Sequence of the ColdChamber Die Casting Process

The die is closed and the molten metal is ladled into the...
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