Design and Analysis of Pressure Die Casting Die for Side Differential Cover of Mini truck

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c _{e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 2, Issue 12, December 2015}

International Journal of Research (IJR)

Available at http://internationaljournalofresearch.org

Design and Analysis of Pressure Die Casting Die for Side

Differential Cover of Mini truck

1 A Chakravarthi

P.G student,

Department of Mechanical Engineering,KSRM CE, kadapa-516003

2. R Rama Krishna Reddy,

M.Tech,Associate Professor Department of Mechanical Engineering,KSRM CE, kadapa-516003

ABSTARCT

The design of die-casting dies requires considerable skill and expertise based on experience. The designer proposes designs of dies employed to cast parts from various alloys, and perform a variety of other operations. Every new job requires original thought in its design and the solving of individual problems in its manufacture.

The objective here is to design dies to be fit for the purpose, operate at optimum shot rate and is of reasonably simple construction. The main purpose of this report is to present the systematic design procedure for pressure die-casting dies. Die-casting dies like any other type of tooling can be very simple or very complex. How difficult they are to design and build depends entirely on the parts they produce.

The function of these SIDE DIFFERENTIAL COVER (part of gear box casing) is to protect and guide the gears used in power transmission. In this casing, power transmission is done by regulating the speed of driving wheels through crank shaft to rear axle. In this project we are also conducting static structural analysis for validating the design. Software used for analysis is Ansys.

Keywords: Side Differential Cover; Core and Cavity Dies; Pro-Engineering; Ansys

Introduction to Differential Cover:

Gears are used as independent units to reduce or increase the input speed. The unit is enclosed in rigid closed housings (called casing) which supports the shafts, hold lubricant inside casing, and protect the gears from dust and moisture. Also the housing provides necessary cooling surfaces to dissipate the heat generated during operation. When the unit is used to get only one reduced output speed for a given input speed then it is called a “SPEED REDUCER”, while for one input speed more than one output speeds are obtained, then the unit is called a GEAR BOX. Gear box is widely used for reduction of speed in automobiles.

Metal Minimum

section

Minimum draft Aluminum alloys 0.89 mm (0.035 in) 1:100 (0.6°)

Brass and bronze 1.27 mm (0.050 in) 1:80 (0.7°) Magnesium

alloys

1.27 mm (0.050 in) 1:100 (0.6°) Zinc alloys 0.63 mm (0.025 in) 1:200 (0.3°) Methodology:

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International Journal of Research (IJR)

After modeling in pro-e it was then converted into <.step or IGES format>, then imported to cosmosworks.

FUNCTION OF SIDE DIFFERENTIAL COVER

The function of these SIDE DIFFERENTIAL COVER (part of gear box casing) is to protect and guide the gears used in power transmission. In this casing, power transmission is done by regulating the speed of driving wheels through crank shaft to rear axle.

The material used in making the Gear box casing is Aluminum alloy Grade LM24. Using this alloy, casting for gear box casing is made which is used in most of the automobiles such as motor bikes, passenger cars and passenger auto’s etc.

The engine capacity of the Mini truck is 26 BHP/19.2 KW and Speed of the engine is 3600R.P.M.

Aluminum alloy Grade LM24 is used due to its following characteristics:

1)

Good thermal conductivity (Heat conducting capacity)

2)

Excellent Fluidity,

3)

Good resistant to corrosion,

4)

Suitable for intricate castings,

5)

Good weld ability,

6)

Electrical conductivity.

Main Aim of the Project:

Objective of this project work is to model the side differential cover of gear box casing using Pro/Engineer Wild fire 5.0 software and perform structural analysis. Side engine cover of Gear box casing taken up for modeling is used in mini trucks.

Steps Followed in the Project:

Pro/ENGINEER is a feature based, parametric solid modeling program. As such as significantly different from conventional drafting programs. In conventional drafting (either manual or computer assisted), various views of a part are created in an attempt to describe the geometry. Each view incorporates aspects of various features (surfaces, cuts, radii, holes, protrusions) but the features are not individually defined. In feature based modeling, each

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International Journal of Research (IJR)

STATIC ANALYSIS OF SIDE DIFFERENTIAL COVER

The Basic concept in FEA is that the body or structure may be divided into smaller elements of finite dimensions called “Finite Elements”. The original body or the structure is then considered as an assemblage of these elements connected at a finite number of joints called “Nodes” or “Nodal Points”. Simple functions are chosen to approximate the displacements over each finite element. Such assumed functions are called “shape functions”. This will represent the displacement with in the element in terms of the displacement at the nodes of the element.

Name: LM24

Model

type:

Linear

Elastic

Isotropic

Default

failure

criterion:

Max von

Mises

Stress

Yield

strength:

4.35e+008

N/m^2

Tensile

strength:

4.35e+008

N/m^2

Elastic

modulus:

7.1e+010

N/m^2

Poisson's

ratio:

0.33

Mass

density:

2710

kg/m^3

Shear

modulus:

2.69e+010

N/m^2

Thermal

expansion

coefficient:

2.16e-005

/Kelvin

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International Journal of Research (IJR)

Static Analysis of Stress, Strain and Displacement of 7 Persons Load condition.

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International Journal of Research (IJR)

RESULTS TABLE

VEHICL E

WEIGHT

VEHICLE WEIGHT +7

PERSONS

VEHICLE WEIGHT+ 10

PERSONS STRESS

(N/mm2) 79.3443 157.4 178.207 DISPLACEME

NT (mm) 0.0525182 0.104157 0.117936

STRAIN 0.0008375

17

0.0016608

4 0.00188

Conclusion:

We have done structural analysis on the side differential cover by applying the loads of only vehicle weight, vehicle weight+ 7 persons weight and vehicle weight + 10 persons weight to validate the strength using material Aluminum alloy LM24. By observing the analysis results, the analyzed stress values are less than the respective yield stress value under all load conditions. So using LM 24 for side differential cover is safe.

Apart from the above mentioned projects, we have done the assembly, detailing and designing of feed system for other castings. This gave me a good exposure to die casting. From these it can be concluded that the scope of the project is fully justified in this project.

In this thesis we are going to conclude that this project fulfills the all the requirements of the side differential cover design and manufacturing.

Reference:

[1] Machine design, T.V.Sundararajamoorthy

(Anuradha agencies),edition: 2006,”gear box”pp-20.1-20.28.

[2] Machine design, R.S.Khurmi/J.K.Guptha

(S.CHAND), “Bearing”edition2008, pp-962

[3] Design data book:P.S.G.College of

Technology (Kalaikathirachchagam), “Aluminum Properties” edition: 2007

[4] www. google.com “online” aluminum Gr:

LM24 composition and LM6 composition

[5] Design of machine element:V.B.Bandari

(TATA McGraw-hill), “edition-2002 pp-58

[6] Injectionmould design: R.G.W. PYE