Lab Report Die Casting

MANUFACTURING PROCESSES

MANUFACTURING PROCESSES

LAB

LAB REPORT

REPORT

CONTENTS:

CONTENTS:

DIE CASTING DIE CASTING

TYPES OF DIE CASTING TYPES OF DIE CASTING PRESSURE DIE CASTING PRESSURE DIE CASTING

TYPES OF PRESSURE DIE CASTING TYPES OF PRESSURE DIE CASTING  APPLICA

 APPLICATIOTIONS OF PRESSURE DIE CASTINGNS OF PRESSURE DIE CASTING

 ALLOYS BEING USE

 ALLOYS BEING USEDD

SUBMITTED BY: MUHAMMAD AAQIB AMIN SUBMITTED BY: MUHAMMAD AAQIB AMIN REG.NO:2015-IM-48

REG.NO:2015-IM-48

SUBMITTED TO: MISS SANA EHSAN SUBMITTED TO: MISS SANA EHSAN

DIE

Die casting is a permanent mol casting proce!re" in #$ic$ t$e mol is mae o% metal an large n!m&er o% castings are pro!ce %rom it'

T$e mol ca(it) is create !sing t#o $arene tool steel ies #$ic$ $a(e &een mac$ine into s$ape an #or* similarl) to an in+ection mol !ring t$e process'

Die casting is one &) t#o met$os,

1 Gr!"#$ D"% C&#"'()P%r*'%'# +"% ,&#"'(

• Lo# press!re ie casting

• Sl!s$ casting

2. Pr%&&r% D"% C&#"'(

• -ot c$am&er ie casting

PRESSURE DIE CASTING:

Press!re Die Casting is a .!ic*" relia&le an cost/e%%ecti(e man!%act!ring process %or pro!ction o% $ig$ (ol!me" metal

components t$at are net/s$ape $a(e tig$t tolerances' Basicall)" t$e press!re ie casting process consists o% in+ecting !ner $ig$ press!re a molten metal allo) into a steel mol 0or tool1' T$is gets solii%ie rapil) 0%rom millisecons to a %e# secons1 to %orm a net s$ape component' It is t$en a!tomaticall) e2tracte'

T$%& / Pr%&&r% D"% C&#"'(: H"( Pr%&&r% D"% C&#"'( L/ Pr%&&r% D"% C&#"'(

-ig$ press!re ie casting $as #ier application encompassing nearl) 345 o% all lig$t allo) casting pro!ction' C!rrentl) lo# press!re ie casting acco!nts %or a&o!t 645 o% t$e total

pro!ction &!t its !se is increasing' -ig$ press!re castings are m!st %or castings re.!iring tig$t tolerance an etaile geometr)'  As t$e e2tra press!re is a&le to p!s$ t$e metal into more etaile

%eat!res in t$e mol' Lo# press!re ie casting is commonl) !se %or larger an non/critical parts'

H"( Pr%&&r% D"% C&#"'(:

-ere" t$e li.!i metal is in+ecte #it$ $ig$ spee an $ig$

press!re into t$e metal mol' T$e &asic e.!ipment consists o% t#o (ertical platens' T$e &olsters are place on t$ese platens an

t$is $ols t$e ie $al(es' O!t o% t$e t#o platens" one is %i2e an t$e ot$er mo(a&le'

H"( Pr%&&r% D"% C&#"'( Pr/,%&&

T$is $elps t$e ie to open an close' A speci%ic amo!nt o% metal is po!re into t$e s$ot slee(e an a%ter#ars intro!ce into t$e

mol ca(it)' T$is is one !sing a $)ra!licall)/ri(en piston' A%ter t$e metal $as solii%ie" t$e ie is opene an t$e casting

e(ent!all) remo(e'

HOT CHAMBER DIE CASTING:

-ot/c$am&er ie casting" sometimes calle goosenec* casting" is t$e more pop!lar o% t$e t#o ie casting processes' In t$is

process" t$e c)liner c$am&er o% t$e in+ection mec$anism is completel) immerse in t$e molten metal &at$' A goosenec* metal %ee s)stem ra#s t$e molten metal into t$e ie ca(it)' 7$ile irect immersion in t$e molten &at$ allo#s %or .!ic* an con(enient mol in+ection" it also res!lts in increase corrosion s!scepti&ilit)'

Machine_,

• P3'(%r , It is a (ertical piston %or p!s$ing molten metal'

Compresse air is also !se %or t$is proce!re'

• G//&%'%, '/3%, For s.!irting o!t metal #it$ $ig$ (elocit)

an press!re'

• M/3#%' *%#3 6&"', For melting metal to pro(ie a contin!o!s

s!ppl) o% metal'

• D"%, It contains a ca(it) o% re.!ire s$ape'

• E7%,#/r "'&, For opening t$e ie an remo(ing t$e casting

• H$+r3", ,"r,"#, T$is operates t$e press!re c)liners an

a!tomates all t$e process'

Process_,

 A ie/c)cle is complete in %ollo#ing steps,

 T$e goosenec* is s!&merge in molten metal &asin'

 T$e pl!nger in !pper position lets t$e molten metal %lo# insie'

7$en metal is %ille in t$e nec*9 incase o% air/operate m8c" it is raise !p to t$e ie an loc*e in contact #it$ t$e ie opening'

 Incase o% t$e pl!nger m8c" t$e $oles are close to trap t$e molten

metal insie t$e nec*" on t$e o#n stro*e' Pl!nger is p!s$e o#n &) a press!re o% nearl) 3444 psi to in+ect t$e molten metal

into t$e ca(it) in t$e ie' A%ter t$e ie is %ille" metal is le%t to solii%)'

 A%ter solii%ication" press!re is remo(e" t$e ie is opene an

*noc*/o!t8e+ector pins are !se to e+ect t$e casting o!t' T$e ie is close an m8c &ecomes rea) %or anot$er casting'

 T$e r!nner part is remo(e %rom t$e casting an as casting is

(er) smoot$ so no special mac$ining process is re.!ire'

 T$e pro!ction rate o% t$is process is $ig$ !e to irect !se

o% t$e molten metal %rom t$e %!rnace'

 T$is process is limite in its applications to lo# melting point

metals

 T$at o not c$emicall) attac$ t$e pl!nger an ot$er

mec$anical components'

THE COLD-CHAMBER DIE CASTING PROCESS:

T$e col/c$am&er ie casting process is (er) similar to $ot/ c$am&er ie casting' 7it$ a esign t$at %oc!ses on minimi:ing mac$ine corrosion rat$er t$an pro!ction e%%icienc)" t$e melte metal is a!tomaticall)/ or $an/lale into t$e in+ection s)stem' T$is eliminates t$e necessit) %or t$e in+ection mec$anism to &e immerse in t$e molten metal &at$'

For applications t$at are too corrosi(e %or t$e immersion esign o%  $ot/c$am&er ie casting" t$e col/c$am&er process can &e an

e2cellent alternati(e' T$ese applications incl!e t$e casting o% metals #it$ $ig$ melting temperat!res" s!c$ as al!min!m an al!min!m allo)s'

 Machine_,

 Plunger , It is a (ertical or $ori:ontal spring/piston to p!s$ t$e

molten metal into t$e ie ca(it)'

 Shot sleeve: It is a c)liner #$ere molten metal is po!re in'

 Die: T$e t#o $al(es ie is connecte in %ront o% t$e s$ot slee(e'

 Ejector pins: T$ese are !se to open t$e ie an e+ect t$e

casting o!t'

 H$+r3", ,"r,"#, T$is operates t$e press!re c)liners an

a!tomates o% all processes' Pr/,%&&,

 A ie/c)cle is complete in %ollo#ing steps,

; T$e lale &rings t$e molten metal %rom t$e %!rnace an po!rs it into t$e s$ot slee(e'

; Pl!nger p!s$es t$e molten metal into t$e ca(it) in t$e ie" #it$ a press!re o% nearl) <=44 psi' A%ter t$e ie is %ille" metal is le%t to solii%)'

; Press!re is maintaine !ring solii%ication &) a pl!nger or  compresse air'

; A%ter solii%ication" press!re is remo(e" t$e ie is opene' T$e $)ra!lic operate *noc*/o!t8e+ector pins are !se to e+ect t$e casting o!t'

; T$e ie is close an m8c &ecomes rea) %or anot$er  casting'

; T$e r!nner part is remo(e %rom t$e casting an as casting is (er) smoot$ so no special mac$ining process is re.!ire' L!&ricants m!st &e spra)e into t$e ca(it) to pre(ent stic*ing'

; >enting $oles an passage#a)s m!st &e &!ilt into t$e ies at t$e parting line to e(ac!ate t$e air an gasses in t$e ca(it)'

-ig$ .!alit) castings" o% al!mini!m allo)s" along #it$ magnesi!m an ot$er lo# melting point allo)s are !s!all) pro!ce t$ro!g$

t$is process'

Castings o% al!mini!m in t$e #eig$t range o% 6/?34 *g are a common %eat!re' T$e process #or*s li*e t$is" %irst a metal ie is positione a&o(e a seale %!rnace containing molten metal' A re%ractor)/line riser e2tens %rom t$e &ottom o% t$e ie into t$e molten metal' Lo# press!re air 0?3 / ?44 @Pa" 6/ ?3 psi1 is t$en intro!ce into t$e %!rnace' T$is ma*es t$e molten metal rise !p t$e t!&e an enter t$e ie ca(it) #it$ lo# t!r&!lence' A%ter t$e metal $as solii%ie" t$e air press!re is release' T$is ma*es t$e metal still in t$e molten state in t$e riser t!&e to %all &ac* into t$e %!rnace' A%ter s!&se.!ent cooling" t$e ie is opene an t$e

casting e2tracte'

7it$ correct ie esign it is possi&le to eliminate t$e nee o% t$e riser also' T$is is &eca!se o% t$e irectional %ree:ing o% t$e casting' A%ter t$e se.!ence $as &een esta&lis$e" t$e process can &e controlle a!tomaticall) !sing temperat!re an press!re controllers to o(ersee t$e operation o% more t$an one ie casting mac$ine'

Casting )iel is e2ceptionall) $ig$ as t$ere is !s!all) onl) one in gate an no %eeers'

; L/ Pr%&&r% D"% C&#"'( Pr/,%&&

APPLICATIONS OF PRESSURE DIE CASTING:

•  A!tomoti(e parts li*e #$eels" &loc*s" c)liner $eas"

mani%ols etc'

•  Aerospace castings'

• Electric motor $o!sings'

• @itc$en #are s!c$ as press!re coo*er'

• Ca&inets %or t$e electronics in!str)'

• General $ar#are appliances" p!mp parts" pl!m&ing parts'

ALLOYS BEING USED:

9 FOR HOT CHAMBER DIE CASTING:

; -ot/c$am&er ie casting can &e !se #it$ :inc" tin" lea" an magnesi!m'

; T$e $ot/c$am&er process is ieal %or metals t$at ont reail) attac* an eroe metal pots" c)liners" an

; T$is process is limite in its applications to lo# melting point metals $a(ing $ig$ %l!iit)'

; inc_{: t$e easiest metal to cast9 $ig$ !ctilit)9 $ig$ impact}

strengt$9 easil) plate9 economical %or small parts9 promotes long ie li%e'

; L%+ '+ #"', $ig$ ensit)9 e2tremel) close imensional acc!rac)9 !se %or special %orms o% corrosion resistance' S!c$ allo)s are not !se in %ooser(ice applications %or p!&lic $ealt$ reasons'

;  M('%&"*, t$e easiest metal to mac$ine9 e2cellent

strengt$/to/#eig$t ratio9 lig$test allo) commonl) ie cast' ;

; FOR COLD CHAMBER DIE CASTING,

; -ig$ melting allo)s o% &rass" al!min!m" an magnesi!m are caste in col/c$am&er m8c #$ic$ $a(e a $ig$ melting

point' D!ring t$is process" metal is li.!e%ie in a %!rnace at e2tremel) $ig$ temperat!res an t$en lale into a col c$am&er to &e in+ecte into t$e ie'

; Alt$o!g$ col c$am&er process is applica&le to most o% allo)s &!t !e to laling operation its pro!ction spee is slo#'

; A3*"'*, lig$t#eig$t9 $ig$ imensional sta&ilit) %or

comple2 s$apes an t$in #alls9 goo corrosion resistance9 goo mec$anical properties9 $ig$ t$ermal an electrical con!cti(it)9 retains strengt$ at $ig$ temperat!res

;  M('%&"*, t$e easiest metal to mac$ine9 e2cellent