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Process Capability Analysis of High Pressure Die Casting Process for Cap Manufacturing

Process Capability Analysis of High Pressure Die Casting Process for Cap Manufacturing

The purpose of this work is to focus on capability of process parameters and to analyse capability of H.P.D.C. process to manufacture die casted product by using statistical tools such as histogram and process capability curve. For this work input data is directly obtained by die casting machine setup run. At the end it needs to be suggested whether to continue with existing process parameters or there needs to modify process parameters to minimize defects occurring in product? Figure 4 shows steps followed in determination of process capability.

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Continuous improvements in die-casting using a Six Sigma approach

Continuous improvements in die-casting using a Six Sigma approach

This paper deals with the application o f a Six Sigma methodology to the continuous improvement o f an aluminium die-casting process. A Six Sigma improvement project was initiated in an aluminium die­ casting process, with the aim to reduce the amount o f machining scrap from an average o f 4.12% to less than 2%, and the amount o f material scrap from 11.43% to an average o f less than 4%. The parameters with a major influence on the level o f scrap were defined in a cause-and-effect diagram, analyzed, improved where necessary, and pu t under control using Six Sigma tools and methods. Although the initial project goals were not completely met, major die-casting process improvements were made, resulting in significant savings.
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Experimental and Analytical Investigating Die Casting Process Parameters

Experimental and Analytical Investigating Die Casting Process Parameters

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. Therefore, a larger part will require a larger clamping force. Also, certain materials that require high injection pressures may require higher tonnage machines. The size of the part must also comply with other machine specifications, such as maximum shot volume, clamp stroke, minimum mold thickness, and platen size.
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Analysis and Validation of
Gravity Die Casting Process using ProCAST

Analysis and Validation of Gravity Die Casting Process using ProCAST

Feng Liu et al [1] in this paper, with the aid of parametric modeling technology of runner and riser are modeled parametrically. By varying each parameter, it is easy to get different casting CAD models. These models output data populate the orthogonal matrix, which is used in the orthogonal array testing strategy to define the most suitable combinations of runners and risers parameters. After inputting the completed orthogonal matrix data and all CAD models into the simulation software the simulation result can be obtained. Marco Aloe et al [2] observed that Gating systems, overflows, venting channels can be optimized using numerical simulation. Solidification related defects can also be predicted taking into account cooling channels and die cycling so as to accurately reproduce production conditions. ProCAST readily addresses all these issues but also includes advanced features to better assess the casting quality. Mohammad Sadeghi et al [3] observed that ProCAST software used to simulate the fluid flow and solidification step of the part, and the results were verified by experimental measurements. By this Paper he concludes that 1) Comparison of the experimental and simulation results indicates that defects in the pieces are placed at the predicted places by simulation. 2) If the die temperature is reduced from the optimum temperature range, probability of cold flow defects and air porosities increase. 3) Determination of optimized places of overflows by simulation led to decrease of some casting defects such as cold shots and air porosities.Dr. S. Shamasundar et al [4] observed that in gravity die casting of Aluminum parts, computer simulation can be a useful tool for rapid process development. Limitation of the conventional die design and gating design has been elaborated. Advantages of computer simulation based design enumerated. The procedures thus described have been demonstrated with two case studies of application of ProCAST simulation at Ennore Foundries. It is demonstrated that the foundries can derive mileage by resorting to FEM simulations of the casting process for process development and optimization.
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Analysis of mechanical properties and microstructure of multiple die cavity products produced in vertical and horizontal arrangement by gravity die casting

Analysis of mechanical properties and microstructure of multiple die cavity products produced in vertical and horizontal arrangement by gravity die casting

is approximately 4 mm because of the limited ability of metal to run into thin sections. The process is used for the volume production ranging from 1000 to more than 100 000 per year. Common permanent mould parts include gears, automotive pistons and car wheels. The alloys commonly cast by permanent mould casting include 319 (AlSi5Cu3), 413 (ALSi12) and A356 (AlSi7Mg). The casting operation ranges from manually-operated die sets) to automatically operated (carousel machines having several dies around 4-10 minutes before the casting can be taken out from the die so the process is relatively slow. If higher production rates are required, multiple die sets have to be employed [4]. Gravity die casting accounts about %30 of all light alloy casting production while high pressure die casting is the most widely used, representing about 50%. and Low pressure die casting currently accounts for about %20 [2].
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A study of dimensional limitations in low pressure die casting

A study of dimensional limitations in low pressure die casting

This project highlights the conditions necessary to maintain minimum thickness in wheel castings, produced by low-pressure die casting, by taking into consideration various process varia[r]

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Optimization Of Process Parameters In Cold Chamber Die Casting Process Using Taguchi Method

Optimization Of Process Parameters In Cold Chamber Die Casting Process Using Taguchi Method

High Pressure die casting process is a process ideally suited to manufacture mass produced metallic parts of complex shapes requiring precise dimensions. In this process, molten metal is forced in to empty cavity of desired shape and is allowed to solidify under high holding pressure. Die casting is a complex process which is controlled by many parameters such as die related parameters, machine related parameters, which has direct impact on casting quality. Improper settings of these parameters end up in producing quality related issues in the casting. One such issue is blow holes and porosity which is caused by improper setting of process parameters. In this paper an industrial component having blow hole problem has been taken. This study proposes application of Taguchi methodology in identifying the optimum process parameters in order to improve the casting quality. Process parameters such as holding furnace temperature, slow shot, Fast shot, Die holding time, Intensification pressure
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Cold Crack Criterion for ADC12 Aluminum Alloy Die Casting

Cold Crack Criterion for ADC12 Aluminum Alloy Die Casting

From the tensile test result in section 3.2, ACD12 alloy die casting showed an elastoplastic behavior even at room temperature and is not completely brittle. Therefore, it is appropriate to consider the occurrence condition of the crack for ACD12 alloy die casting in terms of the strain but not the stress. To investigate the relation between the crack occur- rence and the strain that generated in the die castings during casting, the strain distributions in the die castings in 3 second (the time at which the crack occurred in the die casting having a distance of 1.4 mm between the rings) after melt injection are illustrated in Fig. 9. The maximum strain for each of the die casting is located at the same position, i.e., the narrowest part between the rings at which the crack occurred for the die casting of a distance of 1.4 mm between the rings. Nevertheless, the maximum value of the strain for each die casting is almost the same, about 78%, no matter the crack occurred (The die casting with a distance of 1.4 mm between the rings) or not (The die castings with distances of 2 mm and 4 mm between the rings). At the same time, the strain distributions also do not show much difference.
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Effect of Casting Parameters on the Microstructure and Mechanical Properties of ADC10 Alloys Using a Semisolid Die Casting and Heat Treating Process

Effect of Casting Parameters on the Microstructure and Mechanical Properties of ADC10 Alloys Using a Semisolid Die Casting and Heat Treating Process

To improve the mechanical properties of products made of aluminum alloy through typical casting and forging process- es, heat treating including solution and aging is used. In the solution heat treatment step, alloying elements are dissolved into the aluminum matrix at temperatures above 723 K (450°C) and then quenched in water at room temperature. In the aging step, the aluminum alloy is held between 403 K (130°C) and 473 K (200°C), the elements are precipitated from the matrix and second phase clusters are formed. These clusters prevent the movement of dislocations, which result in improved mechanical properties such as higher hardness and tensile strength. 1,2) For higher productivity and economic feasibility, high-pressure die casting (HPDC) for lightweight vehicles and electronics has been widely used. 3,4) However, in general it is difficult to conduct a commercial scale heat treatment process during HPDC because of the occurrence of inner defects, such as porosity, as gases become trapped during the high-speed fi lling of the mold with molten metal. A porosity increase in the HPDC process up to 1,000 times can be observed when solution heat treatment is applied. 5)
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Various Type of Defects on Pressure Die Casting for Aluminium Alloys

Various Type of Defects on Pressure Die Casting for Aluminium Alloys

Mahesh N Adke et al.(dec-2014) reports on an optimization of Pressure die-casting process parameters to identify optimized level for improving the cycle time using Taguchi method for DOE. AlSic132 up to 20tonn machine capacity is used to calculate cycle time. There are four machining parameters i.e. melting temperature, Injection pressure, Plunger speed, cooling phase. Different experiments are done based on these parameters. Taguchi orthogonal array is designed with three levels and four process Parameters with the help of software Minitab 15. In the first run nine experiments are performed and Cycle time is calculated. Taguchi method stresses the importance of studying the response variation using the signal–to– noise (S/N) ratio, resulting in minimization of cycle time variation due to uncontrollable parameter. The Cycle time was considered as the quality characteristic with the concept of "the larger-the-better". The S/N ratio for the larger-the-better where n is the number of measurements in a trial/row.
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Centralized Monitoring and Controlling Of Die Casting Process

Centralized Monitoring and Controlling Of Die Casting Process

surrounding parts. Designer can gain a number of advantages and benefits by specifying die-casting parts. Die-casting provides complex shapes within closer tolerances than any other mass production process. The general die casting process of manufacturing products to a certain types have been progressed with the condition of process which is generally functioning over monitoring and control with the help of fixed human machine interface. Though it is possible whereas the function is done by displaying significantly via HMI graphically, here the each step of the process over die casting process is generally considered to show with a fixed set of ranges value. Moreover progress is working with the program according to the PLC controller.
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Investigation of factors affecting the Blow Holes in Die Casting Process

Investigation of factors affecting the Blow Holes in Die Casting Process

Abstract: - The objective of this research is to study the factors affecting the blow holes in the die casting process of aluminum alloys R14 for the compressor of the automotive parts. The factors such as the casting pressure, the injection speed, the high starting of the position and the vacuum pressure are investigated. A response surface analysis with the Box-Behnken Design has been employed to obtain the optimum condition in order to minimize the blow holes formation. It has been proved that the amount of blow holes can be reduced by using the experimentally obtained optimum conditions, which are the casting pressure of 85 Mpa, the die casting low injection speed of 0.30 m/s, the high injection speed of 2.49 m/s, the high-speed starting position of 326.81 mm and the vacuum pressure of -97.28 Kpa.
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Design and Fabrication of Semi Automatic Gravity Die Casting Machine

Design and Fabrication of Semi Automatic Gravity Die Casting Machine

In today competitive world of castings, considering competitors and new technology in world we have to change our manual system to automatic or fully automatic system. Casting process also various changing to make the process easy fast and low cost. Out of many processes of casting, there is a process called as Gravity Die Casting. It uses the principle that the molten metal flows under action of gravity

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

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

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.

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Productivity Improvement by Value Stream Mapping in Die Casting Industry

Productivity Improvement by Value Stream Mapping in Die Casting Industry

Abstract: Value Stream Mapping has the reputation of uncovering waste in manufacturing, production and business processes by identifying and removing or streamlining non-value-adding steps. A flow diagram showing the process is drawn to reflect the current state of the operation. The non-value actions are identified in each step and between each step by their waste of time and resources. The process is analyzed with the help of simulation software for opportunity to drastically reduce and simplify it to the fewest actions necessary. By reducing wastefulness the proportion of value adding time in the whole process rises and the process throughput speed is increased. This makes the redesigned process more effective (the right things are being done) and more efficient (needing fewer resources). This paper explains about the corrective methods for eliminating the non-value added activities in the die casting industry with the help of Arena simulation software. The reengineered process is flow charted in its future state with process steps and information flows redesigned, simplified and made less expensive and increase in productivity. Key words: Value Stream, Current Stream Mapping, Future State Mapping, Takt time, Cycle Time, Lean Manufacturing, Simulation.
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Pore Defect Control in Die Casting by Compression Loading

Pore Defect Control in Die Casting by Compression Loading

each area became small; therefore, homogeneity in the specimen was achieved by applying compression. Also, porosity decreased in area III, although the reduction in porosity is lower than for area II. This indicates that, if plastic flow is well controlled, porosity reduction is possible without the direct application of compression. Therefore, compres- sion should be suitable for complex-shape high pressure die casting products.

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Creep Properties of a Zinc-Aluminum Die-casting Alloy as a Function of Grain Size

Creep Properties of a Zinc-Aluminum Die-casting Alloy as a Function of Grain Size

8 characteristic of a 4.0 wt% Al composition. The most common ZAMAK alloy is #3 while #s 2, 5, and 7 are produced but on much smaller scales (6). Each of the alloys differs in their chemical compositions, as listed in Table 1. These alloys have a number of excellent properties such as low cost, high strength and stiffness, and ease of use in hot-chamber die casting machines for large scale production. However, they are unsuitable for service at high temperatures due to their exceptionally poor creep properties [3]. Over the years research has lead to improvements in the creep properties of the zinc based alloys through both increasing the wt% of the primary alloying element Al (the ZA alloys), and through smaller additions of other alloying elements including Al, Ba, Co, Cu, Mg, Ni (14) as well as Li, Cr, Ti, and Ca [15]. More current research is leaning towards Al and Cu as being the most desirable two alloying elements for creep resistance with the ACuZinc alloys patented by General Motors in 1991 [16] and a ternary eutectic alloy being jointly developed by the Council for Scientific and Industrial Research (CSIR) and the International Zinc Association (IZA) [17] each showing improved creep resistance.
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Influence of Processing Parameters on the Performances of High Pressure Die Casting Process

Influence of Processing Parameters on the Performances of High Pressure Die Casting Process

Shrinkage can cause dryness, inaccurate casting dimensions and porosity. The main role of the third stage pressure is to reduce the porosity and give a better casting surface. The action of high pressure fills the pores and defects of the volume. That is why pressure has the greatest influence on the results of experiments. The shrinkage as well as the quality of the casting are influenced by the temperature regime of the mould. When the mould has a high temperature, the melt binds to the mould and the amount of bubbles and pores increases, while in the cold mould the crystalline compounds are formed during the casting, resulting in poorer surface quality. Also melt temperatures are avoided due to heat shocks caused by contact with the colder mould surface. Therefore, the temperature is sought to be somewhere around 10 °C to 20 °C higher than the crystallization temperature of the melt. The temperature of the melt and the mould with additional cooling create crystallization conditions. Those in the die-casting process can significantly improve the mechanical properties and structure.
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Elimination of Wastes In Die Casting Industry By Lean Manufacturing: A Case Study

Elimination of Wastes In Die Casting Industry By Lean Manufacturing: A Case Study

Abstract: - As the competition in market is growing at a very fast pace, one can survive in today’s industrial world by adopting the philosophy of Lean Manufacturing. In order to stay competitive, producing cheaper products at a faster rate Lean Manufacturing would help the industry. This paper represents a case study of Die casting industry. This case study is used to illustrate the steps in implementation of lean manufacturing providing actual and very positive results. The implementation plan is based on five major areas of wastes including Defects, Inventory, Excessive material movement, Delay due to waiting and Inappropriate processing in a die casting industry. The suggested implementation plan is being sub divided into three phases.
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Temperature measurement and thermal control of die casting processes using CCD cameras

Temperature measurement and thermal control of die casting processes using CCD cameras

In order to implement a CCD-based temperature measurement system that is not intrusive or disruptive to the current casting process, the die can only be imaged during the the extraction phase of the casting cycle. Therefore, the only temperature information available shows the temperature distribution of the die immediately after the solidification process completes. Figure 3.1 shows how the vision system would be physically incorporated into the current die casting system without disrupting the casting process. Note that at least two separate camera systems are ultimately needed since there are two separate die halves, and that the camera systems can be placed on either side of the casting machine, not necessarily on top as shown in the figure.
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