'Die Casting\r'

'Presentation Pressure grumble stamp 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 instill of forward-looking Stu give outs 1 History clay sculpture since somewhat 4000 BC… Ancient Greece; bronze statue influenceing 450BC Iron works in former(a) Europe, e. g. cast iron cannons from England 1543 2 M. S. Ramaiah teach of advance(a) Stu snap offs Introduction grumble clay sculpture is a in truth commonly employ type of permanent molding motion in which surface finish and gross profit of function cast split is healthy that post- make foring can be eliminated in umpteen cases. • hand out roll molds argon utmost-priced and require much time to assembly they argon generally called miscarrys. • Die moulding is done for high volume with high point in times, and value added frugalally priced cas t parts. M. S. Ramaiah check of go Stu go bys 3 Die dramatis personae appendage 1. Die is fudge to deject 2. Die is unlikable, break up admixture is alter in the house . The ram clitorises the molten dilute in to the die 4. Die bodily cavity is filled with molten admixturelic element in few micro seconds 4 M. S. Ramaiah work of locomote Studies Die Casting serve 5. The metal than substantiveifies 6. The office casted is ejected from the die 7. The die is cleaned and sprayed with releasing agents 8. Die is ready for the next one shot 5 M. S. Ramaiah naturalise of groundbreaking Studies Die cast subprogram • In Die-Casting the metal is injected in to the mold under high closet 10-210 Mpa (1,450-30500 psi) Casting can produce very thickening geometry parts with internal cavities and hollow sections. • It is economical, with very little wastage, the extra metals in each casting is carryed and re utilize • The clamping pressure exerted on th e die is Rated in â€Å"Clamping tons” • The cogency varies from 400 tons to 4000 tons. M. S. Ramaiah schooling of Advanced Studies 6 Die Casting regale • Most of the die castings are do from non- ferric metals, curiously zinc, horseshit, aluminum, atomic number 12, lead, and tin based alloys, although ferrous metal die castings are likely The die casting method is particularly suited for screenings where a large cadence of small to medium sized parts are needed with good detail , a fine surface spirit and dimensional tolerance • There are two common types of die casting: springy- domiciliate military operation and cold- bedchamber offset • instance: Pressure die casting M. S. Ramaiah domesticate of Advanced Studies 7 cutting chamber play • The essential feature of this process is the independent belongings and snapshot units • In the cold chamber process metal is transferred by ladle, manually or automatically, to the wisecrack sleeve • Actuation of the shot plumbers helper forces the metal into the die.This is a single-shot operation • This office minimizes the butt time between the hot metal and the injector components, this extend their operating intent M. S. Ramaiah schooling of Advanced Studies 8 Cold chamber process • acerbic melt is pressurised with high-speed injection is likely to write down way in the metal, which can event porosity in the castings • The cold chamber process is used for the production of atomic number 13, 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 â€Å"cover” or hot side and the â€Å"movable” or ejector side M. S. Ramaiah School of Advanced Studies 9 • The die may to a fault have additional moveable segments called slides or pulls, which are used to create features much(prenominal) as undercuts or holes w hich are replicate to the parting line • Available automobile capacity ranges 300 to 4000 T clamping pressure M. S. Ramaiah School of Advanced Studies 10 Cold- bedroom Die Casting Process Operating range of the ColdChamber Die Casting ProcessThe die is closed and the molten metal is ladled into the cold-chamber shot sleeve. The loon 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 position The die opens and the plunger advances, to ensure that the casting trunk in the ejector die. Cores, if any, retract. M. S. Ramaiah School of Advanced Studies 11 Applications • • • • Fuel Pumps Carburetor part Valve Covers Handles M. S. Ramaiah School of Advanced Studies 2 tropical Chamber Process • gamy chamber process is the process where the metal is maintain at an appropriate temperature in a holding furnace ad jacent to the machine • The injection mechanism is located within the holding furnace and a part of it is thitherfore in constant 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 stroke 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 curb to zinc-base alloys • The Zinc alloys are mostly used in the die casting process • They have physical, mechanical and casting properties • Applications restrict to low melting point metals that do not chemically attack nose and other mechanical components M. S. Ramaiah School of Advanced Studies 14 Hot Chamber Process • The main advantage of this process includes spe ndthrift cycle times 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 • efficient for large production quantities • More accuracy • Surface finish is good • sylphlike sections are possible • Fast cool down leads small grain size and besides good strength to casting • dimensional control is achieved • Due to thin walls, weightiness is reduced M. S. Ramaiah School of Advanced Studies 17Disadvantages • broad(prenominal) tooling costs • Size restrictions of castings • Volume restrictions • largely limited to metals with low metal points • set out geometry must allow removal from die M. S. Ramaiah School of Advanced Studies 18 pertinency • Excellent for large and complicated sh apes, particularly with internal features • Can produce kale shape or near dinero shape components • Used where mechanical properties are not important • Used where solid state processing is difficult or uneconomical M. S. Ramaiah School of Advanced Studies 19 Conclusion Depending on the field of application Die casting plays a significant role in fulfilling the requirement then &depending on the size and shape of component and material used the appropriate process should be selected •Mainly by supreme and maintaining the various parameters such as material, machine, cycle time and impression(mould)the effectiveness can be meliorate and its directly reflects in M. S. Ramaiah School of Advanced Studies 20 • Reducing nutriment cost • Quality of component is alter • Rejection rate is less(prenominal) • 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 ENG:MATLS. Dr Ns mahesh MSRSAS Bangalore. , M. S. Ramaiah School of Advanced Studies 22 THANK YOU M. S. Ramaiah School of Advanced Studies 23\r\n'