MANUFACTURING PROCESSES LAB REPORT
CONTENTS:
DIE CASTING TYPES OF DIE CASTING PRESSURE DIE CASTING TYPES OF PRESSURE DIE CASTING APPLICATIO APPLICATIONS NS OF PRESSURE DIE CASTING ALLOYS BEING USED USED
SUBMITTED BY: MUHAMMAD AAQIB AMIN REG.NO:2015-IM-48 SUBMITTED TO: MISS SANA EHSAN
DIE CASTING
Die casting is a permanent mol casting proce!re" in #$ic$ t$e mol is mae o% metal an large n!m&er o% castings are pro!ce %rom it' T$e mol ca(it) is create !sing t#o $arene tool steel ies #$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$os,
1 Gr!"#$ D"% C&#"'()P%r*'%'# +"% ,&#"'( •
Lo# press!re ie casting
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Sl!s$ casting
2. Pr%&&r% D"% C&#"'( •
-ot c$am&er ie casting
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Col c$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 !ner $ig$ press!re a molten metal allo) into a steel mol 0or tool1' T$is gets solii%ie rapil) 0%rom millisecons to a %e# secons1 to %orm a net s$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 $as #ier application encompassing nearl) 345 o% all lig$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 $ols t$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#ars intro!ce into t$e mol ca(it)' T$is is one !sing a $)ra!licall)/ri(en piston' A%ter t$e metal $as solii%ie" t$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)liner 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,
T$e $ot/c$am&er ie casting m8c consists o%,
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•
•
• • •
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(ie 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$e casting H$+r3", ,"r,"#, T$is operates t$e press!re c)liners 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# insie'
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 insie 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$e ie is %ille" metal is le%t to solii%)'
A%ter
solii%ication" press!re is remo(e" t$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$anical components' T$e metals incl!es :inc" tin" lea" an magnesi!m'
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 $an/lale into t$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,
T$e col/c$am&er m8c consists o% %ollo#ing parts,
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)liner #$ere molten metal is po!re in' Die: T$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$+r3", ,"r,"#, T$is operates t$e press!re c)liners an a!tomates o% all processes'
Pr/,%&&,
A ie/c)cle is complete in %ollo#ing steps, ; T$e lale &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$e ie is %ille" metal is le%t to solii%)' ; Press!re is maintaine !ring solii%ication &) a pl!nger or compresse air' ; A%ter solii%ication" press!re is remo(e" t$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$e ca(it)' LO PRESSURE DIE CASTING,
-ig$ .!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$is" %irst a metal ie is positione a&o(e a seale %!rnace containing molten metal' A re%ractor)/line riser e2tens %rom t$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 $as solii%ie" t$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$ere is !s!all) onl) one in gate an no %eeers'
; L/ Pr%&&r% D"% C&#"'( Pr/,%&&
APPLICATIONS OF PRESSURE DIE CASTING: •
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A!tomoti(e parts li*e #$eels" &loc*s" c)liner $eas" mani%ols etc' Aerospace castings'
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Electric motor $o!sings'
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@itc$en #are s!c$ as press!re coo*er'
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Ca&inets %or t$e electronics in!str)'
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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 ieal %or metals t$at ont reail) attac* an eroe metal pots" c)liners" an pl!ngers'
; T$is process is limite in its applications to lo# melting point metals $a(ing $ig$ %l!iit)' ; inc: t$e easiest metal to cast9 $ig$ !ctilit)9 $ig$ impact strengt$9 easil) plate9 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 %ooser(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$en lale into a col c$am&er to &e in+ecte into t$e ie'
; Alt$o!g$ col c$am&er process is applica&le to most o% allo)s &!t !e to laling operation its pro!ction spee is slo#' ; A3*"'*, lig$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 strengt$/to/#eig$t ratio9 lig$test allo) commonl) ie cast'
