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HOUSING FOR LIGHT FITTING IN
TRAIN BY DIE CASTING METHOD
ENROLLMENT NO.:- 150490728006
Prepared By : Misal Gandhi
Branch : M.E. (Production)
Guided By : Mr. Hardik Naik
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OBJECTIVE
Within 2 minute faster casting product
Higher Production Rate
Less Human Errors
Faster Products due to Semi –
Automatic DieCasting Process
Highly Customer Satisfaction of Quality Product
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INDUSTRY PROFILE
Nandratan Foundry manufactures ferrous and
nonferrous castings (as cast or with machining),
Plant based in Sarigam, Gujarat and 160 kms
from Mumbai casting and fabrication.
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INDUSTRY PRODUCTS
Ferrous Castings
• Ductile iron (SGCI) castings like valve bodies,
spools, flanges, links, levers, water connection
kits, boxes, dampers, oil seals, housings to name
a few.
Nonferrous Castings
• Aluminum base product like gear cases, housing
for light fittings, venturies, housing for
automobile components, electrical motor housing,
transmission line components etc.
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PLANT LAYOUTS- EQUIPMENTS
Plant & Machinery
• Foundry
• 150 kW medium frequency induction furnace
with 250 kg crucible• 3 oil fired pit furnaces
• 2 coke fired pit furnaces
• Molding machine
Fettling Shop
• Shot blasting machine
• Swing frame grinders
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PLANT LAYOUTS- EQUIPMENTS
Machine Shop
• Heavy duty lathes
• Milling machines
• Drilling machines
•
Tapping machines• Facing machines
Fabrication Shop
• Heat treatment furnace
• Rolling mill• Hydraulic & pneumatic power presses
• Shearing machines
• Pedestal grinders
• Welding equipments
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INTRODUCTION
Die casting is a manufacturing process that can
produce geometrically complex metal parts through
the use of reusable molds, called dies.
The die casting process involves the use of a furnace,
metal, die casting machine, and die. The metal, typically a nonferrous alloy such as
aluminum or zinc, is melted in the furnace and then
injected into the dies in the die casting machine.
There are two main types of die casting machines hotchamber machines (used for alloys with low melting
temperatures, such as zinc) and cold chamber
machines (used for alloys with high melting
temperatures, such as aluminum).
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DIE CASTING HOT CHAMBER MACHINE
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DIE CASTING COLD CHAMBER MACHINE
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DIE – CASTING M/C USED IN INDUSTRY
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PRODUCT PROCESS CYCLE
Clamping
Injection
Cooling Ejection
Trimming
Pouring
Clamping
Cooling Ejection
Removal ofCore
Trimming
General PPC In Industry PPC
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EQUIPMENTS
Cold chamber die casting machine Cold
• Open holding pot – It place in to furnace
• Plunger – Powered by Hydraulic or Manually
• Induction Furnace
• Grinding Machine
• Cutting Machine
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DIE CASTING W ALL THICKNESS
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MACHINE SPECIFICATION
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 thepressure with which the molten metal is injected.
Also, certain materials that require high injection
pressures may require higher tonnage machines.
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MATERIAL
Die casting typically makes use of nonferrous
alloys. The four most common alloys that are die
cast are shown below, along with brief
descriptions of their properties.
Aluminum alloys
• Low density
• Good corrosion resistance
•
High thermal and electrical conductivity• High dimensional stability
• Relatively easy to cast
• Requires use of a cold chamber machine
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1.Wall thickness: 2.Corner:
Incorrect Incorrect
Non-uniform wall thickness. Sharp corner.
Correct Correct
Uniform wall thickness. Rounded corner.
DESIGN RULES
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3.Draft: 4.Undercuts:Incorrect Incorrect
No draft angle. Die cannot separate.
Correct Correct
With draft angle. Die easily separet.
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Flash- Due to injection pressure too high& clamp force too low.
Hot tearing- Due to non-uniform cooling
rate.Bubbles- Due to very high injection
temperature & non-uniform cooling rate.
Unfilled sections- Due to slow injection& low pouring temperature.
Ejector marks- Due to very shortcooling time & high ejection force.
POSSIBLE DEFECTS
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Very high rate of production is achieved.
Close dimensional tolerances of + 0.025 mm is
possible.
Surface finish of o.8 microns can be obtained.
Very thin sections of 0.50 mm can be cast.
Longer die-life is obtained.
Less floor space is required.
Unit cost is minimum.
A DVANTAGES OF DIE CASTING
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Only economical for nonferrous alloys.
Not economical for small runs.
Heavy castings cannot be cast.Cost of die and die casting equipment is high.
Die casting usually contain some porosity due
to the entrapped air.
DISADVANTAGES OF DIE CASTING
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CONCLUSION
By using this casting method we can get complex
casting shapes at Higher production at minimum
time in less effort.
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THANK YOU