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
CONTENTS
Objective
Introduction
Industry Profile
Process Cycle
Equipments
Machine Specification
Suitable Material
Advantages-Disadvantages & Application
Video
Conclusion
Future Scope
OBJECTIVE
Within 2 minute faster casting product
Higher Production Rate
Less Human Errors
Faster Products due to Semi Automatic Die
Casting Process
Highly Customer Satisfaction of Quality Product
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.
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.
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
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
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 hot
chamber 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).
DIE CASTING HOT CHAMBER MACHINE
DIE CASTING COLD CHAMBER MACHINE
DIE CASTING M/C USED IN INDUSTRY
PRODUCT PROCESS CYCLE
General PPC
Clamping
Injection
Cooling
Ejection
Trimming
In Industry PPC
Pouring
Clamping
Cooling
Ejection
Removal of
Core
Trimming
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
DIE CASTING WALL THICKNESS
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 the
pressure with which the molten metal is injected.
Also, certain materials that require high injection
pressures may require higher tonnage machines.
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
DESIGN RULES
1.Wall thickness:
Incorrect
Non-uniform wall thickness.
Correct
Uniform wall thickness.
2.Corner:
Incorrect
Sharp corner.
Correct
Rounded corner.
3.Draft:
Incorrect
No draft angle.
Correct
With draft angle.
4.Undercuts:
Incorrect
Die cannot separate.
Correct
Die easily separet.
POSSIBLE DEFECTS
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 short
cooling time & high ejection force.
ADVANTAGES OF DIE
Very
CASTING
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.
DISADVANTAGES OF DIE
Only
CASTING
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.
CONCLUSION
By using this casting method we can get complex
casting shapes at Higher production at minimum
time in less effort.
THANK YOU
