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Die Casting 12345

The document discusses pressure die casting, including its history, types (hot chamber vs cold chamber), dies used, potential defects, and advantages/disadvantages. It provides an introduction to die casting, then covers the history of casting technology dating back 5000 years, describes the two main types of die casting (hot and cold chamber), lists common defects, and discusses advantages like high production rates and disadvantages like high costs for small runs.

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Ayush Pandey
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48 views15 pages

Die Casting 12345

The document discusses pressure die casting, including its history, types (hot chamber vs cold chamber), dies used, potential defects, and advantages/disadvantages. It provides an introduction to die casting, then covers the history of casting technology dating back 5000 years, describes the two main types of die casting (hot and cold chamber), lists common defects, and discusses advantages like high production rates and disadvantages like high costs for small runs.

Uploaded by

Ayush Pandey
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Dr.

Akhilesh Das Gupta


Institute of
Technology & Management

Manufacturing processes
Topic:
PRESSURE DIE CASTING

Created by :

ADITYA SINGH

AYUSH PANDEY

MADHUR GAUTAM
Introduction.
History of casting.
Types of Die casting.
Types of Dies are used in Die casting.
Possible Defects in Die casting.
Advantages & Disadvantages of die casting.
INTRODUCTION
 Die casting is the art of rapidly and
accurately dimensioned parts producing
by the forcing molten metal under
pressure into split metal dies which
resemble a common type of permanent
mould.
 This process is particularly suitable for
lead , magnesium ,tin , zinc alloy , copper
and aluminium metals.
HISTORY OF CASTING
➢Casting technology , according to biblical records ,
reaches back almost 5000 years B.C., 3200 B.C. a copper
frog , the oldest known casting in existence , was cast in
mesopotamia.
➢ 460 B.C. Bronze statue of zeus (the supreme god of
ancient Greek mythology) was cast in Greece.
➢ 233 B.C. cast iron plowshares were poured in China.
➢ 1455 A.D Dillenburg castle in germany was the first
person to use cast iron pipe to transport water.
➢ 1480 A.D. Birth of vannoccio Biringaccio ( 1480-1539) ,
“the father of foundry industry” in Italy , He was the first
man to document the foundry process in writing.
TYPES OF DIE CASTING

Hot chamber casting Cold chamber casting


HOT CHAMBER DIE CASTING
In hot chamber die casting the plunger operates in one end of
gooseneck which is submerged in molten metal.

Therefore molten metal flow by gravity into the cylinder by help of


intake port, after applying force on plunger , the molten metal is forced into
the die through the gooseneck channel and in gate.

The force on plunger may be manually , mechanically or hydraulically.

And at bottom one burner is provided for continuous heating


throughout the operation to keep the metal in liquid form.

Here the air pressure is below 150 kg/ cm2


HOT CHAMBER DIE CASTING
COLD CHAMBER DIE CASTING

In cold chamber die casting the horizontal plunger is driven by air or


hydraulic pressure to force the molten metal into the die.

After pouring molten metal by ladle into the cylinder , the plunger will
move inside and forces the molten metal into the cavity.

After the metal solidified, the core is removed and then the die is
opened.

Ejectors are provided to remove the casting automatically from the die.

Pressure loosely in cold chamber machine range from 300 to 1600 kg/
cm2 .
COLD CHAMBER DIE CASTING
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
TYPES OF DIE USED IN DIE CASTING

1. Single cavity Die: The single cavity die


mainly used to produce one component
at time of casting.
2. Multiple cavity Die: It is used to produce
a number of identical parts at one time
3. Unit die: Unit die is used to produce
different parts at one time.
4. Combination Die: It is used to produce
several different parts for an assembl
ADVANTAGES OF DIE CASTING

 Very high rate of production is achieved.

 Very thin sections of 0.50 mm can be cast.

 Longer die-life is obtained.

 Less floor space is required.

 Unit cost is minimum.


DISADVANTAGE OF DIE CASTING

 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.

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