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1.Casting design considerations.

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30 views31 pages

1.Casting design considerations.

Uploaded by

Rohan Vashishta
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CASTING DESIGN CONSIDERATIONS

THE CASTING DESIGN CONSIDERATIONS FALLS INTO VARIOUS


CATERGORIES :

 PRODUCT DESIGN

 MACHINE PARAMETERS

 TOOLING PARAMETERS
THE PRODUCT DESIGN

 Maximum wall thickness

 Corners

 Drafts

 Material
Maximum Wall Thickness
• Decrease maximum wall thickness of a part to shorten cycle time
(injection time and cooling time specifically) & reduce the part
volume

Part with thick walls- INCORRECT

Part redesigned with thin walls- CORRECT


Maximum Wall Thickness

Non-uniform wall thickness (t1 ≠ t2) - INCORRECT

CORRECT-Uniform wall thickness (t1 = t2)


Corners
•Round corners to reduce stress concentrations and fracture.

•Inner radius should be at least the thickness of the walls

Incorrect
Sharp corner

Correct

Rounded corner
Draft
Offset of walls of part - slight angle referred as draft angle.

Draft angle often required on surfaces of part are parallel to tooling


direction in order to facilitate easy removal from a mold.

However, some processes do not require part to have any draft.


MATERIALS

Product material selected based

Physical & Mechanical properties


Product application.

Material selected affects part design.


Example zinc - highly ductile metal can allow for thinner walls and
better surface finish than many other alloys.

Material not only determines properties of final casting


Also impacts machine & tooling.
MACHINE PARAMETERS:

1) Machine Capacity – Total Locking Force


2) Injection force adjustable - with intensifier
3) Die mounting plates (Platens) Sizes
4) Space between tie bars
5) Maximum & Minimum Die height
6) Die opening stroke
7) Maximum Shot Weight
8) Injection plunger stroke
9) Ejector stroke adjustable
10)Plunger diameter injection
11)Maximum pressure.
Machine specifications
Hot chamber & Cold chamber die casting machines are typically
characterized by tonnage of total clamp force they provide.

Required clamp force determined by projected area of the casting


in die & pressure with which molten metal injected.

Larger part require larger clamping force.

Materials requiring high injection pressures may require higher


tonnage machines.
Machine specifications

Part size must also comply with other machine specifications

 Maximum shot volume


 Clamp stroke,
 Minimum mold thickness
 Platen size.
TOOLING PARAMETERS
1) Tool size - LxWxH

2) Clamping force – Force required to clamp the tool.

3) Separating force - The outward force exerted on the die halves

4) Cavity pressure - The pressure inside the die cavities caused by

the injection of molten material during the die fill stage

5) Projected area -The area of a part or feature that is projected

onto the X-Y plane. In casting processes


TOOLING PARAMETERS
6) Shot -The amount of material that is injected or poured into a die

7) Parting line - The line along a part where the die halves separate

8) Sprue -The main channel through which molten material enters a die.

9) Runner - A channel in a die that delivers the molten material to the

die cavities.

10) Gate - An opening at the end of a runner, which directs the flow of

molten material into the die cavity.


Clamp Force
Force applied on die by die casting machine keeps die securely closed
while material is injected.

Clamp force ˃ separating force, which is the outward force exerted on


die halves by injected material.
Separating force
Outward force exerted on die halves caused by injection of molten
material during die filling stage.

Separating force is product of cavity pressure and the projected


area of the shot.

Clamp force applied on die ˃ than this separating force to keep die
securely closed → material being injected.
Cavity Pressure
Pressure inside die cavities caused by injection of molten material
during die filling stage.
Cavity pressure depends on material, injection pressure , geometry
of cavities & runner system.
For most alloys cavity pressure is between 4,000 & 10,000 psi.
Cavity
Enclosed space between two mold halves forms shape of desired
part.

Dies designed with more than one cavity


Multiple identical parts casted in one cycle.
Most common number of cavities are 1, 2, 4, or 8.
Projected Area
Part area or feature projected onto X-Y plane. In casting processes
Area projected onto die surface because Z-axis parting direction.
The projected area can be approximated by a percentage of the X-Y
side of the envelope.
Shot
Amount of material injected or poured into die.
The shot volume includes the volume of all part cavities
Feed system which delivers the material.
Amount of material forming the parts relative to total shot volume
is material yield.
Shot volume ˂ than shot capacity of machine being used.
Projected area of shot describes projected area of all die space
that fills with material.
Platen
Large plate onto which a die half is mounted.
One platen is stationary, other is movable.
Larger machine has larger platen dimensions & therefore
accommodate a larger die.

Parting line
Line along part where die halves separate.
Simple mold, this line will be straight.
Complex dies may have a stepped or curved parting line.
PROCESS CYCLE
Process Cycle
Process cycle consist 4 main stages
 Clamping
 Injection
 Cooling
 Ejection
Process Cycle
Clamping

Preparation of die halves

Die halves cleaned first


Spraying – 2/3 cycles once
Closing
Securely locking
Sufficient force applied → dies securely locked during injection
of molten metal
Time required →close & clamp die halves depends on machine
Process Cycle
Injection
 Molten material maintained @ set temp in furnace
 Transferred to shot chamber of machine – depend on type of
machine
 Injected in to die @ high pressure – ranging 1000psi – 20,000 psi
 Injection time → time to fill the die & all channels
 Short time → less than 0.1 sec – prevents early solidification
 Determined by thermodynamics properties
 Greater wall thickness → longer cycle time
 In cold chamber machine injection time includes ladling time
Cooling
Molten metal injected in to die starts cooling and solidify
On solidification → final shape of casting takes place
Die cannot be opened → still cooling time has elapsed &
molten metal solidified
Estimated by several thermodynamics properties of metal
wall thickness of casting → greater wall thickness requires
longer time
Complexity of part design
Ejection
On solidification & at predetermined cooling time

 Die halves opens @ parting surface


 Casting with feed system attached is retained in core side
 Ejection mechanism ejects the casting
 Time to open die → estimated from dry cycle time
 Ejection time determined by casting parameters / geometry
 Ejection completed & die is closed for next cycle
Metal Minimum section Minimum draft
Aluminium alloys 0.89 mm (0.035 in) 1:100 (0.6°)
Brass and bronze 1.27 mm (0.050 in) 1:80 (0.7°)

Magnesium alloys 1.27 mm (0.050 in) 1:100 (0.6°)


Zinc alloys 0.63 mm (0.025 in) 1:200 (0.3°)
Typical die temperatures and life for various cast materials[16]
Brass
Zinc Aluminiu Magnes (leaded
m ium yellow)
Maximum die life
[number of cycles] 1,000,000 100,000 100,000 10,000
260
Die temperature [C° (F°)] 218 (425) 288 (550) (500) 500 (950)
Casting temperature [C° 660 760
(F°)] 400 (760) (1220) (1400) 1090 (2000)
The die casting process relies on controlling a
number of critical variables. Specifically, they
are:
• Alloy temperature during injection

• Cavity fill time, expressed in milliseconds

• Die temperature measured in the die cavity area

• Gate velocity, expressed in feet, meters or inches per second

• In the cold chamber process, critical slow shot velocity expressed in


meters or inches per second
• Cavity pressure during intensification expressed in P.S.I. or Kg/cm
• Hydraulic intensification pressure, expressed in P.S.I. or Kg/cm
• Rise time to intensification expressed in milliseconds
• Controlling the locking force on the die, expressed in U.S. or metric tons
• Limiting the force on the die faces and platens expressed in tons/square
inch or tons/square centimeter

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