Permanent Mold Casting Processes. Permanent Mold Casting Processes. Permanent Mold Casting Processes. Introduction. Permanent-Mold Casting

Size: px
Start display at page:

Download "Permanent Mold Casting Processes. Permanent Mold Casting Processes. Permanent Mold Casting Processes. Introduction. Permanent-Mold Casting"

Transcription

1 Permanent Mold Casting Processes Permanent Mold Casting Processes Economic disadvantage of expendable mold casting: A new mold is required for every casting In permanent mold casting, the mold is reused many times Permanent Mold Casting Processes The processes include: Basic permanent mold casting Die casting Centrifugal casting Introduction In expendable mold casting, a separate mold is produced for each casting Low production rate for expendable mold casting If multiple-use molds are used, productivity can increase Most multiple-use molds are made from metal, so most molds are limited to low melting temperature metals and alloys Permanent-Mold Casting Also known as gravity die casting Mold can be made from a variety of different materials Gray cast iron, alloy cast iron, steel, bronze, or graphite Most molds are made in segments with hinges to allow rapid and accurate closing Molds are preheated to improve properties Liquid metal flows through the mold cavity by gravity flow Process can be repeated immediately because the mold is still warm from the previous casting Most frequently cast metals Aluminum, magnesium, zinc, lead, copper, and their alloys If steel or iron is to be used, a graphite mold must be used 1

2 The Basic Permanent Mold Process Uses a metal mold constructed of two sections designed for easy, precise opening and closing Molds used for casting lower melting point alloys are commonly made of steel or cast iron Molds used for casting steel must be made of refractory material, due to the very high pouring temperatures Steps in (1) Mold is preheated and coated for lubrication and heat dissipation (2) Cores (if any are used) are inserted and mold is closed Steps in Steps in (3) Molten metal is poured into the mold, where it solidifies Advantages of Permanent-Mold Casting Near- net shapes Little finish machining Reusable molds Good surface finish Consistent dimensions Directional solidification Disadvantages of Permanent Mold Casting Limited to lower melting temperature alloys High mold costs Mold life is strongly tied to cost Mold life is dependent on the following Alloys being cast Mold material Pouring temperature Mold temperature Mold configuration High production runs can validate high mold costs Molds are not permeable Limited mold complexity 2

3 Applications and Metals for Due to high mold cost, process is best suited to high volume production and can be automated accordingly Typical parts: automotive pistons, pump bodies, and certain castings for aircraft and missiles Metals commonly cast: aluminum, magnesium, copper-base alloys, and cast iron Unsuited to steels because of very high pouring temperatures Applications and Metals for Low-Pressure and Vacuum Permanent-Mold Casting Schematic of the low-pressure permanent-mold process. Schematic illustration of vacuum permanent-mold casting. Note the similarities to the low-pressure process. Low Pressure Permanent-Mold Casting Tilt-pour permanent-mold casting Mold is rotated to force flow into the cavity Low pressure permanent-mold casting Mold is upside down and connected to a crucible that contains the molten metal Pressure difference induces upward flow Metals are exceptionally clean because it is fed directly into the mold Little or no turbulence during flow Typical metals cast using low pressure process Aluminum, magnesium, and copper Low Pressure Permanent-Mold Casting Vacuum Permanent-Mold Casting Atmospheric pressure in the chamber forces the metal upward after the vacuum is drawn Thin-walled castings can be made Excellent surface quality Cleaner metals than low pressure Lower dissolved gas content Better mechanical properties than low pressure casting 3

4 Die Casting Molten metal is forced into the mold under high pressure Held under high pressure during solidification Castings can have fine sections and complex details Long mold life Typical metals cast Zinc, copper, magnesium, aluminum, and their alloys Die Casting A permanent mold casting process in which molten metal is injected into mold cavity under high pressure Pressure is maintained during solidification, then mold is opened and part is removed Molds in this casting operation are called dies; hence the name die casting Use of high pressure to force metal into die cavity is what distinguishes this from other permanent mold processes Basic Types of Die-Casting Hot chamber castings Fast cycling times No handling or transfer of molten metal Used with zinc, tin, and lead-based alloys Heated-manifold direct injection die casting Molten zinc is forced though a heated manifold Next through heated mini-nozzles directly into the die cavity Eliminates the need for sprues, gates and runners Basic Types of Die Casting Cold-chamber machines Used for materials not suitable for hot chamber machines Typical materials Aluminum, magnesium, copper, and high-aluminum zinc Longer operating cycle than hot-chamber High productivity Summary of Die Casting Dies fill so fast with metal that there is little time for the air in the runner and die to escape Molds offer no permeability Air can become trapped and cause defects Risers are not used because of the high pressures used Sand cores can not be used due to high pressures Cast-in inserts can be used High production rates Little post casting finishing necessary Hot-Chamber Die Casting Metal is melted in a container, and a piston injects liquid metal under high pressure into the die High production rates 500 parts per hour not uncommon Applications limited to low melting-point metals that do not chemically attack plunger and other mechanical components Casting metals: zinc, tin, lead, and magnesium 4

5 Hot-Chamber Die Casting Hot-chamber die casting cycle: (1) with die closed and plunger withdrawn, molten metal flows into the chamber Hot-Chamber Die Casting (2) plunger forces metal in chamber to flow into die, maintaining pressure during cooling and solidification. Hot-Chamber Die Casting (3) Plunger is withdrawn, die is opened, and casting is ejected Cold-Chamber Die Casting Machine Molten metal is poured into unheated chamber from external melting container, and a piston injects metal under high pressure into die cavity High production but not usually as fast as hot-chamber machines because of pouring step Casting metals: aluminum, brass, and magnesium alloys Advantages of hot-chamber process favor its use on low melting-point alloys (zinc, tin, lead) Cold-Chamber Die Casting Cycle (1) With die closed and ram withdrawn, molten metal is poured into the chamber Cold-Chamber Die Casting Cycle (2) Ram forces metal to flow into die, maintaining pressure during cooling and solidification 5

6 Cold-Chamber Die Casting Cycle (3) Ram is withdrawn, die is opened, and part is ejected Molds for Die Casting Usually made of tool steel, mold steel, or maraging steel Tungsten and molybdenum (good refractory qualities) used to die cast steel and cast iron Ejector pins required to remove part from die when it opens Lubricants must be sprayed onto cavity surfaces to prevent sticking Die Modifications and Die Life Die complexity can be improved through the use of Water cooled passages Retractable cores Moving pins to eject castings Die life Limited by erosion and usage temperature Surface cracking Heat checking Thermal fatigue Advantages of Die Casting High production rates Good strength Intricate shapes Dimensional precision Excellent surface qualities Small-medium sized castings Die Casting: Advantages Advantages: Economical for large production quantities Good accuracy and surface finish Thin sections possible Rapid cooling means small grain size and good strength in casting Die Casting: Limitations Disadvantages: Generally limited to metals with low metal points Part geometry must allow removal from die 6

7 Die-Casting Dies Die Cast Materials Various types of die-casting dies. Die Casting Machines Die Casting Products Squeeze Casting Combination of casting and forging in which a molten metal is poured into a preheated lower die, and the upper die is closed to create the mold cavity after solidification begins Differs from usual closed-mold casting processes in which die halves are closed before introduction of the molten metal Compared to conventional forging, pressures are less and finer surface details can be achieved Squeeze Casting 7

8 Semi-Solid Metal Casting Family of net-shape and near net-shape processes performed on metal alloys at temperatures between liquidus and solidus Thus, the alloy is a mixture of solid and molten metals during casting (mushy state) To flow properly, the mixture must consist of solid metal globules in a liquid Achieved by stirring the mixture to prevent dendrite formation Semi-Solid Metal Casting: Advantages Complex part geometries Thin part walls possible Close tolerances Zero or low porosity, resulting in high strength of the casting Squeeze Casting and Semisolid Casting Advantages High production Thin-walled parts Good surface finish Dimensional precision Good mechanical properties Squeeze Casting Large gate areas and slow metal velocities to avoid turbulence Solidification occurs under high pressure Intricate shapes with good mechanical properties Reduced gas and shrinkage porosity Semisolid Casting Semi-solid processing is typically classified into two major categories: Thixocasting and Rheocasting. Rheocasting Molten metal is cooled to semisolid Metal is stirred to break up dendrites Rheocasting Thixocasting Thixocasting refers to any process that starts with a specially prepared alloy that is reheated from ambient to the desired No handling of molten metal Metal is stirred as in rheocasting and produced into blocks or bars Metal is then reheated to semisolid and can be handled as a solid but processed as a liquid Injection system used is similar to the one used in plastic injection molding 8

9 Centrifugal Casting A family of casting processes in which the mold is rotated at high speed so centrifugal force distributes molten metal to outer regions of die cavity The group includes: True centrifugal casting Semicentrifugal casting Centrifuge casting Centrifugal Casting Methods True centrifugal casting Semicentrifugal casting Centrifuge casting True centrifugal casting Semicentrifugal casting Centrifuge casting Molten metal is poured into rotating mold to produce a tubular part In some operations, mold rotation commences after pouring rather than before Parts: pipes, tubes, bushings, and rings Outside shape of casting can be round, octagonal, hexagonal, etc, but inside shape is (theoretically) perfectly round, due to radially symmetric forces Setup for true centrifugal casting 9

10 Advantages: Pipe and similar products can be produced without using core. Fine structure can be obtained. (Better mechanical properties.) Fine finished surface. No scrap Filling time is low, therefore a lower pouring temperature can be choosen. Limitations: The shape of the parts is limited. High investment cost of the casting machines. In alloy elements, segragation can be seen due to different densities. Semicentrifugal Casting Centrifugal force is used to produce solid castings rather than tubular parts Molds use risers at center to supply feed metal Density of metal in final casting is greater in outer sections than at center of rotation Often used on parts in which center of casting is machined away, thus eliminating the portion where quality is lowest Examples: wheels and pulleys 10

11 Semicentrifugal Casting Semicentrifugal Casting Semicentrifugal Casting Centrifuge Casting Mold is designed with part cavities located away from axis of rotation, so molten metal poured into mold is distributed to these cavities by centrifugal force Used for smaller parts Radial symmetry of part is not required as in other centrifugal casting methods Centrifuge Casting Centrifuge Casting 11

Casting. Training Objective

Casting. Training Objective Training Objective After watching the program and reviewing this printed material, the viewer will learn the essentials of the various metal casting processes used in industry today. The basic principles

More information

DIE CASTING. This process if for high volume, high detail, and value added economically priced cast parts. HOW IT WORKS

DIE CASTING. This process if for high volume, high detail, and value added economically priced cast parts. HOW IT WORKS DIE CASTING PROCESS This process if for high volume, high detail, and value added economically priced cast parts. HOW IT WORKS A metal tool is built and attached to a furnace of molten metal Then molten

More information

Die casting Figure M2.3.1

Die casting Figure M2.3.1 Die casting Die casting is a moulding process in which the molten metal is injected under high pressure and velocity into a split mould die. It is also called pressure die casting. The split mould used

More information

POURING THE MOLTEN METAL

POURING THE MOLTEN METAL HEATING AND POURING To perform a casting operation, the metal must be heated to a temperature somewhat above its melting point and then poured into the mold cavity to solidify. In this section, we consider

More information

Plastic Injection Molds

Plastic Injection Molds Training Objective After watching the program and reviewing this printed material, the viewer will become familiar with the variety, design, and productive use of plastic injection molds. Mold components

More information

Fe-C Phase Diagram Introduction

Fe-C Phase Diagram Introduction FUNDAMENTALS OF METAL CASTING 0. Phase Diagram 1. Overview. Heating & Pouring 3. Solidification and Cooling 0. Alloys and Phase Diagram Pure Metals Alloys Solid solutions Substitutional Solid Solution

More information

Copyright 1999 Society of Manufacturing Engineers. FUNDAMENTAL MANUFACTURING PROCESSES Die Casting NARRATION (VO): UTILIZED. NARRATION (VO): THE DIE.

Copyright 1999 Society of Manufacturing Engineers. FUNDAMENTAL MANUFACTURING PROCESSES Die Casting NARRATION (VO): UTILIZED. NARRATION (VO): THE DIE. FUNDAMENTAL MANUFACTURING PROCESSES Die Casting SCENE 1. CG: Die Casting Machines white text centered on black SCENE 2. tape 445, 12:06:10-12:06:19 zoom out, horizontal die casting machines tape 443, 09:11:47-09:11:55

More information

THE CAPABILITIES OF ZINC DIE CASTING

THE CAPABILITIES OF ZINC DIE CASTING THE CAPABILITIES OF ZINC DIE CASTING Presented by: Ryan Winter (Manager Customer Engineering Services) Eastern Alloys, Inc. Eastern Alloys, Inc. Introduction to ZINC Introduction to Zinc Zinc is the 4th

More information

Plastic Injection Molding

Plastic Injection Molding Training Objective After watching this video and reviewing the printed material, the student/trainee will understand the principles and physical operations of the plastic injection molding process. An

More information

RESEARCH PROJECT. High Pressure Die Casting Defects and Simulation Process by Computer Added Engineering (CAE)

RESEARCH PROJECT. High Pressure Die Casting Defects and Simulation Process by Computer Added Engineering (CAE) RESEARCH PROJECT High Pressure Die Casting Defects and Simulation Process by Computer Added Engineering (CAE) ME8109 CASTING AND SOLIDIFICATION OF MATERIALS Presented by: Irshad Ali (Student # 500482510)

More information

Modern High Pressure Die-casting Processes for Aluminium Castings

Modern High Pressure Die-casting Processes for Aluminium Castings Modern High Pressure Die-casting Processes for Aluminium Castings M. Thirugnanam E-mail: callvmthiru@gmail.com, Mobile No. : 98402 56816 ABSTRACT There are about 33 processes commercially available for

More information

ALUMINUM CASTING PROCESS COMPARISON CHARTS. Copyright 2002 Austin Group, LLC. All rights reserved.

ALUMINUM CASTING PROCESS COMPARISON CHARTS. Copyright 2002 Austin Group, LLC. All rights reserved. ALUMINUM CASTING COMPARISON CHARTS A Qualitative Comparison of Several Competing Processes for the Production of Aluminum Castings The following charts are intended to provide a relative guide to compare

More information

CHAPTER 2 INJECTION MOULDING PROCESS

CHAPTER 2 INJECTION MOULDING PROCESS CHAPTER 2 INJECTION MOULDING PROCESS Injection moulding is the most widely used polymeric fabrication process. It evolved from metal die casting, however, unlike molten metals, polymer melts have a high

More information

Aluminium Foundry Practice

Aluminium Foundry Practice Aluminium Foundry Practice M Dept. of Metallurgical Engineering & Materials Science, Indian Institute of Technology Bombay (IIT Bombay), India. Email: amitjoshi@iitb.ac.in, mechamit2002@yahoo.co.uk Fabrication

More information

Simulation of Centrifugal Casting via STAR-Cast. Santhanu Jana, Access e.v., Aachen

Simulation of Centrifugal Casting via STAR-Cast. Santhanu Jana, Access e.v., Aachen Simulation of Centrifugal Casting via STAR-Cast Santhanu Jana, Access e.v., Aachen Talk overview Centrifugal casting STAR-Cast s modelling basis Motivation for centrifugal investment casting Centrifugal

More information

CENTRIFUGAL CASTING. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca

CENTRIFUGAL CASTING. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca CENTRIFUGAL CASTING Amit M Joshi (B.Engg. Mechanical, A.M.I.Prod.E, A.I.E) Dept. of Metallurgical Engg. & Material Science, Indian Institute of Technology Bombay, India. Email: amitjoshi@iitb.ac.in amitjoshi1000@yahoo.ca

More information

Zinc pressure die Casting Processes 1

Zinc pressure die Casting Processes 1 Zinc pressure die Casting Processes Pressure die casting is a process in which molten metal is injected at controlled high velocity and pressure into the cavity of a mould (die) which is usually made of

More information

INTRODUCTION INTRODUCTION. to DIE CASTING NORTH AMERICAN DIE CASTING ASSOCIATION

INTRODUCTION INTRODUCTION. to DIE CASTING NORTH AMERICAN DIE CASTING ASSOCIATION INTRODUCTION INTRODUCTION to DIE CASTING NORTH AMERICAN DIE CASTING ASSOCIATION Item# 101BK Although great care has been taken to provide accurate and current information, neither the author(s) nor the

More information

MIT 2.810 Manufacturing Processes and Systems. Homework 6 Solutions. Casting. October 15, 2015. Figure 1: Casting defects

MIT 2.810 Manufacturing Processes and Systems. Homework 6 Solutions. Casting. October 15, 2015. Figure 1: Casting defects MIT 2.810 Manufacturing Processes and Systems Casting October 15, 2015 Problem 1. Casting defects. (a) Figure 1 shows various defects and discontinuities in cast products. Review each one and offer solutions

More information

Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen

Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen Der Einfluss thermophysikalischer Daten auf die numerische Simulation von Gießprozessen Tagung des Arbeitskreises Thermophysik, 4. 5.3.2010 Karlsruhe, Deutschland E. Kaschnitz Österreichisches Gießerei-Institut

More information

3D Printed Injection Molding Tool ("PIMT") Guide. Objet Ltd.

3D Printed Injection Molding Tool (PIMT) Guide. Objet Ltd. 3D Printed Injection Molding Tool ("PIMT") Guide Objet Ltd. 2 Injection molding is a high speed, automated and versatile process that can produce high precision complex three dimensional parts from a fraction

More information

Unit 6: EXTRUSION. Difficult to form metals like stainless steels, nickel based alloys and high temperature metals can also be extruded.

Unit 6: EXTRUSION. Difficult to form metals like stainless steels, nickel based alloys and high temperature metals can also be extruded. 1 Unit 6: EXTRUSION Introduction: Extrusion is a metal working process in which cross section of metal is reduced by forcing the metal through a die orifice under high pressure. It is used to produce cylindrical

More information

FEATURES AND BENEFITS OF DIFFERENT PLATINUM ALLOYS. Kris Vaithinathan and Richard Lanam Engelhard Corporation

FEATURES AND BENEFITS OF DIFFERENT PLATINUM ALLOYS. Kris Vaithinathan and Richard Lanam Engelhard Corporation FEATURES AND BENEFITS OF DIFFERENT PLATINUM ALLOYS Kris Vaithinathan and Richard Lanam Engelhard Corporation Introduction There has been a significant increase in the world wide use of platinum for jewelry

More information

GLOBAL MANUFACTURING. ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ

GLOBAL MANUFACTURING. ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ GLOBAL MANUFACTURING ARAUJO, Anna Carla AUG, 2015 Mechanical Engineering Department POLI/COPPE/UFRJ Workpiece Presentation Powder Metallurgy and Additive Manufacturing [#7] Powder Metallurgy PM parts can

More information

General Guidelines for Building Aluminum Production Injection Molds

General Guidelines for Building Aluminum Production Injection Molds General Guidelines for Building Aluminum Production Injection Molds Using 7000 series Aluminum Mold Plate By David Bank Aluminum Injection Mold Company Rochester, New York 1 Introduction This high strength

More information

Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield

Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield Analysis and Optimization of Investment Castings to Reduce Defects and Increase Yield Arunkumar P 1, Anand.S.Deshpande 2, Sangam Gunjati 3 1 Associate Professor, Mechanical Engineering, KLS Gogte Institute

More information

Copyright 1998 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES PLASTIC BLOW MOLDING NARRATION (VO): NARRATION (VO):

Copyright 1998 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES PLASTIC BLOW MOLDING NARRATION (VO): NARRATION (VO): FUNDAMENTAL MANUFACTURING PROCESSES PLASTIC BLOW MOLDING SCENE 1. CG: EXTRUSION BLOW MOLDING white text centered on black SCENE 2. tape 401, 07:25:29-07:25:41 zoom in, extrusion process tape 401, 07:08:50-07:09:06

More information

ARMSTRONG MOLD GRAPHITE DIE CASTING DIVISION

ARMSTRONG MOLD GRAPHITE DIE CASTING DIVISION ARMSTRONG MOLD CORPORATION GRAPHITE DIE CASTING DIVISION Getting Started The Evolution of GDC The GDC technology was developed as a hybrid of traditional permanent mold, graphite mold and the die casting

More information

Injection molding equipment

Injection molding equipment Injection Molding Process Injection molding equipment Classification of injection molding machines 1. The injection molding machine processing ability style clamping force(kn) theoretical injection volume(cm3)

More information

NetShape - MIM. Metal Injection Molding Design Guide. NetShape Technologies - MIM Phone: 440-248-5456 31005 Solon Road FAX: 440-248-5807

NetShape - MIM. Metal Injection Molding Design Guide. NetShape Technologies - MIM Phone: 440-248-5456 31005 Solon Road FAX: 440-248-5807 Metal Injection Molding Design Guide NetShape Technologies - MIM Phone: 440-248-5456 31005 Solon Road FAX: 440-248-5807 Solon, OH 44139 solutions@netshapetech.com 1 Frequently Asked Questions Page What

More information

Introduction to Metallography

Introduction to Metallography Introduction to Metallography Metallography has been described as both a science and an art. Traditionally, metallography has been the study of the microscopic structure of metals and alloys using optical

More information

Engineering & Design: Coordinate Dimensioning

Engineering & Design: Coordinate Dimensioning s e c t i o n Section Contents NADCA No. Format Page Frequently Asked Questions (FAQ) -2 1 Introduction -2 2 Section Objectives -3 3 Standard and Precision Tolerances -3 4 Production Part Technologies

More information

Analysis of Casting Defects in Foundry by Computerised Simulations (CAE) - A New Approach along with Some Industrial Case Studies

Analysis of Casting Defects in Foundry by Computerised Simulations (CAE) - A New Approach along with Some Industrial Case Studies Analysis of Casting Defects in Foundry by Computerised Simulations (CAE) - A New Approach along with Some Industrial Case Studies Tapan Roy Asst. General Manager - Methods, Texmaco Rail & Engg. Ltd., Steel

More information

EML 2322L MAE Design and Manufacturing Laboratory. Welding

EML 2322L MAE Design and Manufacturing Laboratory. Welding EML 2322L MAE Design and Manufacturing Laboratory Welding Intro to Welding A weld is made when separate pieces of material to be joined combine and form one piece when heated to a temperature high enough

More information

Module - 2 Advanced Metal Casting Processes Lecture - 2 Evaporative Pattern Casting Processes (EPC)

Module - 2 Advanced Metal Casting Processes Lecture - 2 Evaporative Pattern Casting Processes (EPC) Advanced Manufacturing Processes Prof. Dr. Apurbba Kumar Sharma Department of Mechanical and Industrial Engineering Indian Institute of Technology, Roorkee Module - 2 Advanced Metal Casting Processes Lecture

More information

What is a mold? Casting. Die casting. Injection Molding Machine. Injection Molding. 2.008 Design & Manufacturing II. Spring 2004

What is a mold? Casting. Die casting. Injection Molding Machine. Injection Molding. 2.008 Design & Manufacturing II. Spring 2004 2.008 Design & Manufacturing II What is a mold? From Webster: a cavity in which a substance is shaped: as (1) : a matrix for casting metal (2) : a form in which food is given a decorative shape Spring

More information

Injection molding overview

Injection molding overview Injection molding overview This injection molding overview is designed to help our customers understand the process of injection molding and mold-making. Please read it fully as it helps to define what

More information

Optimization of die-casting process parameters using DOE

Optimization of die-casting process parameters using DOE Optimization of die-casting process parameters using DOE Mahesh N. Adke, Shrikant V. Karanjkar Student of mechanical Engg. Department, MET s IOE, Adgaon, Nashik (Maharashtra,India). Email. Id: maheshadke@gmail.com,

More information

the runnerless types of molds are explained post molding operations are described the basic methods of applied decoration methods are examined

the runnerless types of molds are explained post molding operations are described the basic methods of applied decoration methods are examined Training Objectives After watching the video and reviewing this printed material, the viewer will gain knowledge and understanding of the various plastic finishing processes used in industry and their

More information

STUDY OF PROCESS PARAMETERS OF GRAVITY DIE CASTING DEFECTS

STUDY OF PROCESS PARAMETERS OF GRAVITY DIE CASTING DEFECTS International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 2, March-April 2016, pp. 208 211, Article ID: IJMET_07_02_023 Available online at http://www.iaeme.com/ijmet/issues.asp?jtype=ijmet&vtype=7&itype=2

More information

p l a s t i c i n j e c t i o n m o l d i n g p a r t 1 p r o c e s s, m o l d a n d m a c h i n e e r i k d e l a n g e

p l a s t i c i n j e c t i o n m o l d i n g p a r t 1 p r o c e s s, m o l d a n d m a c h i n e e r i k d e l a n g e p l a s t i c i n j e c t i o n m o l d i n g p a r t 1 p r o c e s s, m o l d a n d m a c h i n e e r i k d e l a n g e H R O R o t t e r d a m B r n o U T j o i n t p r o j e c t 1 plastic injection

More information

Electrical Discharge Machining

Electrical Discharge Machining Training Objectives After watching the video and reviewing this printed material, the viewer will gain knowledge and understanding of electrical discharge machining, or EDM, principles and capabilities.

More information

Start the Design Study!

Start the Design Study! A Design Study in Centrifugal Steel Castings Hydraulic Accumulator Cylinder for Navy Submarines Design Study Outline Introduction Design for Performance Duplex Steel Approach Alloy Selection Design for

More information

Remarkable magnesium: the 21st century structural alloy for small components

Remarkable magnesium: the 21st century structural alloy for small components WHITE PAPER FisherCast Global Corporation Remarkable magnesium: the 21st century structural alloy for small components By Bruce Mark Production and New Program Manager, Magnesium Castings FisherCast Global

More information

TROUBLESHOOTING THE SHELL PROCESS

TROUBLESHOOTING THE SHELL PROCESS TROUBLESHOOTING THE SHELL PROCESS Operating problems can occasionally crop up, even in the most carefully supervised shell process operations. When they do, quick corrective action can make the difference

More information

1) Cut-in Place Thermoforming Process

1) Cut-in Place Thermoforming Process Standard Thermoforming Equipment Overview There are three standard configurations for thermoforming equipment: 1. Heat and Cut-in-Place Forming 2. In-Line Forming with Steel Rule or Forged Steel Trim wand

More information

Single Cavity Mould. Basic Mould Construction. Ejection System. Multi Cavity Mould

Single Cavity Mould. Basic Mould Construction. Ejection System. Multi Cavity Mould Basic Mould Construction Basic mould construction: Core plate and Core (moving) Cavity plate and cavity (fixed) Other features include Guide pillars / guide bush Sprue bush Locating ring Single Cavity

More information

Effects of the MuCell Molding Process

Effects of the MuCell Molding Process Effects of the MuCell Molding Process Molding MuCell versus Solid Shot size is reduced Final mold fill is completed with cell growth Little or no Hold Time or Pressure Reduced molded-in stress Less warp

More information

Aluminum Alloys. casting or a semisolid casting

Aluminum Alloys. casting or a semisolid casting Functionality & Service Requirements When determining how a component will function, the first question to ask is: what purpose will the component serve? Choosing the alloy, casting process and thermal

More information

Module 3 Selection of Manufacturing Processes IIT BOMBAY

Module 3 Selection of Manufacturing Processes IIT BOMBAY Module 3 Selection of Manufacturing Processes Lecture 2 Design for Casting Instructional Objectives The purpose of this lecture is to outline various casting processes, several defects that appear in casting

More information

Aluminium as Construction Material in Ammonia Refrigeration Cycles

Aluminium as Construction Material in Ammonia Refrigeration Cycles Aluminium as Construction Material in Ammonia Refrigeration Cycles Experiences With Aluminium Compared to other metals, aluminium has only a brief history as an engineering material. While, about 150 years

More information

Lapping and Polishing Basics

Lapping and Polishing Basics Lapping and Polishing Basics Applications Laboratory Report 54 Lapping and Polishing 1.0: Introduction Lapping and polishing is a process by which material is precisely removed from a workpiece (or specimen)

More information

Lecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth

Lecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth Lecture slides on rolling By: Dr H N Dhakal Lecturer in Mechanical and Marine Engineering, School of Engineering, University of Plymouth Bulk deformation forming (rolling) Rolling is the process of reducing

More information

1. Injection Molding (Thermoplastics)

1. Injection Molding (Thermoplastics) 1. Injection Molding (Thermoplastics) l Molding: Injection (thermoplastics) INJECTION MOLDING of thermoplastics is the equivalent of pressure die casting of metals. Molten polymer is injected under high

More information

IMPROVEMENTS TO THE MACRO-SHRINKAGE MODEL FOR HPDC AND APPLICATION WITH SQUEEZE PIN

IMPROVEMENTS TO THE MACRO-SHRINKAGE MODEL FOR HPDC AND APPLICATION WITH SQUEEZE PIN HPDC MOULD IMPROVEMENTS TO THE MACRO-SHRINKAGE MODEL FOR HPDC AND APPLICATION WITH SQUEEZE PIN Daniele Grassivaro, Form S.r.l. Italy User of FLOW-3D CAST Extended (v3.5.2) FORM S.r.l. - Via Vittorio Veneto,

More information

This chapter describes how you can model solidification and melting in FLUENT. Information is organized into the following sections:

This chapter describes how you can model solidification and melting in FLUENT. Information is organized into the following sections: Chapter 21. Melting Modeling Solidification and This chapter describes how you can model solidification and melting in FLUENT. Information is organized into the following sections: Section 21.1: Overview

More information

Part and tooling design. Eastman Tritan copolyester

Part and tooling design. Eastman Tritan copolyester Part and tooling design Eastman Tritan copolyester Part and tooling design Process Part design Tooling design High cavitation considerations Process Process Project development flow chart Concept OEM generates

More information

Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling Channels for Block Laminated Molds

Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling Channels for Block Laminated Molds International Journal of Engineering and Advanced Technology (IJEAT ISSN: 2249 8958 Volume-4 Issue-5 June 2015 Verification Experiment on Cooling and Deformation Effects of Automatically Designed Cooling

More information

How to reduce the cure time without damaging the rubber compound during injection molding?

How to reduce the cure time without damaging the rubber compound during injection molding? How to reduce the cure time without damaging the rubber compound during injection molding? 0Introduction This article aims at analyzing the rubber injection process and highlighting the limits that prevent

More information

Using Injection Molding Process for Manufacturing a HDPE Mini Wheel

Using Injection Molding Process for Manufacturing a HDPE Mini Wheel J. Eng. Technol. Educ. (2013) 10(4): 450-466 December 2013 Using Injection Molding Process for Manufacturing a HDPE Mini Wheel Thi Truc-Ngan Huynh* Department of Mechanical Engineering, National Kaohsiung

More information

Avoiding Pump Wear in Centrifugal Pumps

Avoiding Pump Wear in Centrifugal Pumps Pump Wear Avoiding Pump Wear in Centrifugal Pumps Introduction: In the moment of starting a new pump, that pump is headed for a day when it will need repair even if the design and operation is correct.

More information

TWIN-SCREW RHEOMOULDING OF AZ91D Mg-ALLOY

TWIN-SCREW RHEOMOULDING OF AZ91D Mg-ALLOY TWIN-SCREW RHEOMOULDING OF AZ91D Mg-ALLOY S. Ji, Z. Fan, G. Liu, X. Fang, S. Song Walfson Centre for Materials Processing Brunel University, Uxbridge, Middlesex, UB8 3PH, UK. ABSTRACT Twin-screw rheomoulding

More information

Mould and Die Standard Parts

Mould and Die Standard Parts Mould and Die Standard Parts Tampere University of technology - Tuula Höök Mould standard parts can be divided into the following groups: Standard mould set with guide bars, guide sleeves and other guiding

More information

A Guide to Aluminum Casting Alloys

A Guide to Aluminum Casting Alloys A Guide to Aluminum Casting Alloys The specification of an aluminum alloy for a cast component is based upon the mechanical properties it can achieve. For the designer and purchaser, it is vital to understand

More information

VALIDATION OF FOUNDRY PROCESS FOR ALUMINUM PARTS WITH FLOW3D SOFTWARE

VALIDATION OF FOUNDRY PROCESS FOR ALUMINUM PARTS WITH FLOW3D SOFTWARE LMPC 2011 VALIDATION OF FOUNDRY PROCESS FOR ALUMINUM PARTS WITH FLOW3D SOFTWARE Ngadia Taha Niane 1 and Jean-Pierre Michalet 2 1 PSA Peugeot Citroën; 18, rue des Fauvelles, 92250 La Garenne Colombes, FRANCE

More information

Processing the denture

Processing the denture . Processing the denture After the trial dentures (Acrylic base, wax and teeth) have been waxed, they are prepared for denture processing to substitute the acrylic record base and the wax with a hot cure

More information

Tooling for Die Casting

Tooling for Die Casting Section Contents NADCA No. Format Page Frequently Asked Questions (FAQ) - s e c t i o n 1 Introduction -3 Types of Die Casting Dies -4.1 Prototyping -4. Rapid Tooling Dies -4.3 Production Dies -5.4 Unit

More information

Why Plastic Flows Better in Aluminum Injection Molds

Why Plastic Flows Better in Aluminum Injection Molds Why Plastic Flows Better in Aluminum Injection Molds An investigative study directly comparing melt flow characteristics of general purpose resins in QC-10 aluminum molds and P20 steel molds. By: David

More information

INJECTION MOULD DESIGN: MARPLEX PVC RESINS

INJECTION MOULD DESIGN: MARPLEX PVC RESINS MACHINE RECCOMENDATIONS PVC requires reciprocating screw injection moulding machine with a plasticising screw to produce homogeneous melt. It is recommended that a shot weight of the part should take two

More information

Tool Design and Concurrent Engineering using Rapid Tooling Construction Methods

Tool Design and Concurrent Engineering using Rapid Tooling Construction Methods Section Number 3563 Tool Design and Concurrent Engineering using Rapid Tooling Construction Methods Nicole Hoekstra Engineering Technology Department Western Washington University Abstract Prior to rapid

More information

AISI O1 Cold work tool steel

AISI O1 Cold work tool steel T OOL STEEL FACTS AISI O1 Cold work tool steel Great Tooling Starts Here! This information is based on our present state of knowledge and is intended to provide general notes on our products and their

More information

Rolling - Introductory concepts

Rolling - Introductory concepts Rolling - Introductory concepts R. Chandramouli Associate Dean-Research SASTRA University, Thanjavur-613 401 Joint Initiative of IITs and IISc Funded by MHRD Page 1 of 8 Table of Contents 1. Rolling -

More information

AN OVERVIEW OF GAS ASSIST

AN OVERVIEW OF GAS ASSIST GAS ASSIST INJECTION MOLDING AN OVERVIEW OF GAS ASSIST April 2010 www.bauerptg.com GAS ASSIST INJECTION MOLDING TECHNOLOGY It is a fact that packing force must be applied and maintained to an injection

More information

Introduction to JIGS AND FIXTURES

Introduction to JIGS AND FIXTURES Introduction to JIGS AND FIXTURES Introduction The successful running of any mass production depends upon the interchangeability to facilitate easy assembly and reduction of unit cost. Mass production

More information

INJECTION MOLDING PROCESSING GUIDE Polymer

INJECTION MOLDING PROCESSING GUIDE Polymer FOAMAZOL Chemical Foaming Agents INJECTION MOLDING PROCESSING GUIDE Polymer Foaming Agent INJECTION MOLDING WITH CHEMICAL FOAMING AGENTS Introduction The injection molding of structural foam molded parts

More information

Rapid Prototyping. Training Objective

Rapid Prototyping. Training Objective Training Objective After watching the program and reviewing this printed material, the viewer will understand the principles and practical applications of Rapid Prototyping. Basic concepts are explained

More information

SAND CAST CHILL CAST LM4 - TF

SAND CAST CHILL CAST LM4 - TF 1 This alloy conforms with British Standards 1490 and is similar to the obsolete specifications BS.L79 and D.T.D 424A. Castings may be in the cast (M) of fully heat treated (TF) conditions. CHEMICAL COMPOSITION

More information

ME 612 Metal Forming and Theory of Plasticity. 1. Introduction

ME 612 Metal Forming and Theory of Plasticity. 1. Introduction Metal Forming and Theory of Plasticity Yrd.Doç. e mail: azsenalp@gyte.edu.tr Makine Mühendisliği Bölümü Gebze Yüksek Teknoloji Enstitüsü In general, it is possible to evaluate metal forming operations

More information

DIRECT METAL PRINTERS. Metal Additive Manufacturing with the ProX DMP Series

DIRECT METAL PRINTERS. Metal Additive Manufacturing with the ProX DMP Series DIRECT METAL PRINTERS Metal Additive Manufacturing with the ProX DMP Series Go Further with Direct Metal Printing UNLOCK YOUR PRODUCT S POTENTIAL With complete design freedom, direct metal 3D printed parts

More information

After watching the program and reviewing this printed material, the viewer will understand the principles of rapid tooling design and processes.

After watching the program and reviewing this printed material, the viewer will understand the principles of rapid tooling design and processes. Training Objective After watching the program and reviewing this printed material, the viewer will understand the principles of rapid tooling design and processes. Design aspects are detailed Indirect

More information

DIESEL EFFECT PROBLEM SOLVING DURING INJECTION MOULDING

DIESEL EFFECT PROBLEM SOLVING DURING INJECTION MOULDING RESEARCH PAPERS FACULTY OF MATERIALS SCIENCE AND TECHNOLOGY IN TRNAVA SLOVAK UNIVERSITY OF TECHNOLOGY IN BRATISLAVA 2014 Volume 22, Special Number DIESEL EFFECT PROBLEM SOLVING DURING INJECTION MOULDING

More information

Effective Cooling Method for Spin Casting Process

Effective Cooling Method for Spin Casting Process Effective Cooling Method for Spin Casting Process Yong-Ak Song, Sehyung Park, Yongsin Kwon Korea Institute of Science and Technology KIST, CAD/CAM Research Center P.O. Box 131, Cheongryang, Seoul, Korea

More information

Objectives/Introduction Extraction of zinc Physical properties of zinc Zinc casting alloys Wrought zinc alloys Engineering design with zinc alloys

Objectives/Introduction Extraction of zinc Physical properties of zinc Zinc casting alloys Wrought zinc alloys Engineering design with zinc alloys Lecture 7 Zinc and its alloys Subjects of interest Objectives/Introduction Extraction of zinc Physical properties of zinc Zinc casting alloys Wrought zinc alloys Engineering design with zinc alloys Objectives

More information

Standard Specifications for Casting Tolerances- Linear Dimensions

Standard Specifications for Casting Tolerances- Linear Dimensions Standard Specifications for Casting Tolerances- Linear Dimensions K. A. Silva, InForce RapidProtoCasting, Inc., Vancouver, WA USA 98685 ABSTRACT This standard provides guidance for casting dimension tolerances

More information

Experiment 12- Classification of Matter Experiment

Experiment 12- Classification of Matter Experiment Experiment 12- Classification of Matter Experiment Matter can be classified into two groups: mixtures and pure substances. Mixtures are the most common form of matter and consist of mixtures of pure substances.

More information

HOW CAST GOLD BARS ARE MANUFACTURED

HOW CAST GOLD BARS ARE MANUFACTURED TECHNICAL REPORT Supplement 2014 HOW CAST GOLD BARS ARE MANUFACTURED BACKGROUND INFORMATION Cast gold bars are normally produced directly from gold that has been melted. However, the way in which melted

More information

Solid shape molding is not desired in injection molding due to following reasons.

Solid shape molding is not desired in injection molding due to following reasons. PLASTICS PART DESIGN and MOULDABILITY Injection molding is popular manufacturing method because of its high-speed production capability. Performance of plastics part is limited by its properties which

More information

Understanding Plastics Engineering Calculations

Understanding Plastics Engineering Calculations Natti S. Rao Nick R. Schott Understanding Plastics Engineering Calculations Hands-on Examples and Case Studies Sample Pages from Chapters 4 and 6 ISBNs 978--56990-509-8-56990-509-6 HANSER Hanser Publishers,

More information

An ECS Staff Report SAND CASTING PROCESSES. Fundamentally, a mold is produced by

An ECS Staff Report SAND CASTING PROCESSES. Fundamentally, a mold is produced by Guide to Casting and Molding Processes Understanding the metalcasting basics can help you design for manufacturability and utilize processes that meet your specific requirements. The versatility of metalcasting

More information

Chp 5 - Manufacturing Processes in Design

Chp 5 - Manufacturing Processes in Design ME 530 Designing for Production Chp 5 - Manufacturing Processes in Design Mechanical Engineering University of Gaziantep Dr. A. Tolga Bozdana Assistant Professor Classification of Manufacturing Processes

More information

Development of Metal Injection Molding Process for Aircraft Engine Part Production

Development of Metal Injection Molding Process for Aircraft Engine Part Production Development of Metal Injection Molding Process for Aircraft Engine Part Production IKEDA Shuji : Manager, Engine Technology Department, Research & Engineering Division, Aero-Engine & Space Operations SATOH

More information

7 Cobalt in Cemented Carbides

7 Cobalt in Cemented Carbides 7 Cobalt in The ability to cut metal faster and faster is to a great extent at the heart of the economic growth in the 20 th Century. Up until World War I, cutting tools were made from high carbon steels

More information

MSci PolySci-Lab Modul P104 P & Injection molding. Injection molding machine Arburg 320 S (Neue Materialien Bayreuth GmbH)

MSci PolySci-Lab Modul P104 P & Injection molding. Injection molding machine Arburg 320 S (Neue Materialien Bayreuth GmbH) MSci PolySci-Lab Modul P104 P Poollyym meerrm maatteerriiaalliieenn & & P Poollyym meerrtteecchhnnoollooggiiee Injection molding 1 Introduction Figure 1: Injection molding machine Arburg 320 S (Neue Materialien

More information

Corrosion-induced cracking of model train zincaluminium

Corrosion-induced cracking of model train zincaluminium Nationaal Lucht- en Ruimtevaartlaboratorium National Aerospace Laboratory NLR Corrosion-induced cracking of model train zincaluminium die castings R.J.H. Wanhill and T. Hattenberg This report may be cited

More information

Kursus i Produktions- og materialeteknologi

Kursus i Produktions- og materialeteknologi Kursus i Produktions- og materialeteknologi Plastsprøjtestøbning / Injection Molding Basics Short history of plastics 1862 first synthetic plastic 1866 Celluloid 1891 Rayon 1907 Bakelite 1913 Cellophane

More information

COMPETENCE IN ALUMINIUM AND MAGNESIUM HIGH PRESSURE DIE CASTING

COMPETENCE IN ALUMINIUM AND MAGNESIUM HIGH PRESSURE DIE CASTING COMPETENCE IN ALUMINIUM AND MAGNESIUM HIGH PRESSURE DIE CASTING 2014 Make use of our experience. For your advantage. Foundry experts worldwide in the field. Source of pic: //blog.mercedes-benz-passion.com/2010/02

More information

Sample preparation for X-ray fluorescence analysis

Sample preparation for X-ray fluorescence analysis Technical articles Sample preparation for X-ray fluorescence analysis III. Pressed and loose powder methods Gakuto Takahashi* 1. Introduction There are two main sample preparation techniques for measurement

More information

Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS

Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS Chapter 5 POWDER-BASED RAPID PROTOTYPING SYSTEMS 5.1 3D SYSTEMS SELECTIVE LASER SINTERING (SLS) 5.1.1 Company 3D Systems Corporation was founded by Charles W. Hull and Raymond S. Freed in 1986. The founding

More information

Investigation of process parameters for an Injection molding component for warpage and Shrinkage

Investigation of process parameters for an Injection molding component for warpage and Shrinkage Investigation of process parameters for an Injection molding component for warpage and Shrinkage Mohammad Aashiq M 1, Arun A.P 1, Parthiban M 2 1 PGD IN TOOL & DIE DESIGN ENGINEERING-PSG IAS 2 ASST.PROFESSOR

More information

LOST FOAM PROTOTYPING METHODS

LOST FOAM PROTOTYPING METHODS LOST FOAM PROTOTYPING METHODS A Comparison of Methods and Processes Copyright 2002 Austin Group, LLC. All rights reserved. INTRODUCTION TERRY AUSTIN PRESIDENT AUSTIN GROUP, LLC QUINCY, ILLINOIS INTRODUCTION

More information