High Pressure Die Casting

Size: px
Start display at page:

Download "High Pressure Die Casting"

Transcription

1 High Pressure Die Casting High pressure die casting is the worldwide most commonly used casting technique for light metal alloys such as aluminum, zinc and magnesium. Therefore almost 80% of our products are manufactured by the high pressure die casting technique. Using the die casting process the molten metal is pushed into the mould under high pressure. This production process is also suitable for a high level of automation, rendering it very efficient. High pressure die casting can reach the highest tolerances among metal castings and realizes high surface quality levels and levels of automation. Die casting is especially suitable for medium to mass production series starting from batch quantities of 2500 up to several millions of pieces. Information on implementation Degree of Complexity Tolerances Process Cores Inserts Part weights Batch quantity Heating treatment Mechanical treatment Surface treatments Cast investment high highest level of metal casting semi-automatic with high degree of automation 20g 10000g from 2500 pieces up not suitable CNC machine powder coating, wet paint, E-coating, polishing, nickel electro plating, technical chrome anodization, aesthetic anodization limited high

2 Cold-chamber die casting In cold-chamber die casting the molten charge (more material than is requires to fill the casting) is ladled from the crucible into a shot sleeve, where a hydraulically operated plunger pushes the metal into the die. The extra material is used to force additional metal into the die cavity to supplement the shrinkage that takes place during solidification. The principle components of a cold-chamber die casting machine are shown below. Injection pressures over 10,000 psi or 70,000 KPa can be obtained from this type of machine. Operating Sequence of the Cold-Chamber Die Casting Process 1. The die is closed and the molten metal is ladled into the cold chamber shot sleeve.

3 2. The plunger pushes the molten metal into the die cavity where it is held under pressure until solidification. CC Die Casting 3. The die opens and the plunger advances, to ensure that the casting remains in the ejector die. Cores, if any, retract. 4. Ejector pins push the casting out of the ejector die and the plunger returns to its original position. Hot-chamber Die Casting The hot-chamber process is the only used for zinc and other low melting-point alloys that do not readily attack and erode metal pots, cylinders and plungers. Development of this technology, through the use

4 of advanced materials, allows this process to be used for some magnesium alloys. The basic components of a hot chamber die casting machine and die are illustrated below. In this process, the plunger and cylinder, which constitute the injection mechanism, are submerged in the molten metal in the crucible (or pot), which is integral to the machine. The operation sequence for the hot-chamber cycle is illustrated below. Operating Sequence of the Hot-Chamber Die Casting Process 1. The die is closed and the piston rises, opening the port and allowing molten metal to fill the cylinder.

5 2. The plunger moves down and seals the port pushing the molten metal through the gooseneck and nozzle into the die cavity, where it is held under pressure until it solidifies. 3. The die opens and the cores, if any, retract. The casting remains in only on die half, the ejector side. The plunger returns, allowing residual molten metal to flow back through the nozzle and gooseneck. 4. Ejector pins push the casting out of the ejector die. As the plunger uncovers the filling hole, molten metal flows through the inlet to refill the gooseneck, as in step 1.

6 Multi-slide tooling Multi-slide tooling is designed to use 4 perpendicular slides in the tool to enable very complex and accurate castings to be produced. In some cases, up to 6 slides can be used, which may be at angles other than 90 degrees. The process is used principally for small zinc components but also Alumess has developed a multi-slide machine for die casting magnesium parts. Multi-slide die casting process: The multi-slide tool is made up of the die block, sliders, crosshead and cover plate. Each die block has either a cavity and/or cores on its face, which together form the complete cavity and runner profile into which the molten metal is injected. These die blocks are mounted onto sliders, which fit precisely into a crosshead, ensuring repeatable opening and closing operations. A cover plate, bolted onto the top of the tool, holds all these components together. Each slide is managed by our PC controller, and moves independently of the other, both during the closing and opening sequences. This provides tremendous flexibility, which ensures part integrity and prevents damage to the tool. Ejection of the parts is achieved with an airblast, which blows the shot clear of the cavity and into a padded collection mechanism. The machines themselves cycle at speeds of up to 75 cycles per minute (4,500 shots per hour). This is achieved by using pneumatics, rather than slower hydraulics, to operate the different parts of the machine. Mechanical toggle mechanisms and hydraulic thrusters supplement the weaker locking force available with pneumatics, ensuring that the die casting tool is held together securely during the injection process. Alumess had also developed fully hydraulic multi-side machines, allowing us to further match the process to the part. BENEFITS OF ALUMESS PRECISION DIE CASTING High volume cost-effective production with consistent quality Value engineered parts save money by eliminating costly post-casting operations Easily manufacture complex net shaped parts with tight tolerances Lower tool cost and longer tool life Lowest total acquisition cost

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

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

Subject Area Foundry

Subject Area Foundry Subject Area Foundry 1. Date: 1-7 Trainee 2. Subject / Class : Workshop Technology, 2nd Year of Training 3. Topics of instruction sections : 1. Outline 2. Low-pressure die casting 3. Pressure die casting

More information

General environment. Basic structure of the machines. CAE DS Mould Design. Tampere University of Technology Tuula Höök

General environment. Basic structure of the machines. CAE DS Mould Design. Tampere University of Technology Tuula Höök General environment Tampere University of Technology Tuula Höök This chapter discusses injection molding and high pressure die casting machines. Most of the topics are important for the tool designers,

More information

DIE CASTING ALLOYS. KenWalt Die Casting Company - All Rights Reserved

DIE CASTING ALLOYS. KenWalt Die Casting Company - All Rights Reserved DIE CASTING ALLOYS A wide variety of die casting alloys, a mixture of two or more metals, are available with a comprehensive range of physical and mechanical properties for almost any application a designer

More information

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

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

More information

Engineering & Design: Miniature Die Casting

Engineering & Design: Miniature Die Casting Section Contents NADCA No. Format Page Frequently Asked Questions (FAQ) -2 s e c t i o n 1 Introduction -2 2 Typical Design and Tolerance Data S--1-12 Standard -3 3 Miniature Die Casting Machines -4 4

More information

Introduction of Die Casting Process

Introduction of Die Casting Process Introduction of Die Casting Process Editor: Sanjian What is Die Casting Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mould cavity, which

More information

Injection Moulding. Design and Manufacture

Injection Moulding. Design and Manufacture Injection Moulding Design and Manufacture Overview Injection Moulding (or molding to use the US spelling) along with extrusion, ranks as one of the main processes for producing plastic articles. It is

More information

Casting Methods. Prof. Juhani Orkas

Casting Methods. Prof. Juhani Orkas Casting Methods Prof. Juhani Orkas Overview Google Books: Handbuch für technisches Produktdesign Lost mould Permanent pattern Sand casting Manual shaping Mechanical shaping Shell moulding Ceramic moulding

More information

Die Casting Machine Buyers Guide

Die Casting Machine Buyers Guide Die Casting Machine Buyers Guide Cold Chamber Die Casting Machine for Aluminum Hot Chamber Die Casting Machine for Zinc How to Choose The Right Machine FORWARD: This ebook is a continuing work in progress.

More information

DIE DESIGNING AND MOLTEN METAL FLOW ANALYSIS FOR INTERMEDIATE FLANGE

DIE DESIGNING AND MOLTEN METAL FLOW ANALYSIS FOR INTERMEDIATE FLANGE Int. J. Mech. Eng. & Rob. Res. 2013 G Sureshkumar and K Maheswari, 2013 Research Paper ISSN 2278 0149 www.ijmerr.com Vol. 2, No. 4, October 2013 2013 IJMERR. All Rights Reserved DIE DESIGNING AND MOLTEN

More information

Expendable molds: a separate mold for each pour, rather low production rates

Expendable molds: a separate mold for each pour, rather low production rates MULTIPLE-USE-MOLD CASTING PROCESSES 13.1 INTRODUCTION Expendable molds: a separate mold for each pour, rather low production rates Multiple-use-molds overcome many of these limitations Molds, generally

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

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

2.4_3 Casting Processes

2.4_3 Casting Processes 2.4_3 Casting Processes pouring a liquid material (molten metal) into a prepared mold materials: iron steel aluminum brass bronze magnesium certain zinc alloys iron is used most often - fluidity, low shrinkage,

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

METAL CASTING 1.1 OVERVIEW OF CASTING TECHNOLOGY. Definitions. Casting nomenclature

METAL CASTING 1.1 OVERVIEW OF CASTING TECHNOLOGY. Definitions. Casting nomenclature 1 METAL CASTING CHAPTER CONTENTS 1.1 Overview of Casting Technology Definitions Casting nomenclature Heating and pouring Solidification and cooling 1.2 Casting Processes Expandable mold casting Permanent

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

Casting dimensional stability and tolerances 1

Casting dimensional stability and tolerances 1 Casting dimensional stability and tolerances Tampere University of Technology Tuula Höök High pressure die casting dimensional and geometrical accuracy depends on the following details: die thermal balance

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

Chapter 13 Multiple Use Casting Processes. Casting Processes. Materials Processing. MET Manufacturing Processes

Chapter 13 Multiple Use Casting Processes. Casting Processes. Materials Processing. MET Manufacturing Processes MET 33800 Manufacturing Processes Chapter 13 Multiple Use Casting Processes Before you begin: Turn on the sound on your computer. There is audio to accompany this presentation. Casting Processes Chapter

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

1.2 CASTING PROCESSES EXPENDABLE MOLD CASTING. Sand Casting

1.2 CASTING PROCESSES EXPENDABLE MOLD CASTING. Sand Casting Valery Marinov, Manufacturing Technology Metal Casting 5 1.2 CASTING PROCESSES Sand Casting EXPENDABLE MOLD CASTING In expendable mold casting, the mold is destroyed to remove the casting and a new mold

More information

Chapter 11 Metal-Casting Processes

Chapter 11 Metal-Casting Processes Metal Casting Processes: Introduction Chapter 11 Metal-Casting Processes Alexandra Schonning, Ph.D. Mechanical Engineering University of North Florida Figures and figure text by Manufacturing Engineering

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

2 Injection plunger system

2 Injection plunger system - 3. Specifications of DC2500CST Die Casting Machine (1) Main specifications 1 Die clamping system Die clamping force (ton) Die platen dimensions (mm) (vertical by horizontal) Space between tie-bars (mm)

More information

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

Casting Prof. Timothy Gutowski

Casting Prof. Timothy Gutowski Casting 2.810 Prof. Timothy Gutowski 0 Casting since about 4000 BC Ancient Greece; bronze statue casting circa 450BC Iron works in early Europe, e.g. cast iron cannons from England circa 1543 1 Outline

More information

Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 16/2

Dr. M. Medraj Mech. Eng. Dept. - Concordia University Mech 421/6511 lecture 16/2 Injection Molding Outline Injection molding Injection molding of thermosets Shrinkage Polymer foam Compression molding Transfer molding Polymer is heated to a highly plastic state and forced to flow under

More information

Processes. Conventional aluminum die casting. Magnesium die casting. Vacuum casting process. Squeeze casting. Standard die casting processes.

Processes. Conventional aluminum die casting. Magnesium die casting. Vacuum casting process. Squeeze casting. Standard die casting processes. Processes. Conventional aluminum die casting. Magnesium die casting. Vacuum casting process. Squeeze casting. Standard die casting processes. Standard die casting processes. Rugged and economic. Regardless

More information

Casting Technologies. Pau Torne May, 2016

Casting Technologies. Pau Torne May, 2016 Casting Technologies Pau Torne May, 2016 Casting Technologies SIMULATION-Driven Design software 1. Additional Components 2. Ingate Definition 3. HPDC - High Pressure Die Casting 4. LPDC - Low Pressure

More information

[Injection Moulding Calculations]

[Injection Moulding Calculations] Table of Contents Dryer Residence Time Calculator... 2 Barrel Residence Time Calculator... 3 Hydraulic Speed Calculator... 4 Projected Area Calculator... 6 Clamp Tonnage and Cavity Pressure Calculator...

More information

Multiple Choice Questions

Multiple Choice Questions Multiple Choice Questions 1. The metal is subjected to mechanical working for a. Refining grain size b. Reducing original block into desired shape c. Controlling the direction of flow lines 2. The temperature

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

General Mold Specifications and Classifications of Injection Molds and Inserts used by C&H Plastics, Inc.

General Mold Specifications and Classifications of Injection Molds and Inserts used by C&H Plastics, Inc. General Mold Specifications and Classifications of Injection Molds and Inserts used by C&H Plastics, Inc. The following mold specifications and classifications are guidelines used by C&H Plastics, Inc.

More information

BZ Hydraulic Locking Cylinder

BZ Hydraulic Locking Cylinder 1 For use in Plastic Injection Molds & Die Casting Molds Ideal for molds with side actions, slides or core pulls 2 Simplifies mold design & improves design flexibility - saving design time & effort Simplifies

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

Outline Metal Casting. Some Facts. Example Sand Casting. Introduction Process Constraints Green Sand Casting Other Processes

Outline Metal Casting. Some Facts. Example Sand Casting. Introduction Process Constraints Green Sand Casting Other Processes 2.008 Metal Casting Outline Introduction Process Constraints Green Sand Casting Other Processes Some Facts Example Sand Casting First casting: 5000-3000 BC Bronze, iron age, light metal age? Versatility

More information

How to Cast Using an Investment Mold

How to Cast Using an Investment Mold How to Cast Using an Investment Mold If you have plastic or wax objects that you want to use as the mold directly, skip to (creating wax tree) section. Otherwise, if you have an object is something that

More information

A large number of metal components in designs we use every day are made by casting. The reasons for this include:

A large number of metal components in designs we use every day are made by casting. The reasons for this include: 1 Lecture 2. Basics of Metal-Casting 2.1. Casting methods Metal casting process begins by creating a mold, which is the reverse shape of the part we need. The mold is made from a refractory material, for

More information

Results of Monitoring & Controlling a 660-Ton Die Casting Machine

Results of Monitoring & Controlling a 660-Ton Die Casting Machine QUALITY IMPROVEMENTS AND COST REDUCTION RESULTS REPORTED THROUGH LONG-TERM APPLICATION OF COMPUTERIZED MONITORING AND REAL-TIME INJECTION CONTROL TO A 660-TON CONVENTIONAL DIE CASTING MACHINE. INTRODUCTION

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

The Rationalization of Automatic Units for HPDC Technology

The Rationalization of Automatic Units for HPDC Technology ARCHIVES of FOUNDRY ENGINEERING DOI: 10.2478/v10266-012-0031-z Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences ISSN (2299-2944) Volume 12 Issue 2/2012 29 34

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

PROCESS OPTIMIZATION OF PRESSURE DIE CASTING TO ELIMINATE DEFECT USING CAE SOFTWARE

PROCESS OPTIMIZATION OF PRESSURE DIE CASTING TO ELIMINATE DEFECT USING CAE SOFTWARE PROCESS OPTIMIZATION OF PRESSURE DIE CASTING TO ELIMINATE DEFECT USING CAE SOFTWARE Vinod V Rampur 1 Assistant professor, Department of mechanical engineering, PESITM Shimoga, Karnataka, India Abstract

More information

Lecture 4.4: Transfer Molding and Compression Molding Transfer Molding Transfer molding process combines the principle of compression and transfer of

Lecture 4.4: Transfer Molding and Compression Molding Transfer Molding Transfer molding process combines the principle of compression and transfer of Lecture 4.4: Transfer Molding and Compression Molding Transfer Molding Transfer molding process combines the principle of compression and transfer of the polymer charge. In the transfer molding, polymer

More information

FOUNDRY MOULDING (moulding refractory materials in general B28B)

FOUNDRY MOULDING (moulding refractory materials in general B28B) CPC - B22C - 2016.11 B22C FOUNDRY MOULDING (moulding refractory materials in general B28B) Methods, machines and materials for manufacturing moulds or cores used in a foundry; the necessary patterns, accessory

More information

PROCESS AUTOMATION IN ACTION. Jürgen Wüst

PROCESS AUTOMATION IN ACTION. Jürgen Wüst PROCESS AUTOMATION IN ACTION Process Automation In Action! Defect Prevention less scrap reduced metal & energy costs greater OEE The Porosity Problem Trapped Gases Material Separation Shrinkage Porosity

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

Lecture 15: Powder Metallurgy

Lecture 15: Powder Metallurgy MSE 440/540: Processing of Metallic Materials Instructors: Yuntian Zhu Office: 308 RBII Ph: 513-0559 ytzhu@ncsu.edu Lecture 15: Powder Metallurgy Department of Materials Science and Engineering 1 Powder

More information

INTRODUCTION TO MOULDING

INTRODUCTION TO MOULDING MOULDING INTRODUCTION TO MOULDING In 1860 s there was invention of the first plastic, Cellulose Nitrate. Plastics are hydrocarbons consisting of large chains of Carbon and Hydrogen atoms. Plastics do not

More information

Construction & building technology mold

Construction & building technology mold Construction & building technology mold Construction & building technology mold Intertech Machinery is good at manufacturing of construction & building mold components used in mold. Per customer s demand,

More information

Plastics Processing. Plastics can be machined, cast, formed, and joined with relative ease requiring little post-processing or surfacefinish

Plastics Processing. Plastics can be machined, cast, formed, and joined with relative ease requiring little post-processing or surfacefinish Plastics Processing Plastics Processing Plastics can be machined, cast, formed, and joined with relative ease requiring little post-processing or surfacefinish operations Plastics melt or cure at relative

More information

Gravity Die Casting Process Die Design and Process Optimisation

Gravity Die Casting Process Die Design and Process Optimisation Gravity Die Casting Process Die Design and Process Optimisation Dr.S.Shamasundar, V.Gopalakrishna, Manjunatha, Badrinath ProSIM- AFTC, 326, III Stage IV Block, Basaveshwara Nagar, Bangalore 560079 Abstract.

More information

Engineering & Design: Additional Specification Guidelines

Engineering & Design: Additional Specification Guidelines Section Contents NADCA No. Format Page Frequently Asked Questions (FAQ) -2 s e c t i o n Introduction -2 1 Pressure Tightness G--1-12 Guideline -3 2 Fillets G--2-12 Guideline -4 3 Ribs and Corners G--3-12

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

LUBRICANT SPECIFICATION CATALOG

LUBRICANT SPECIFICATION CATALOG LUBRICANT SPECIFICATION CATALOG NICHIBEI CO., LTD - 1 - CASTER ACE No.160X (Water soluble lubricant for Aluminum die-casting.) P 3 No.220 (Water soluble lubricant for Aluminum die-casting.) P 4 No.225

More information

Product Design Considerations

Product Design Considerations Product Design Considerations 1) Uniform Wall Thickness, Coring & Mass Reduction since injection molding is employed as the shape forming process step, part designs can avoid the limitations of traditional

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

Modeling the Mechanical Performance of Die Casting Dies FINAL REPORT

Modeling the Mechanical Performance of Die Casting Dies FINAL REPORT Modeling the Mechanical Performance of Die Casting Dies Project DE-FC07-00ID13973 FINAL REPORT R. Allen Miller, Professor Industrial, Welding and Systems Engineering Center for Die Casting The Ohio State

More information

Experimental Simulation of Reduction of Erosion Damage in Dies. Used in Aluminium Casting Ali Hashim Mohammed

Experimental Simulation of Reduction of Erosion Damage in Dies. Used in Aluminium Casting Ali Hashim Mohammed Experimental Simulation of Reduction of Erosion Damage in Dies Summary Used in Aluminium Casting Ali Hashim Mohammed A review of damage mechanisms in dies used for aluminium casting revealed that erosion

More information

Bringing Metal Parts to Life with Complex Geometry and Precision Tolerances. Phillips-Medisize Corporation April 2016

Bringing Metal Parts to Life with Complex Geometry and Precision Tolerances. Phillips-Medisize Corporation April 2016 Bringing Metal Parts to Life with Complex Geometry and Precision Tolerances Phillips-Medisize Corporation April 2016 Introduction Metal injection molding (MIM) is an effective way to produce complex and

More information

SECTION G2: CABLE PROCESSOR MODULE MAINTENANCE

SECTION G2: CABLE PROCESSOR MODULE MAINTENANCE SECTION G2: CABLE PROCESSOR MODULE MAINTENANCE Cable Processor Module overview WARNING! When tipping the Cable Processor Module back, (after removing the toggle arm pin), use extreme caution not to drop

More information

Cutting processes encompass a variety of manual and mechanized cutting tools for deburring, such as:

Cutting processes encompass a variety of manual and mechanized cutting tools for deburring, such as: Training Objectives After watching the program and reviewing this printed material, the viewer will gain knowledge and understanding of the various deburring processes used in industry and their application

More information

INTRODUCTION TO METAMAG INC. 30 YEARS SERVING THE MAGNESIUM INDUSTRY

INTRODUCTION TO METAMAG INC. 30 YEARS SERVING THE MAGNESIUM INDUSTRY INTRODUCTION TO METAMAG INC. 30 YEARS SERVING THE MAGNESIUM INDUSTRY 1 INTRODUCTION TO METAMAG INC. Established in 1979 as a privately owned company, Metamag Inc. is now celebrating its 25th year in business

More information

Optimization of die-casting process parameters to identify optimized level for cycle time using Taguchi method

Optimization of die-casting process parameters to identify optimized level for cycle time using Taguchi method Optimization of die-casting process parameters to identify optimized level for cycle time using Taguchi method Mahesh N Adke Department of Mechanical Engineering Late G. N. Sapkal COE, Nashik, Maharashtra,

More information

1. Technology Introduction & Benefits

1. Technology Introduction & Benefits Macromelt Molding Agenda 1. Technology Introduction & Benefits 2. Product Range 3. Typical Project Procedure 4. Equipment 5. Design Guidelines 6. Contacts & Further Information 1. Technology Introduction

More information

DIE CASTING ALUMINUM AND ZINC for INJECTION MOLDERS. By Howard Mullin Control Plastics Inc.

DIE CASTING ALUMINUM AND ZINC for INJECTION MOLDERS. By Howard Mullin Control Plastics Inc. DIE CASTING ALUMINUM AND ZINC for INJECTION MOLDERS By Howard Mullin Control Plastics Inc. www.controlplastics.com If Casey Stengel were around, he probably would have said something like: Die Casting

More information

Designing Cast Features

Designing Cast Features Designing Cast Features Miskolc University The features of high pressure die castings must be designed to allow three essential process requirements. The mould or die cavity must fill completely with molten

More information

Two main components of extruder are Barrel and Screw Die is not a component of extruder; it is a special tool that is fabricated for the particular

Two main components of extruder are Barrel and Screw Die is not a component of extruder; it is a special tool that is fabricated for the particular Two main components of extruder are Barrel and Screw Die is not a component of extruder; it is a special tool that is fabricated for the particular profile to be produced Internal diameter of barrel typically

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

INJECTION MOULDING. Advantages. Introduction

INJECTION MOULDING. Advantages. Introduction Introduction INJECTION MOULDING This is a simple process in which the molten polymer is forced into a mould cavity where it solidified. The product is then ejected from the mould cavity. Advantages The

More information

THE INVESTMENT PROCESS

THE INVESTMENT PROCESS THE INVESTMENT PROCESS WHERE IT STARTED The Egyptians and Chinese used the process in their early history to make statues and jewelry. The investment casting method was largely ignored as an industrial

More information

Investigation the Effects of Process Parameters on Product Quality in Cold Chamber High Pressure Die Casting of Magnesium Alloys

Investigation the Effects of Process Parameters on Product Quality in Cold Chamber High Pressure Die Casting of Magnesium Alloys Investigation the Effects of Process Parameters on Product Quality in Cold Chamber High Pressure Die Casting of Magnesium Alloys Ali Serdar Vanli, Yildiz Technical University, Turkey Anil Akdogan, Yildiz

More information

The TMU has 2 components: Active Warmer Unit (AWU) Thermal Bypass Valve (TBV)

The TMU has 2 components: Active Warmer Unit (AWU) Thermal Bypass Valve (TBV) PRESENTATION BY: SACHIN BHATIA OBJECTIVE INTRODUCTION DIE CASTING ADVANTAGES & DISADVANTAGES DANA CORP S THERMAL MANAGEMENT UNIT (TMU) HIGH PRESSURE DIE CASTING (HPDC) DEFECTS FOR HPDC RESULTS & CONCLUSIONS

More information

Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing

Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing J. Mater. Sci. Technol., Vol.24 No.1, 2008 65 Thin-Wall Aluminum Die-Casting Technology for Development of Notebook Computer Housing Chang-Seog Kang, Jae-Ik Cho, Chang-Yeol Jeong, Se-Weon Choi and Young-Chan

More information

MASTER CYLINDER. Section 2. Master Cylinder. Tandem Master Cylinder. Master Cylinder

MASTER CYLINDER. Section 2. Master Cylinder. Tandem Master Cylinder. Master Cylinder MASTER CYLINDER Master Cylinder The master cylinder converts the motion of the brake pedal into hydraulic pressure. It consists of the reservoir tank, which contains the brake fluid; and the piston and

More information

Introduction Of High Pressure Die-Casting And Common Defects In Die-Casting

Introduction Of High Pressure Die-Casting And Common Defects In Die-Casting Introduction Of High Pressure Die-Casting And Common Defects In Die-Casting Collected By Arman Rahimi Islamic Azad Univercity Of Saveh Die casting is a manufacturing process that can produce geometrically

More information

DIE CASTING ALLOYS ALUMINUM ALLOYS

DIE CASTING ALLOYS ALUMINUM ALLOYS M DIE CASTING ALLOYS Die casting alloys are normally non-ferrous, and there is a large number available with a wide range of physical and mechanical properties covering almost every conceivable application

More information

METAL CASTING PROCESS

METAL CASTING PROCESS METAL CASTING PROCESS 1. Permanent Pattern a. Sand casting b. Shell molding 2. Expandable pattern. a. Investment Casting b. Expanded polystyrene process (full-mold) c. Permanent mold casting process 3.

More information

Machine Nozzles. Molding 2014 Newport Beach

Machine Nozzles. Molding 2014 Newport Beach 1 H. Müller Mekaniska AB In 1970 H. Müller Mekaniska AB started with the design & manufacture of molds. Hans Müller s basic idea was to develop dependable and more efficient molds to reduce maintenance

More information

Zinc alloys and the die casting sector

Zinc alloys and the die casting sector Zinc alloys and the die casting sector Is there growth and where? JOSEF UNGERHOFER EXECUTIVE VICE PRESIDENT - EUROPE GLOBAL COVERAGE WORLDWIDE Turnover 2014: USD 630 million Number of employees 2014: 6.000

More information

UNIT 8 DESIGN OF METAL CASTING TOOLS

UNIT 8 DESIGN OF METAL CASTING TOOLS UNIT 8 DESIGN OF METAL CASTING TOOLS Design of Metal Casting Tools Structure 8.1 Introduction Objectives 8.2 Principal Types of Casting Tools and its Application 8.2.1 Hand Tools 8.2.2 Mechanical Tools

More information

CLASSIFICATIONS OF INJECTION MOLDS

CLASSIFICATIONS OF INJECTION MOLDS CLASSIFICATIONS OF INJECTION MOLDS General Notes The following classifications are guidelines to be used in obtaining quotations and placing orders for uniform types of molds. It is our desire, through

More information

Handout Activity: HA181

Handout Activity: HA181 Cylinder block Handout Activity: HA181 HA181-2 Cylinder block The cylinder block is the largest part of the engine. Its upper section carries the cylinders and pistons. Normally, the lower section forms

More information

TECHNICAL INSTRUCTIONS FOR TILITE ALLOYS

TECHNICAL INSTRUCTIONS FOR TILITE ALLOYS WAXING COPINGS Wax-up very thin, from 0.2mm, one dip in the wax pot is sufficient. If the teeth are broken down build them up, to about 4 mm under occlusion. WAXING PONTICS Wax-up pontics on the small

More information

C Series Pneumatic Rack & Pinion Rotary Actuators - Spring Return & Double Acting -

C Series Pneumatic Rack & Pinion Rotary Actuators - Spring Return & Double Acting - C Series Pneumatic Rack & Pinion Rotary Actuators - Spring Return & Double Acting - Features and Benefits Torque Range at 80 Psig Air Pressure: Double Acting: 195-28,500 lbf-in Spring Return: 50-16,500

More information

BLOCK TYPE A PILOTAIR VALVE

BLOCK TYPE A PILOTAIR VALVE BOSCH REXROTH CORPORATION, Pneumatics 1953 Mercer Road, Lexington, Kentucky 40511-1021 (859) 254-8031 - Fax (859) 254-4188 A PILOTAIR VALVE BLOCK TYPE AND PANEL MOUNTED SERVICE INFORMATION BLOCK TYPE A

More information

Saifull Nizar bin Ahmad 1, Mohd Noor Arib bin Md Rejab 2, Sazali bin Yaacob 2, Fauziah bin Mat 2

Saifull Nizar bin Ahmad 1, Mohd Noor Arib bin Md Rejab 2, Sazali bin Yaacob 2, Fauziah bin Mat 2 The Use of Acoustic Control Technology to Improve the Manufaturing Process to Foster Better Engineering Environment. (Phase 1: Automatic Pouring Machine) Saifull Nizar bin Ahmad 1, Mohd Noor Arib bin Md

More information

ZincDie Casting Process Audit -India

ZincDie Casting Process Audit -India ZincDie Casting Process Audit -India Joe Annetts UN CFC Project 2012-2013 Introduction The aim of any zinc die casting process is to manufacture zinc castings that meet the customer s requirements at the

More information

D-Series Heavy Duty Pneumatic Cylinders

D-Series Heavy Duty Pneumatic Cylinders Nitra Heavy Duty Pneumatic Air Cylinders The NITRA D-Series heavy duty cylinders include bore sizes from 1-1/2 to 4 and stroke lengths from 1" to 24 to meet a broad range of applications where abusive

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

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

Abstract. Introduction

Abstract. Introduction Abstract Results of an investigation of methods of controlling flash and the applications of a real-time closed-loop shot control system to control impact pressure are presented. The process of making

More information

23 December In general, manufacturing operations and processes can be categorized as:

23 December In general, manufacturing operations and processes can be categorized as: Overview of Metals Manufacturing Processes Production of Iron INPUT Iron ore: rocks and minerals from which metallic iron can be economically extracted Limestone: it gathers the impurities in the iron

More information

Injection unit Babyplast 6/10

Injection unit Babyplast 6/10 Injection unit Babyplast 6/10 Injection unit Babyplast In 1984, RAMBALDI+Co. I.T. developed a commercial business of high technology focusing on the injection moulding of thermoplastics,. Since its creation

More information

GLOSSARY OF TERMS. BURN-OUT Firing a mold at a high temperature to remove pattern material residue.

GLOSSARY OF TERMS. BURN-OUT Firing a mold at a high temperature to remove pattern material residue. BOSS A heavy piece of metal projecting from the casting. BRINELL HARDNESS - The relative hardness of metals and alloys, determined by forcing a steel ball into a test piece under standard conditions and

More information

Injec on Molds. Understanding. HANSER Hanser Publishers, Munich Hanser Publica ons, Cincinna. Harry Pruner Wolfgang Nesch.

Injec on Molds. Understanding. HANSER Hanser Publishers, Munich Hanser Publica ons, Cincinna. Harry Pruner Wolfgang Nesch. Harry Pruner Wolfgang Nesch Understanding Injec on Molds Sample Pages ISBN 978-1-56990-527-2 HANSER Hanser Publishers, Munich Hanser Publica ons, Cincinna 2.2 Molded Parts with Undercuts 29 2.2.2 Demolding

More information

Engine Porting and Polishing

Engine Porting and Polishing Engine Porting and Polishing Copyright 2009 Easthill Group, Inc. What It Is? Porting or Port & Polish refers to the reshaping and smoothing of the intake and exhaust passageways in engine cylinder heads.

More information