Project report

on
Industrial
training in
Maruti Suzuki
India limited
casting plant
(Manesar)
Submitted to :- Submitted by :-
Manik Chauhan
Roll no. - 11610618
Branch – Mechanical

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 ContentS

name of content page no.

OBSERVATIONS 3–6
LEARNINGS 7 - 18
TRAINING 19 - 25
DESIGN AND ANALYSIS 26 - 31

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 OBSERVATIONS

CASTING :- It is a manufacturing process in which a liquid material is usually poured into a

mold, which contains a hollow cavity of the desired shape, and then allowed to solidify.

TYPE OF CASTING :-

Sand Casting :-
Tempered sand is packed into wood or metal pattern halves, removed form the pattern, and
assembled with or without cores, and metal is poured into resultant cavities. Various core
materials can be used. Molds are broken to remove castings. Specialized binders now in use
can improve tolerances and surface finish

Investment Casting :-
Metal mold makes wax or plastic replica. There are sprued, then surrounded with
investment material, baked out, and metal is poured in the resultant cavity. Molds are
broken to remove the castings.

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Die Casting :-
Molten metal is injected, under pressure, into hardened steel dies, often water
cooled. Dies are opened, and castings are ejected.
Types Of Die Casting :-
1. High Pressure Die Casting :- Die Casting is a metal casting process that is
characterized by forcing molten metal under high pressure into a mold cavity.
i) Cold Chamber Die Casting :- It is a Die Casting Process in which molten
metal is poured in sleeve and then forced into the die cavity by hydraulically
actuated plunger. Since the sleeve or the pouring chamber is not heated, it is
called Cold Chamber Die Casting.

ii) Hot Chamber Die Casting :- It is a Die Casting Process in which injection
mechanism is immersed in the molten metal the furnace is attached to the
machine by a metal feed system called a gooseneck.

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2. Gravity Die Casting :- It is a simple casting process which utilises reusable metallic
moulds. The process is primarily used to simple shapes with some basic coring possible. It is
mostly suited to casting light alloys but can also be used to steel and cast irons.

3. Low Pressure Die Casting :- It is a Process in which a ceramic tube is connected to a

steel die above and extends into a furnace of molten metal below. The furnace is then
pressurized to fill the part by forcing fluid up through the sprue once the casting has solidified
the air pressure is reduced allowing the rest of the metal still in liquid form in the tube to
recede back into the furnace. Low pressure die casting is used for high production rates,
thicker parts up to 2.5mm, for better surface quality and when high temperature heat
treatment is needed to improve strength.

CASTING DEFECTS

 SAND HOLES :- It is the holes on the external surface or inside the casting. It occurs
when loose sand washes into mould cavity and fuses into the interior of the casting or
rapid pouring of the molten metal.

Causes :-
1. Loose ramming of the sand.
2. Improper cleaning of the mould cavity.
Remedies :-
1. Proper ramming of the sand.
2. Molten metal should be poured carefully in the mould

 MISRUN :- When the molten solidifies before completely filling the mould cavity
and leaves a space in the mould called as misrun.

Causes :-
1. Low fluidity of the molten metal.
2. Low temperature of the molten metal which decreases its fluidity
Remedies :-
1. Increasing the pouring temperature of the molten metal increases the fluidity.
2. Proper gating system.

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 Blow Holes :- When gases entrapped on the surface of the casting due to solidifying
metal, a rounded or oval cavity is formed called as Blow Holes.

Causes :-
1. Excessive moisture in the sand.
2. Low permeability of the sand.
3. Sand grains are to fine.
Remedies :-
1. High permeability sand should be used.
2. Sufficient ramming should be done.
3. The moisture content in the sand must be controlled and kept at desired level.

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 TRAINING

PRESSURE DIE CASTING:- It is a process in which molten metal is forced under high
pressure with high velocity in to a cavity in a fraction of second and then allowed to solidify.
When casting is solidified, the die is opened and the casting is removed.

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DIE CASGTING PROCESS REQUIREMENTS :-

MELTING PROCESS FLOW :-

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 METAL TREATMENT :- Metal treatment is the process of removal of dross and
other impurities from the molten metal before it is poured.

Need :- Aluminium at high temperature has tendency to form aluminium oxide due
to its high affinity for oxygen. This oxide (Dross) has almost same density hence it
often remain in the melt during melting and handling. If it is not removed it may
remain in the casting as INCLUSIONS. Inclusion reduces the strength of the casting
and therefore must be avoided .

Sources of Inclusion :-
1. Oxidation of Metal
2. Furnace refractory wall
3.Contaminated foundry returns .

Metal Treatment Method:-

1.From molten metal. Cleaning flux ‘met Flux is a chemical powder form that is used
to remove oxides and other undesirable material al flux -1’ is used for this purpose.

2.The flux is sprayed over metal surface . After stirring the suspended non-metallic
particles are removed by the flux.

3.Dross is the product of oxidation of molten metal the open metal bath surface is
covered with flux.to minimize oxidation of molten metal and to facilitate of
suspended dross from melt. The flux forms a protective layer over metal surface
which reduces oxidation.

4.The dross is removed with the help of skimmers.it is necessary to ensure that dross
is removed very gently and carefully without causing turbulence in the melt.

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CLEANING OF METAL FURNACE:-

At the end of the every shift, the cleaning flux is injected on wall with the help of flux
injector. The oxides deposited on the furnace wall are removed by scrapping.

A thorough exothermic cleansing action removes oxides and non- metallic impurities leaving
behind dry dross with low aluminium content. This dry dross removed easily by scrapping .

Regular cleaning of melting and holding chambers is must to achieve good life of furna e
refractory lining.

QUALITY CHECKS IN MELTING:

A). CHEMICAL COMPOSITION:
Effect of various alloying elements:

SILICON Si : (8.0 – 11.0%)

Improves casting characteristics by improving fluidity, feeding and hot tear resistance. The
silicon rich phase is hard, so that the hardness of the alloy is increased with Si content but
ductility and machinability are reduced.

COPPER Cu: (1.5 – 3.0%)

Improves strength, hardness, machinability and thermal conductivity. It reduces cast ability
and hot tear resistance together with corrosion resistance .

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 MAGNESIUM Mg: (0.5% max)
Small additions of 0.25 – 0.5% allow Al – Si alloys to be hardened by heat treatment,
improving mechanical properties. In pressure die casting alloys the Mg content is kept low
to avoid embrittlement.

IRON Fe:(0.7 – 1.2%)

Small amount of iron increases the strength and the hardness. Iron also increases hot
strength which reduces the tendency towards hot cracking. It also retards the attack of
aluminium on iron and steel thus avoids soldering to steel dies . Increase in the level of Fe
above 1.2% reduces tensile strength. It increases the tendency towards cracking.

Effects of various impurity elements :

MANGANESE Mn:(0.2 – 0.5%)

Manganese alters the inter – metallic form of iron in the alloy. The shape of needle like
structure characteristics of the iron constituent is then has the appearance of Chinese script
and is much less deleterious to mechanical properties. Manganese increases impact
strength.

ZINC Zn (1% max)

Zinc above 35 reduces the strength and can cause hot cracking.

NICKEL Ni (0.5%max)
Nickel is not serious impurity in pressure die casting alloys. When combined with copper , Ni
enhances strength and hardness at elevated temperature.

TITANIUM Ti: (0.2% Max)

Refines the grain structure when combined with boron. The severe cooling rate in the
pressure die casting eliminates the need to promote fine grain size artificially. If
concentration exceeds 0.25%, it may cause machining difficulties from hard inter metallic
compounds.

BISMUTH Bi, CADMIUM Cd, LEAD Pb, TIN Sn

Concentration above the recommended values can lead to a tendency of hot cracking and
excessive dross formation.

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 HIGH PRESSURE DIE CASTING MACHINE

FUNCTIONS OF DIE CASTING MACHINE

1. Provides means for mounting both the die halves – Platens

2. Provide adequate force required to hold two die halves together - Hydraulic Cylinder and
Toggle Arrangement.
3. Mechanism for injecting or forcing the molten metal into the die – Shot Cylinder,
accumulator and intensifier.
4. Mechanism for ejecting the casting after solidification – Ejector cylinder.
5. Mechanism for holding and pouring molten metal into the sleeve – Holding furnace and
auto ladle or dosing furnace.
6. Mechanism for removing the ejected casting – Extractor
7. Mechanism for lubrication of the die parts for production cycles-Sprayer mechanism.

HYDRAULIC SYSTEM
High pressure / Low volume and Low pressure / High volume pump: -
For die casting machine application, we need very fast movements of die and injection
piston.
At any time, different combination of hydraulic pumps are used to achieve required velocity
and pressure.
For any movement of actuator we need high volume at low pressure. At soon as system
pressure is reached to set low pressure delivery of high volume pump is diverted to tank at
zero pressure and then high pressure acts at low volume.
We require high volume at the time of die closing movement. Once movement is complete
we need only high pressure and low volume to keep die closed at desired clamping force.

INJECTION SYSTEM :-
Shot sleeve:-
The round metal cylinder, also called as a ’Cold Chamber’ or ‘Shot Sleeve’, has an opening cut
in its outer diameter to permit molten metal to be poured inside. This sleeve has bore size
corresponding to sprue bush in the die and is located in the fixed half of the die on the
projected shoulder. Sleeves are made of heat-treated steel so that they withstand the
thermal shock. The sleeve and sprue are in single piece also and are called as ‘Straight
through sleeves’. They are dedicated to the die.

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Injection plunger and plunger rod:-
During injection the molten metal is forced with the help of plunger tip or piston. The plunger
tip is fastened at one end of the plunger rod, which is coupled through a cross head to the
piston rod of the shot cylinder. The plunger tips are made of high strength cast iron or
beryllium copper alloy. To prevent the excessive expansion of the plunger tip and subsequent
sticking in the sleeve, the inside is hollowed out to permit the entrance of the cooling water.
The plunger rod has drilled holes for circulation of water in plunger tip.

Plunger & plunger rod

 They inject the molten metal into the die at very high velocity @2 to 4 m/sec.
 Plunger enhances solidification of biscuit. The plunger is cooled, by circulating water
through the piston rod. The direction of flow of water circulation is very important.
 Plunger cooling also reduces its excessive expansion and avoids friction between
sleeve and plunger. If friction increases the quality of the casting is affected due to
cold shuts and blow hole defects.
 It is also important to lubricate the plunger during production to reduce friction. The
plunger cooling and lubrication are very important for automatic production.

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ACCUMULATOR:-
Accumulator bottles charged with compressed N2 gas are used to store up energy from
hydraulic pump. This enables a fast injection speed to be achieved . They act as hydraulic
springs, which stores energy when it is required most. This is achieved by compressing and
decompressing of nitrogen.

INTESIFIER:-
They are used to allow sudden build up of pressure at the end of the injection. No volume
displacement of plunger is needed. However there is a small amount of plunger is needed.
However there is a small amount of plunger displacement take place during intensification.
The intensification stage can have a large effect on the porosity in the casting.

EJECTION SYSTEM:-
1. Due to extremely high injection pressure and the tendency of shrinkage, casting tends to
grip the male feature of the die as the casting shrinks onto it during solidification. Hence
extra force is needed to start the initial casting movement of the casting from the cavity.
This force is provided by an additional hydraulic ejection cylinder.

2. This cylinder is mounted on moving platen. The piston rod of the cylinder is connected to
the ejection system of the die, which consists of ejector plate and ejector pins. During
ejection casting is stripped of the punch.

3. Ejector pins are connected to the ejector pates , which is actuated by machine ejection
cylinder through ejection rod, which is coupled with the ejector plate.

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EXTRACTION SYSTEM:-

1. After the ejection, casting ids removed with the help of extractor by holding the biscuit of
the casting ion gripper jaws.

2. Importance of extractor:-
a. Cycle time control.
b. Removal of hot casting.
c. It can determine completeness of the casting after extraction by means of sensors.

3. For the effective working of the extractor it should have:

a. Proper alignment between jaws and biscuit.
b. Proper and sharp jaws to grip the casting.
c. Rapid travel, inside and outside the machine.

LUBRICATION METHODS:-

1. Automatic lubrication:

Operation sequence:
a. Die opens.
b. Movement of sprayer into die area.
Spray according to program in following sequence:
Fixed half
Moving half
Air blow

Manual lubrication:

This is done manually with a spray gun. Spray gun has two connections. One for lubricant
and another for air. Lubricant line is connected to central tank where lubricant is stored.
Dilution ratio of lubricant is maintained in the tank. Initially a mixture of lubricant and air is
sprayed on the die surface followed by only air to remove excess lubricant.

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 DIE CASTING DIES

1. FUNCTION OF PRESSURE DIE CASTING DIES.

A. To hold the molten metal entering at high velocity and pressure in the shape of the
desired casting – Cavity.

B. To provide the means for molten metal to get into the cavity – Runner And Gating
system.

C. To remove the heat from the molten metal to get into the cavity – Die Cooling System.

D. To provide for the removal of the solidified casting – Ejection System.

VARIOUS PARTS OF THE DIE

1. Two large pieces of steel called ‘Die Blocks’ from the frame of the die. These blocks hold
all other die parts. Slots are provided around the edges for clamping the die to the machine
platen.

2. The ‘Cavity’ is the space between the die halves that is the size and shape of the part that
is to be cast. It is machined into an insert block in each of these die halves.

3. The two halves of the die must align together when the die is closed. This is achieved by
means of Guide pins and Bushes. The dowel pins are always placed in the fixed half.

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4. Some castings have complex shapes that cannot be formed by dies that opens in only one
direction. Dies for these parts have Core slides which moves sideways as the die opens and
closes. The slides are moved by the hydraulic cylinder.

5. Ejection mechanism: The die is constructed that the casting is held in the moving half
when the die opens. The casting is then pushed out with ejector pins that comes through
holes in the die. These pins are actuated by the ejector plate powered by the machine.
Ejector plates move inside the ejector box – a hollow structure which spaces the
die away from the movable platen.

6. Gating system :

a. Consists of biscuit, runner and gate.

b. The mating surface of the die halves is known as the parting line. Both surfaces forming
this parting line must be smooth and finished so that the die halves fit closely together.
Otherwise the molten metal can escape through the gap, when forced into the cavity under
pressure.

c. As the metal is injected into the die, it first enters the die from the shot hole or sprue.
d. The metal then passes through the main runner, spreads out into the branch runner and
finally fills the cavity through the gates.

e. As the metal fills the cavity, air and gasses trapped in the cavity are pushed ahead of the
metal through the overflows and out the vents.

f. The molten metal should completely fill the cavity and should drive the air into the
overflow and allow to escape from vents. The air should be forced out before the column of
advancing molten metal. The vents are deliberately made so thin that only air should exit
and molten metal will freeze and terminates in the vents.

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g. Types of cores :-

 Intake core :- The core which is used to create the intake manifold lines of the
engine are known as Intake core.
 Exhaust core :- The core which is used to create the holes for the exhaust lines of
the removal of gases are known as Exhaust core.
 Water jacket core :- The core which is used to create the holes for the circulation of
the water in the cooling system of the engine are known as Water jacket core.
 Oil jacket :- The core which is used to create the holes for the circulation of the oil in
the lubrication system of the engine are known as Oil jacket core.

GRAVITY DIE CASTING MACHINE

Holding Furnace :- It is the electric resistance furnace used to controlled supply of liquid
metal to casting equipment. Typically the furnaces are tiltable. They can be equipped with
ambient air or regenerative burner systems.

Pouring ladle :- A Ladle is a vessel used to transport and pourout molten metals. Ladels are
often used in foundries and range in size from small hand carried vessels that resemble a
kitchen ladle and hold 20 kg to large steelmill ladles that hold up to 300 tons.

Pouring robot :- Robots can automate the die cast process by quickly and efficiently
pouring molten metal into a reusable mold. Die casting machines are used in a variety of
indutries and while material handling is a natural application, casting and foundry
applications can be challenging.

Gating system :-
 Consists of biscuit, runner and gate.
 As the metal is injected into the die, it first enters the die from the shot hole or sprue.
 The metal then passes through the main runner, spreads out into the branch runner
and finally fills the cavity through the gates.
 As the metal fills the cavity, air and gasses trapped in the cavity are pushed ahead of
the metal through the overflows and out the vents.
 The molten metal should completely fill the cavity and should drive the air into the
overflow and allow to escape from vents. The air should be forced out before the
column of advancing molten metal. The vents are deliberately made so thin that only
air should exit and molten metal will freeze and terminates in the vents.

Tilting mechanism :- It is a mechanism used to tilt the die so that the molten metal
completely fills the cavity as it Is very difficult to pour the molten metal into the cavity
without tilting it.

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 LEARNINGS

QUALITY CHECK EQUIPMENTS :-

1. Coordinate Measuring Machine (CMM) :- Coordinate measuring machines are
relatively recent developments in measurement technology. Basically, they consist of a
platform on which the workpiece being measured is placed and moved linearly or rotated.
A probe attached to a head capable of lateral and vertical movements records all
measurements. Coordinate measuring machines are also called measuring machines. They
are versatile in their capability to record measurement of complex profiles with high
sensitivity (0.25 m) and speed.

Parts of CMM :-
 Main structure :- The machine incorporates the basic concept of three
coordinate axes so that precise movement in x, y, and z directions is possible.
Each axis is fitted with a linear measurement transducer. The transducers sense
the direction of movement and gives digital display. Accordingly, there may be
four types of arrangement.
1. Cantilever :- The cantilever construction combines easy access and relatively
small floor space requirements. It is typically limited to small and medium
sized machines.

2. Bridge Type :- The bridge arrangement over the table carries the quill (z-axis)
along the x-axis and is sometimes referred to as travelling bridge.it is claimed
back the bridge construction provides better accuracy.

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 3. Column Type :- The column type machine is commonly referred to as a
universal measuring machine rather than a CMM. These machines are usually
considered gage room instruments rather than production floor machine.

4. Horizontal :- The open structure of this arrangement provides optimum

accessibility for large objects such as dies, models and car bodies. Some
horizontal arm machines are referred to as layout machines.

 Probing System :- It is the part of a CMM that sense the different parameters
required for the calculation. Appropriate probes have to be selected and placed
in the spindle of the CMM. Originally, the probes were solid or hard, such as
tapered plugs for locating holes. These probes required manual manipulation to
establish contact with the workpiece, at which time the digital display was read.

1 Inductive transmission probe :- Power is transmitted using inductive linking

between modules fitted to the machine structure and attached to the probe.
2 Optical transmission probe :- The optical transmission probe allows probe
rotation between gaging moves, making it particularly useful for datuming
the probe

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 ADVANTAGES OF CMM

 Flexibility :- CMMs are essentially universal measuring machines and need not be
dedicated to any particular task. They can measure almost any dimensional characteristic
of a part configuration, including cams, gears and warped surfaces.
 Reduced Setup Time :- Part alignment and establishing appropriate reference points are
very time consuming with conventional surface plate inspection techniques. Software
allows the operator to define the orientation of the part on the CMM, and all subsequent
data are corrected for misalignment between the parts-reference system and the
machine coordinates.
 Single Setup :- Most parts can be inspected in a single setup, thus eliminating the need to
reorient the parts for access to all features.
 Improved Accuracy :- All measurements in a CMM are taken from a common geometrically
fixed measuring system, eliminating the introduction and the accumulation of errors that
can result with hand-gage inspection methods and transfer techniques.
 Reduced Operator Influence :- The use of digital readouts eliminate the subjective
interpretation of readings common with dial or Vernier type measuring devices. Operator “feel”
is virtually eliminated with modern touch-trigger probe systems, and most CMMs have routine
measuring procedures for typical part features, such as bores or centre distances.
 Improved Productivity :- The above-mentioned advantages help make CMMs more
productive than conventional inspection techniques. Furthermore, productivity is
realized through the computational and analytical capabilities of associated data-
handling systems, including calculators and all levels of computers.

2. Blue Light Scanner :- 3D scanning comes in different shapes and sizes. When
something is scanned in 3D it means that the shape of an object or a scene is captured by a
sensor which can recognize the location of objects in three dimensions. Depending on the
object of interest there are different equipment available for 3D scanning. Small objects or
scans which require extremely accurate data for engineering purposes can be scanned with
structured light scanners.

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 In Blue light 3D surface scanning there is a striped pattern projected on to the target object
and the shape of the object is detected by one or two cameras from the distortion of the
projected pattern. Blue light scanning uses the principal of triangulation to obtain the
distance to the object from the sensor. Blue light scanners come in different versions. The
main types of Blue light scanner set-ups are scanners with one camera and scanners with two
cameras, stereo vision. Stereo vision scanners have the possibility of creating a three
dimensional image from one shot because of the two views per image. As more pictures are
taken the computer software connects the images to create a 360 degree 3D model of the
object, if necessary the part is flipped and scanned again to get the full part.

3. Spectrometer :- Optical Emission Spectroscopy, or OES, is a well trusted and widely used
analytical technique used to determine the elemental composition of a broad range of
metals. The part of the electromagnetic spectrum which is used by OES includes the visible
spectrum and part of the ultraviolet spectrum. In terms of wavelength, that’s from 130
nanometres up to around 800 nanometres OES can analyse a wide range of elements from
Lithium to Uranium in solid metal examples covering a wide concentration range, giving very
high accuracy, high precision and low detection limits.

All OES analysers contain three major components, the first is an electrical source to excite
atoms within a metallic sample so that they emit characteristic light, or optical emission,
lines – requires a small part of the sample to be heated to thousands of degrees Celsius. This
is done using an electrical high voltage source in the spectrometer via an electrode.

The second component is an optical system. The light, the multiple optical emission lines
from the vaporized sample known as a plasma pass into the spectrometer. A diffraction

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 grading in the spectrometer separates the incoming light into element-specific wavelengths
and a corresponding detector measures the intensity of light for each wavelength. The
intensity measured is proportional to the concentration offset element in the sample.

The third component is a computer system. The computer system acquires the measured
intensities and processes this data via a predefined calibration to produce elemental
concentrations. The user interface ensures minimal operator intervention with results
clearly displayed which can be printed or stored for future reference.

4. Microscope :- To be able to see smaller defects, microscopic techniques are used. The
metallurgical microscope can be used for inspection and identification of defects not visible
to the naked eyes. The microscope can be used in either dark filled conditions or bright filled
conditions. The advantages is that these systems can be automated, to directly identify
defects particles and provide information on their distribution. This can be used to find out
the density of particle defects and their location the surface. By analysing the particle
patterns on the surface, it is possible to pin point the origin of the defect.

5. Profilometer :- A Profilometer is a measuring instrument used to measure a surface profile

in order to quantify its roughness. Critical dimensions as step, curvature, flatness are
computed from the surface topography. In the Profilometer, a stylus is used that travels
along the length of the surface and obtains the surface contours

6. Surface Roughness Tester :- A roughness tester is used to quickly and accurately

determine the surface texture or surface roughness of a material. Roughness texture shows
the measured roughness depth as well as the main roughness value in micrometres or
microns.

7. Thermography :- Infrared thermography technique which is non -contact, non

destructive test method uses an infrared imaging to detect, display and record thermal
patterns and temperature across the surface of an object. Thermography can be
applied to any situation where thermal profile and temperature will provide meaning
data about a system or object. It is equipment which senses infrared radiation by
converting it into temperature and displays image of temperature distribution.

Principle :- Since infrared radiation is e mitted by all objects based on their

temperatures, according to the black body radiation law, thermography makes it
possible to “see” one’s environment with or without visible illumination. The amount of
radiation emitted by an object increases with temperature; therefore thermography
allows one to see variations in temperature. The higher an object’s temperature is the
more infrared radiation as black-body radiation it emits. A special camera can detect
this radiation in a way similar to an ordinary camera does visible light.

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Scanning Mechanism :- The image formed on detector element by the lens system
which is move in well -controlled fashion. There are three classes of scanner system as
represented by one-dimensional (1D) oscillating mirror scanner arrangements. In the
first arrangement, space between optical system and the detector take place by
scanner. In the next arrangement, space between the externa l object and the image
forming optical system take p lace by scanner and in the third arrangement scanner is
place between focal front end and image-forming back end of optical System.
For scanning IR image, one type of scanning mechanism is shown in figure below. In
figure, there are two mirrors with its respective motors and at the bottom of image there
is IR lands with detector. There is one way to scan FOV (field of vie w) by IR camera with
single IR detector that is left mirror scans the vertical axis and right mirror scans the
horizontal axis.

ADVANTAGES

1. Large Area :- Large area is required for Thermography equipment to be assessed.

Thermography use thermo-imaging equipment that allows seeing through
smoke, so it is used in fire fighters. Thus, thermography provides safety
innovation. Thermography is a non-contact method. It keeps user out of danger.

2. Real Time :- Thermography enables user to capture fast moving targets and also
capture of fast changing thermal patterns of objects. Thermal patterns can be
visualized for analysis. Real time recording is done by a current thermography
technology.

3. Detecting Defects :- For pipes and shafts that are built into homes, skyscrapers and
building, infrared detection is used. To detect leaks in pipes, thermographic cameras
can be used in many construction companies for their high end project to ensure
they are repaired prior to finishing the project.

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 MACHINES USED FOR CASTING DIE
MAINTAINANCE

1. ELECTRIC OVERHEAD TRAIN(EOT) :-

It is an electrically operated crane which is used to transfer dies from one place to
another. It is impossible to transfer the dies manually because their weight is about
6-15 tonnes, therefore EOT is used for the purpose. This crane can move in all the three axes
(x, y and z). The crane mechanism is installed jus below the roof, the whole crane
mechanism moves along the x-axis, the rail mechanism with which the ropes are attached
can move along the y-axis and the ropes and D-shackle bolts can move along z-axis. The D-
shackle bolts of the crane are attached with the eye bolts of the die and then the crane lifts
the and transfer it from one place to another.
2. WELDING MACHINE :-
After the production of a certain number of components, cracks may be generated on
the surface of the cavity. Therefore welding machine is used to fill those cracks so that they
will not affect the surface finish of the component to be cast. Extra material is grinded with
the help of hand grinder in order to maintain the dimensional tolerance of the casting
component. Generally, gas welding machines are used for this purpose.
3. DIE WASHING MACHINE:-
This machine is used for washing the holes of the casting dies with the help of a high
pressure water jet. The machine has an operator panel which is used to regulate the
pressure of water jet and the ratio of the mixture of water and detergent. It has a detergent
valve from where the detergent is added into it. The can spray cold as well as hot water
according to the requirement. While working with hot water spray gun is changed and
pressure is reduced in order to avoid the damage.
4. SPARK COATING MACHINE :-
The technique used by this machine can be defined as the micro-pulsed welding
technique that allows deposition of one electrode material on a metallic sublayer;
mass transfer is made in high current intensity and in short time periods. Spark coating
method applies heat and mass transfer phenomena. Basically multiple phenomena involve
such as heating to incandescence, melting and eventually evaporating of the electrode
material.
The process of electro-spark deposition on the surface of the material is based on the
electro-erosion phenomenon and the polar transfer of the anode material to the cathode
material during the electrical discharge in pulses between the anode and the cathode,
discharge which occurs in a gaseous medium. In this method, the impulse electric discharge
process has the air as the gaseous medium.

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 Design and Analysis of Pressure Die Casting
Die for Automobile Component

Methods :-
These are the following steps used while designing the component:
1. The component is identified and all relevant information required for design is
collected.
2. The number of cavities is decided based on yearly requirement.
3. Identical components are grouped in the unit die.
4. The design calculations are done to find the suitable machine
5. Details of machine are collected
6. Component parting line was being decided based on part geometry, ejection, and
aesthetics.
7. The runner, gate dimensions and type are selected based on the part geometry,
Global Journal of Researches in Engineering ( A)

cavity location.
8. The type of ejection will be selected based on aesthetics, parting line location,
part geometry, etc.
9. The amount of heat being injected into the die will be calculated and the suitable
cooling system is provided.
10. 3-Diamensional modelling of the die, gate design, and core cavity extraction will be
conducted using Solidworks software by considering shrinkage of material.
11. Assembly and part drawings are to be made in 2- Diamensional using Solidworks
software.
12. Part drawings will be carefully checked at the end and approved.

i) Design Calculations:-

 Number of Cavities
Production required per month: 20,000 per month (Die will be loading only for 5days)
Number of component per day: 4000 Number of shifts per day: 3

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 Number of shots per shift = 8 x 60 / Cycle time.
= 8 x 60 /0.5
= 960 shots

Number of component per shot = 4000/ (3x960)

= 1.0
Hence we have to use a single cavity die.

 Tonnage Requirement
Projected area of the component = 7900mm2 Projected area including
overflows and feed system
= 7900 x 1.5

= 11850mm2
Specific Injection pressure = 600 kgf/cm2 = 600 x 10-2 kgf/ mm2
Total force acting on the die plate = Projected
area x Injection Pressure
= 7900x 600 x 10-2

= 47400 kgf

= 47.4 T
Considering machine efficiency of 80%, Locking tonnage required = 47.4 x 1.2
= 57T
Hence according to locking tonnage ranges, we can select 80 T machine.
 Shot Weight
Component volume = 217,553 mm3
Volume of component + Volume of overflow and feed system (excluding Biscuit)
=217,553 x 1.2

= 261,063.6 mm3
Actual shot volume = 261,063.6 + πd2 h/4
Where h is biscuit thickness, and d is the plunger diameter Stroke length for 80 T
machine = 250 mm
Effective stroke length = 250 – biscuit thickness
= 250 – 25
= 225 mm
Assume fill ratio = 0.50 Volume delivered by machine
= π d2 x (225/4) x 0.5 261,063.6 + πd2 x (225/4) 0.5 = πd2 x (225/4)
261,063.6 = 88.40625 d2
d2 = 2953 mm2 d = 54.3 mm
Available plunger sizes in 80 T machines are 35, 45, and 55 mm Hence we can select 55 mm
plunger tip

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Shot volume = 261,063.6 +πd2 h/4
= 261,063.6 +π (54.3)2 x 25/4
= 261,063.6 +π (54.3)2 x 25/4
= 261,063.6 + 57,900.97
= 318,964.57 mm3
Shot weight = Shot volume x density
= 318,964.57 x 2.7 x 10 -3
= 861.2g = 0.9kg

 Fill Ratio

Fill Ratio = Shot sleeve volume/ Metal

318,964.57 = π (55)2 x (225/4) x y y = 0.6
This value for fill ratio is acceptable for the process
 Fill Time
Fill Time = K[Ti – Tf + sz] T
[ Tf – Td ]
Where
k empirically derived constant = 0.0346
Ti, Temperature of molten metal as it enters the die = 6500c
Tf, Minimum flow temperature of metal = 5700c
Td, Temperature of die cavity surface just before the metal enters = 2000c
S, percent solid fraction allowable in the metal at the end of filling = 30%
Z, Units conversion factor = 3.8 T, casting wall thickness = 3 mm
t = 0.0346[650 – 570 + 30 x 3.8] x3
[570 – 200]
= 0.054 second
= 54 milli seconds

ii) PQ2 Calculations:-

Maximum (Hydraulic) Accumulator Pressure = 150kgf/cm2

Diameter of (hydraulic) cylinder = 130 mm
Plunger diameter= 55 mm
Dry Shot Velocity (DSV) = 4.5 m/sec
 Maximum Static Metal Pressure
= MAP X (Cylinder Dia)2 / (Plunger Dia)2

= 150 x (130)2/(55)2

= 838.02kgf/cm2

 Dry Shot Flow Rate = (Plunger Dia)2 x π x DSV/4

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 = (55)2 x π x 4.5 x 103/4
= 10,692,618.75 mm3/sec
= 10,692.62 cm3/sec
 Max. Metal Pressure (lines)
= Density x Gv2 / 2g x Cd2

Where
Gv is maximum gate velocity = 400cm/s (recommended)
g is acceleration due to gravity = 981 cm/sec Cd is coefficient of
discharge = 0.4
= 2.58 x (4000)2
2 x 981 x (0.4)2
= 131,498.5 gf/cm2
= 131.5 kgf/cm2
 Min. Metal Pressure (lines)

Volume XVI Issue III Version I

= Density x Gv2 2g x Cd2
Gv is the minimum gate velocity = 2500cm/s (NADCA recommended)

= 2.58 x (2500)2
2 x 981 x (0.4)2
= 51,366.6 gf/cm2
= 51.4 kgf/cm2
 Flow rate (fill rate), Q
(A theoretical minimum fill rate that can be used to produce the highest quality
casting)
= Volume (casting and overflow) of metal (passing) through Gate /Fill time

Global Journal of Researches in Engineering( A)

= 261,063.6 / 0.054
= 4,834,511.111 mm3 /sec
 Runner Design Runner Area (A) = 1.3Ag
= 69 x 1.3
= 86.7 mm2
Depth (D) = 

= 10.42mm

Width = 2D = 20.84 m
From P-Q2 Graph
P=91.5 kgf/ cm2
Q = 7,255.7 cm3/sec

Therefore
Ag = Q/ Cd(p*2g/)
= 7255.7/0.4 x2x981/2.58)
= 0.6877 cm2

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 = 69 mm2
Therefore area of the gate = 69 mm2
Gate thickness = 3mm (will produce atomization)
Gate length hence = 23mm

P-Q2 Graph

iii) Cooling Calculation

Heat input = hGn
h is the heat factor = 145 Kcal/kg for Aluminum n is the number of shots = 120
per hour
G is weight of casting, overflow and feed system
= 705g
= 0.705kg
Therefore Heat input = 145 x 0.705 x 120
= 12,267 kcal/hr
50 % of heat is lost by convection to atmosphere and by spray cooling
Heat accumulated =12,267 x 50/100
= 6,133.5 kcal/hr
Heat removing capacity = 35 kcal/hr
Length of cooling line = 6,133.5/35
= 175 mm

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RESULTS SUMMARY

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