SID - 510654115

Manufacturing
Engineering
Assignment 2A

Squeeze Casting
Vacuum Permanent-Mold
Casting

Yuvraj Tyagi
EXECUTIVE SUMMARY
The purpose of this report is to choose an Aluminium alloy and two appropriate
manufacturing methods to produce 1000 gearbox covers. The chosen manufacturing
technology is casting because of its flexibility, and the two casting techniques selected are
Squeeze Casting and Vacuum Permanent-Mold Casting, both of which are Multiple-Use
Mold Casting processes. The material selected for the gearbox cover is Aluminium A360, a
commonly used alloy with excellent castability, high tensile strength, good fatigue properties,
and sufficient corrosion resistance.
This report provides a detailed analysis of the material selection, process parameters such as
gate area and die clamping force, tooling setup, and advantages of each process. Finally, a
comparison is made between the two casting techniques to determine which is more suitable
for manufacturing the 1000 gearbox covers.

INTRODUCTION
The process of manufacturing involves the creation of finished goods using raw materials,
tools, and machines. To produce 1000 Gearbox Covers, it is essential to select a
manufacturing process that can meet all of the functional requirements of the product.
Different manufacturing techniques such as casting, metal forming, and powder metallurgy
are available, each with their unique advantages and limitations. However, the selection of
the most appropriate material and manufacturing process must consider factors such as
precision, efficiency, and cost-effectiveness.

Fig 1. Gearbox Cover CAD model Fig 2. Rendered image of joined Gearbox
The ideal combination of material and manufacturing process that can meet the functional
requirements of the Gearbox Cover with the highest degree of precision, efficiency, and cost-
effectiveness must be identified. This report aims to evaluate the different manufacturing
processes and select the best material and manufacturing method to produce 1000 Gearbox
Covers. The report will provide a detailed analysis of the material selection and
manufacturing process, including process parameters such as gate area and die clamping
force, tooling setup, and the advantages of each process. Ultimately, the report will conclude
with a comparison of the selected manufacturing techniques to determine the most suitable
method for producing the 1000 Gearbox Covers.

Selection of the two Manufacturing Processes

The aim of this report is to choose two appropriate manufacturing processes for the
production of 1000 Gearbox Covers. The chosen processes are part of the casting materials
processing method, specifically, the Multiple-Use Mold casting processes. Casting is a highly
versatile manufacturing method that is ideal for producing parts with hollow sections, such as
the Gearbox Cover design. This project requires the selection of an appropriate grade of
Aluminium alloy for the manufacturing process. The use of Expendable Mold casting
processes, which destroy the mold cavity and gating system after each use, would be
expensive, time-consuming, and counter-productive. Instead, the Multiple-Use Mold casting
processes will be used since the exact same Gearbox Cover needs to be produced 1000 times.
The appropriate mold cavity, riser, and gating system only need to be designed and
incorporated into the dies once.
The report outlines two casting processes chosen for the Gearbox Cover manufacturing:
1. Squeeze Casting process
2. Vacuum Permanent-Mold Casting process
The report provides a detailed description of the mechanism, process parameters, and analysis
of each process. Finally, the report concludes with a comparison of the two casting processes
to determine which one is better suited for manufacturing 1000 Gearbox Covers.

Material Selection
The best candidate, from an engineering standpoint, would be the material that offers more
desirable mechanical properties, as demanded by the functions of the Gearbox Cover.
Another crucial factor for the material selection is which material is more suitable for the
chosen manufacturing methods, which in this case are Squeeze Casting and Vacuum
Permanent-Mold Casting.
Aluminium A360 is a highly suitable material for the production of Gearbox covers, offering
a range of advantageous properties[1]. Due to its excellent castability, it is widely used in
various casting processes. Its low melting point and good fluidity facilitate the casting of
complex shapes, such as those required for Gearbox covers that feature hollow sections. The
low shrinkage characteristics of Aluminium A360 prevent deformation and cracking during
the casting process, further enhancing its appeal.
The alloy is also characterized by high tensile strength, good fatigue properties, and sufficient
levels of corrosion resistance, which are all essential for Gearbox covers. The high tensile
strength ensures that the covers can withstand the required load and torque, while its good
fatigue properties enable them to withstand repeated cycles of stress and strain. The silicon
content of Aluminium A360 enhances its mechanical properties by making it highly resistant
to hot cracking during casting. It also improves its wear resistance and decreases its
coefficient of thermal expansion.
 The low iron content of Aluminium A360 provides excellent resistance to high-temperature
heat treatment, which is a crucial factor in the manufacturing process. In summary, the
desirable characteristics and properties of Aluminium A360 make it an excellent material for
the production of Gearbox covers, providing reliability and durability in this application.
Between these two materials, Magnesium is lighter, has better machinability, and boasts of a
higher strength-to-weight ratio. However, for load-bearing applications, Aluminium is more
widely used, because it has a higher modulus of elasticity, along with having better wear and
fatigue characteristics.

Table 1: Elemental composition of Al A360[2] Table 2: Material properties of Al A360[2]

Fig 3: Stress v/s Strain graph of Al A360 [2]

SQUEEZE CASTING
Squeeze Casting is a manufacturing method that utilizes metal molds to create a desired
shape while applying high pressure to the molten metal during solidification. This process
differs from other die casting processes, as it only applies pressure from the upper die, which
can range from 20-175 MPa depending on the material being cast[3]. This makes Squeeze
Casting a hybrid technique that combines forging and casting methods to produce products
with excellent detail, surface finish, and mechanical properties that approach those of forged
products.
The Squeeze Casting process minimizes defects and produces good mechanical properties
through several factors. The large gate area and slow feeding of molten metal into the lower
die cavity reduce turbulence and the occurrence of gas entrapment, resulting in fewer defects
such as gas porosity and shrinkage porosity. The use of lower die temperatures below the
metal's solidus temperature, combined with high pressure during solidification, leads to rapid
freezing and finer grain size, enhancing the mechanical properties of the final product. The
high-pressure values also compensate for any solidification shrinkage that may occur,
eliminating the need for a riser in the mold cavity.
By incorporating Squeeze Casting with the casting alloy Aluminium A360, the resulting
Gearbox Covers will have precise dimensions, excellent surface finish, high strength and
hardness, good fatigue properties, and adequate corrosion resistance. This process satisfies all
the design requirements of Gearbox Covers.

Equipment and Setup

The Squeeze Casting process requires several pieces of equipment to be used, as stated in [4].
These include
1. Lower die
2. Retractable upper die
3. Hydraulic press
4. Oil die heater
5. Furnace equipped with a crucible for melting the Aluminium A360
6. Pouring ladle
7. Injection shot sleeve.
In the Squeeze Casting process, molten metal is injected into a mold cavity using an injection
shot sleeve, which requires the use of several pieces of equipment. The successful
implementation of this process relies on the presence of two dies that have gating systems
and mold cavities machined into them to match the shape of the pattern required for casting
the Gearbox Cover. The upper die cavity represents the top half of the shape of the casting,
while the lower die cavity represents the bottom half of the casting shape. The bottom die is
also referred to as the ejection die, and the top die as the cover die, because it needs an
ejection system to facilitate the removal of the casting from the bottom die.
The temperature of both the dies needs to be maintained between 150℃ to 260℃ below the
solidus temperature of the alloy being cast. A hardened, hot-work tool steel is used to make
the dies to withstand the high amount of casting pressures involved in the process. An oil die
heater is used to circulate oil in the dies to achieve the desired temperature range, while a
water cooler is used to cool the dies after the process has been completed. The molds walls
can be covered with graphite coatings to prevent the casting from sticking to the mold surface
after solidification, improve the surface finish of the cast product, direct the direction of
cooling, and prolong the die life.
A minimum draft of 1:100 (0.254mm / 25.4mm) needs to be provided in the mold cavity
because alloys of Aluminium are very susceptible to solidification shrinkage, ensuring easy
removal of the casting afterwards [5]. The solidus temperature of Aluminium A360 is 560℃,
suggesting that the die temperatures would be kept in the range of 310℃ to 420℃ for this
process. The temperature in the crucible containing the molten Aluminium A360 would be
much higher, in the range of 620℃ to 750℃ [5].

Manufacturing Process
The Squeeze Casting process involves a series of steps that are carried out in the following
order:
1. Fabrication of upper and lower dies: The upper and lower dies are fabricated, and the
mold cavity and gating system are machined inside them. A hydraulic press is
attached to the upper die.
2. Heating of Aluminium A360: Aluminium A360 is heated inside the furnace to the
required melt temperature needed for the casting operation.
3. Transfer of molten contents: The ladle picks up the molten contents from the furnace
and carries the molten alloy to the shot sleeve.
4. Injection of molten Aluminium A360: The shot sleeve is tilted, and the ladle pours the
molten alloy in it. The plunger inside the shot sleeve injects the molten Aluminium
A360 in the mold cavity of the bottom die at a pre-set pressure value. The shot sleeve
then regains its vertical position and the plunger retreats.
5. Lowering of upper die: The upper die is then lowered down to the bottom die, until
both the mold cavities are touching one another at the parting line.
6. Application of pressure: Pressure is then applied on the upper die by the hydraulic
press. This pressure squeezes the upper die into the liquid pool of molten Aluminium
A360. The molten liquid then fills up the mold cavity of the upper die.
7. Maintenance of pressure: The pressure being applied by the hydraulic press is
maintained until the complete solidification of the molten A360 is achieved.
8. Release of pressure: The pressure is released, and the upper die is then retracted back
to its original position.
9. Extraction of finished cast: The finished cast is extracted from the bottom die using
the ejector pin or rods.
10. Cleaning of dies: The mold cavity and gating system in both the dies is cleaned for the
next casting operation.
11. Repeat: The entire process is then repeated for the next casting operation.
 Fig 4: Schematic of the Squeeze Casting process [6]

VACUUM PERMANENT-MOLD CASTING

Vacuum Permanent-Mold Casting is a type of casting process that uses a sealed chamber to
hold molten metal. The chamber contains a crucible and a die assembly, which consists of an
upper and lower die that form the mold. The upper die is moveable and is brought down to
align with the lower die at the parting line when the casting begins. A vacuum is drawn on
the upper half of the die assembly, which creates a pressure differential that draws the molten
metal up through a feed tube and into the mold cavity[5]. This process results in very low
turbulence and eliminates the chance of gas entrapment. The mold is turned upside down
during the process to allow the molten metal to be drawn upwards.
The Vacuum Permanent-Mold Casting process has several advantages. The low turbulence
and directional solidification ensure that the final product has excellent mechanical properties
and a great surface finish. The process also eliminates the need for additional risers to be
accommodated as part of the mold cavity. If certain areas of the casting are difficult to fill,
multiple fill tubes can be used to reduce the chances of shrinkage porosity[5].
Using Aluminium A360 in the casting process ensures that the Gearbox Cover obtained will
be corrosion resistant and possess good fatigue properties for a long product life. The
Vacuum Permanent-Mold Casting process is ideal for producing complex shapes and thin-
walled parts. It is a cost-effective alternative to other casting methods such as sand casting or
investment casting. Overall, Vacuum Permanent-Mold Casting is a reliable process that
produces high-quality castings with consistent results.
Equipment and Setup
For the Vacuum Permanent-Mold Casting process the following equipment setup is needed
[7]:
1. Lower die
2. Retractable upper die
3. Hydraulic press
4. Furnace with a crucible for melting the Alumnium A360,
5. Feed tube for transferring the molten metal to the mold
6. Mechanism for creating a vacuum depending on the size and configuration of the cast.
The casting process for the Gearbox Cover involves machining both dies to create the gating
system and mold cavity required to form the shape. The shape is divided into two parts: the
upper die cavity represents the top half, and the lower die cavity represents the bottom half.
Ejection pins are necessary for the upper die to facilitate mold removal. The dies must be
made from hardened hot-work tool steel to withstand the high casting pressures involved in
the process. The Aluminium A360 is heated to a melt temperature of 620℃ to 750℃ inside a
furnace. To prevent the casting from adhering to the mold surface after solidification,
graphite coatings can be applied to the mold walls. These coatings offer additional benefits
such as improving surface finish, directing the direction of cooling, and extending the die's
lifespan. Due to Aluminium alloys' susceptibility to solidification shrinkage, a minimum draft
of 1:100 (0.254mm / 25.4mm) needs to be provided in the mold cavity to facilitate easy
removal of the casting.

Manufacturing Process
The Vacuum Permanent-Mold Casting process involves a series of steps for the
manufacturing process, which are as follows:
1. The upper and lower dies are created, with the mold cavity and gating system
machined inside. A hydraulic press is then connected to the upper die.
2. The Aluminium A360 is heated in a furnace to achieve the necessary melt
temperature required for the casting process. The molten metal is stored in a crucible,
which is located in a sealed chamber at the bottom of the machine setup.
3. The casting process is initiated when the upper die is lowered down to the lower die,
bringing both the mold cavities into contact at the parting line.
4. Pressure is applied to the upper die through the hydraulic press, clamping the two dies
together and tightly sealing the mold cavity.
5. A vacuum is created on the upper half of the die assembly, which establishes a
pressure differential between it and the molten metal pool located in the chamber
below.
6. The molten metal flows from the crucible to the mold cavity through a feed tube due
to the pressure differential.
7. The molten metal fills up the mold cavity from the top down, with the vacuum being
maintained until solidification occurs.
 8. Once the solidification of the molten metal is complete, the pressure differential is
released by retracting the upper die, which carries the casting with it
9. The casting is then held in the upper die cavity for a certain period of time to cool
down, after which it is removed using ejector pins.
10. The mold cavity and gating system in both the dies are cleaned for the next casting
operation, and the process is repeated.

Fig 5: Schematic of the Vacuum Permanent-Mold Casting process [8]

ANALYSIS
Squeeze Casting and Vacuum Permanent-Mold Casting are two popular techniques used to
manufacture high-quality aluminium alloy castings such as gearbox covers. Both methods
involve the use of an upper die that exerts high clamping force on the molten metal inside the
die cavity to achieve a rapid solidification process, leading to enhanced mechanical properties
and minimal defects. The clamping force of the die is a critical parameter for both processes,
which can be calculated based on certain process parameters.
In this report, we have performed a comparative analysis of the Squeeze Casting and Vacuum
Permanent-Mold Casting processes to determine important process parameters required to
manufacture an Aluminium A360 Gearbox Cover. Firstly, we calculated the clamping force
of the die for the Squeeze Casting process, which involved the injection force applied by the
plunger in the shot sleeve injector and the metal casting pressure in the die cavity. Using
geometrical dimensions given for the Gearbox Cover in the CAD design, we computed the
volume of molten metal required for casting and projected casting area. Based on these
parameters and literature available on Squeeze Casting of Aluminium alloys, we arrived at a
metal casting pressure of 173 MPa and die clamping force of 13.78 × 𝟏𝟎𝟔 N for the
Squeeze Casting process.
Secondly, we calculated the gate area for both processes, which is an essential parameter for
the casting process. The gate area must be large enough to freeze only after the solidification
is completed in the mold cavity, so additional molten metal can be fed to the casting where
the solidification shrinkage has occurred. For this, we assumed reasonable values for certain
parameters like gate velocity and filling time based on literature available. We found that the
Gate area for the Squeeze Casting process was 0.00024 m2, while for the Vacuum
Permanent-Mold Casting process, it was 0.00016 m2.
The results showed that the Squeeze Casting process requires a somewhat larger gate area to
minimize the turbulence of the molten metal injected from the shot sleeve into the die cavity.
In contrast, flow turbulence is not a significant problem for the Vacuum Permanent-Mold
Casting process. These process parameters are critical for achieving high-quality aluminium
alloy castings with minimal defects. In the Squeeze Casting process, the retractable upper die
is made to clamp down on the lower die through the use of a hydraulic press. This leads to
high pressure values being created inside the die cavity, where the molten metal is sitting. It
is through these high-pressure values that the molten metal is rapidly solidified, leading to the
casting exhibiting enhanced mechanical properties and minimal defects. In the Vacuum
Permanent-Mold Casting process too, the upper die works in a similar fashion, although the
method of injecting the molten metal into the die cavity is different. Nevertheless, the
“clamping force of the die” is a critical parameter in both the processes.
The calculations are shown in Appendix of this report.

Jigs and Fixtures

During the manufacturing process, jigs and fixtures play a crucial role in keeping the
workpiece fixed in place. While fixtures are used to hold the workpiece, jigs offer the
additional benefit of guiding the machining tool.
Both Squeeze Casting and Vacuum Permanent-Mold Casting processes yield Gearbox Covers
with excellent surface finish and dimensional precision. This eliminates the need for any
further machining operations to improve the surface finish or modify the dimensions. The
only remaining task is to drill the 4 clamp holes with a diameter of 11 mm, and the 2 centre
bores with diameters of 32 mm and 16 mm as per the CAD design. To carry out this task, a
drilling machine is required, and a jig can be used to hold down the Gearbox Cover and guide
the drill bit accurately. This jig setup can provide precision and repeatability, enabling
the holes to be quickly machined in each of the 1000 Gearbox Covers. As a result, the
production lead time and overall costs associated with manufacturing the Gearbox
Covers can be significantly reduced.
With the requirements in mind, a jig setup for the Gearbox Cover was designed using
SolidWorks. The design for the jig setup is illustrated below.
 Figures 6: Isometric view of the jig designed in Solidworks

Figure 7: Front top and isometric projections of the cad model

The designed model of jig consists of 4 jaws which are designed in such a way that the
contact patch with the gearbox cover is minimized, so that surface finish is not
compromised while drilling operation. These jaws are movable and can be fixed at a
point, which in then provides stability to the Gearbox cover.

Surface Coating
Powder coating is a surface finishing technique that is widely used for coating gearbox
covers. This process involves applying a fine powder made of thermoplastic or thermoset
polymer to the surface of the cover using an electrostatic charge. The powder adheres to the
metal surface of the cover and is then heated in an oven, melting the powder and creating a
smooth and durable coating [9].
There are several advantages to using powder coating for gearbox covers. The foremost
advantage is its exceptional durability. Powder coatings offer excellent resistance to
scratches, chips, and other types of damage, making them a perfect choice for gearbox
covers that are frequently exposed to harsh environments and rough handling.

Fig 8: Schematic Diagram of Powder Coating technique [9]

In addition to durability, powder coatings are available in a vast range of colours and finishes,
which makes them a versatile option for customizing the appearance of gearbox covers.
These coatings can be applied in matte, glossy, or metallic finishes, and can be matched to
any colour desired. As a result, powder coating offers an excellent combination of durability
and customization options, making it a popular choice for coating gearbox covers.

CONCLUSION
The Gearbox Cover has been produced through two different casting processes, namely
Squeeze Casting and Vacuum Permanent-Mold Casting, both of which offer excellent surface
finish and high as-cast strength for the casting. However, the setup cost for these processes is
considerably high as the die cavities need to be specifically machined for a particular product
and cannot be used for any other. As a result, these high operational costs can only be
justified when a high number of products are being manufactured. For the current objective
of producing 1000 Gearbox Covers, the selection of these two processes was primarily based
on this criterion.
Comparing the two casting processes, the Vacuum Permanent-Mold Casting process is more
beneficial in terms of surface finish as the molten metal never comes in contact with the
atmosphere, which results in negligible gas porosity in the casting. Additionally, the molten
metal in the Vacuum Permanent-Mold Casting process enters the cavity due to a pressure
differential between it and the die assembly, which minimizes turbulence in the flow and
contributes to an overall smoother finish. On the other hand, the molten metal in the Squeeze
Casting process is injected via a shot sleeve injector, which can lead to higher turbulence in
the flow and, therefore, a lower surface finish. Thus, for obtaining a higher quality of
surface finish, the Vacuum Permanent-Mold Casting process is a better option than
Squeeze Casting.
The Vacuum Permanent-Mold Casting process also offers enhanced mechanical properties of
the casting compared to the Squeeze Casting process. This is because directional
solidification of the molten metal occurs in the Vacuum Permanent-Mold Casting process,
leading to better mechanical properties. However, directional solidification may not occur in
the Squeeze Casting process, which primarily relies on rapid freezing of the molten metal. As
a result, the Vacuum Permanent-Mold Casting process is a preferred option for achieving
better mechanical properties in the casting.
It should be noted that the overall cost of operation and production time for the Vacuum
Permanent-Mold Casting process is higher than that of the Squeeze Casting process.
However, since the Gearbox Cover is a crucial component, whose failure can lead to
catastrophic consequences for the entire mechanical assembly, the Vacuum Permanent-Mold
Casting process should be chosen from an engineering standpoint.

REFERENCES
[1] A360 aluminum properties: Die cast materials (no date) Dynacast. Available at:
https://www.dynacast.com/en/knowledge-center/material-information/aluminum-die-
castingmetals/a360#:~:text=A360%20is%20an%20aluminum%20alloy,strength%2C%20
even%20in%20elevated%20temperatures. (Accessed: 10 May 2023).
[2] Aluminum A360.0-F die casting alloy. Available at:
https://www.matweb.com/search/DataSheet.aspx?MatGUID=87a0d0817ebd44008a967cb
f3e9cd378 (Accessed: 10 May 2023).
[3] Chapter 13: Multiple-use-mold casting processes DeGarmo’s materials and processes in
manufacturing - vdocument.in. Available at: https://vdocument.in/chapter-13-multiple-
use-mold-casting-processes-degarmos-materials-and-processes.html (Accessed: 10
May 2023).
[4] Schwam D, Wallace FJ, Chang Q, Qingming, Zhu Y. Optimization of Squeeze Casting
for Alumnium Alloy Parts. 2002 https://www.osti.gov/servlets/purl/801193
[5] http://zhangjun.ca/DeGarmo's%20Materials%20and%20Process%2011th.pdf
[6] https://ars.els-cdn.com/content/image/1-s2.0-S0924013699002915-gr2.jpg
[7] Arnold, T. F., Krubsack, W. L. Mechanical Properties/High Ductility from Alumnium
Permanent Mold Castings. SAE Transactions. 1986; 95, 543–549.
http://www.jstor.org/stable/44725406
[8] World-class vacuum die casting service - inox casting (2022) Inox Cast. Available at:
https://www.inoxcast.com/vacuum-die-casting/ (Accessed: 10 May 2023).
[9] Nagato, T. et al. (2010) ‘Study of design and optimization of tablet coating process by
Taguchi method’, Journal of the Society of Powder Technology, Japan, 47(6), pp. 394–
401. doi:10.4164/sptj.47.394.
APPENDIX

1. Calculations of the die clamping force for the Squeeze Casting process:

Fig 9: Calculation of “injection force” and “metal casting pressure” for the Squeeze Casting
process
 Fig 10: Calculation of the “Die Clamping Force” for the Squeeze Casting process and
Vacuum Permanent Die Casting process
2. Calculation of Gate area for Squeeze Casting process

Fig 11: Calculating the “Gate Area” for the Squeeze Casting process
3. Calculation of the gate area for the Vacuum Permanent-Mold Casting process:

Fig 12: Calculating the “Gate Area” for the Vacuum Permanent-Mold Casting process