MECHANICAL ENGINEERING

DEPARTMENT

MANUFACTURING PROCESS JD 605


Assignment 1 Die Casting




Name Fatin Aadila Binti Ismail
Matrix No. 19DRP11F2002
Class DRP 6
Lecturer Mrs. Suyani Binti Arifin
Submit Date 21 July 2014


DIE CASTING
1.0 Definition :
A manufacturing process for producing metal parts by forcing molten metal
under high pressure into a die cavity. This process if for high volume, high detail, and
value added economically priced cast parts.
2.0 Process :
1. A metal tool is built and attached to a furnace of molten metal
2. Then molten metal is mechanically poured or injected into the metal mold
3. The mold cools for a brief time
4. The mold is opened
5. The parts are ejected
6. The process repeats over and over again

Diagram 1 : Die casting process.
Detail part :
1. Cover die - The stationary half of a die-casting die, which forms the exterior
or appearance surfaces of the casting.
2. Die cavity The impression in a die into which pattern material is forced.
3. Ladle Metal receptacle frequently lined with refractories used for
transporting and pouring molten metal.
4. Gate - The passage connecting a runner or overflow with a die cavity.
5. Gate runner - The runner in a die-casting die that is directly adjacent to the
gate. The runner feeds the injected metal to the gate.
6. Platen - Portion of a casting machine against which die sections are fastened,
or of trim presses against which trim dies are fastened.
7. Plunger - Ram or piston that forces molten metal into a die.
8. Parting line - The joint between the cover and ejector portions of the die or
mold. Also, the mark left on the casting at this die joint.
9. Parting line, stepped - A condition on a die-casting where the parting line
changes abruptly from one level to another.
10. Sleeve - The molten metal chamber of a cold-chamber die-casting machine.
This is a hardened steel tube through which the shot plunger moves to inject
the molten metal into the die.
11. Ejector pins - A pin actuated to force the casting out of the die cavity and off
the cores.
12. Ejector plate - Plate to which the ejector pins are attached and which actuates
them.

3.0 Advantages :
1. It requires less floor space as compared to other casting processes.
2. Rate of production is high. 75 to 150 casts per hour in cold chamber and 300
to 350 casts per hour in hot
3. chamber process.
4. Die casting dies retain their accuracy for a very long time.
5. Very thin sections can be cast and holes up to minimum of 1.6 mm diameter
can be easily cored.
6. High surface finish is obtained and often no further finishing is required.
7. Cost per unit is minimum hence economical.

4.0 Disadvantages :
1. All metals and alloys can not be cast.
2. The cost of machines, dies and other equipment used is high.
3. Not economical for small quantity production.
4. Heavy casting cannot be cast.
5. Special precautions are necessary for evacuation of air from die cavity,
otherwise cause porosity.





HOT CHAMBER
This process involves the use of a plunger which traps a certain volume of molten
metal and forces it into the die cavity through a gooseneck and nozzle. After the metal has
solidified in the die cavity, the plunger is withdrawn, the die opens and the casting is ejected.
Metals having low melting points such as zinc, copper, magnesium and lead are cast using
Hot chamber die casting.
PROCESS OF HOT CHAMBER
Diagram Process



(1) The mould is closed and sealed. The
plunger is in the upper position.




(2) The plunger injects liquid metal through
the gooseneck and along to the mould, whilst
preserving static pressure with the movement,
until the material solidifies





(3) After casting the plunger returns to it's
original position, whilst the product remains in
the mould





(4) The product is removed from the mould by
moving side ejectors




COLD CHAMBER
This process molten metal is poured into the injection cylinder manually by a hand
ladle or by an automatic ladle. The metal is forced into the die cavity at high pressures. High
melting point alloys of aluminum and copper are normally cast using cold chamber die
casting.

PROCESS OF HOT CHAMBER
Diagram Process


Molten metal is poured into the
injection cylinder manually by a hand
ladle or by an automatic ladle.



The metal is forced into the die cavity
at high pressures




Eject.



Remove product.