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Presented to:

Sir Syed Amjad Ahmad Sir Shah Nawaz

Presented by:
M. Kashif Ijaz 09-MC-18

Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various cold setting materials that cure after mixing two or more components together; examples are epoxy, concrete,plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods.

Die-casting is similar to permanent mold casting except that the metal is injected into the mold under high pressure of 10210Mpa (1,450-30,500psi) . Most die castings are made from nonferrous metals, specifically zinc, copper, aluminium, magnesium, lead, and tin based alloys, although ferrous metal die castings are possible.

Pressure: high to 300MPa Pouring rate: 10~50m/s (sometimes100m/s) Filling time: 0.01~0.2s Advantages : dimensional accuracy and stability smooth surface high strength and hardness high efficiency Disadvantages: unstable flow difficult for complex castings

Two basic types of die casting machines: hot-chamber machines (gooseneck machines) and cold-chamber machines. Machine sizes range from 400 tons to 4000 tons. Regardless of their size, the only fundamental difference in die casting machines is the method used to inject molten metal into a die.

Hot-chamber machines rely upon a pool of molten metal to feed the die. At the beginning of the cycle the piston of the machine is retracted, which allows the molten metal to fill the "gooseneck". The gas or oil powered piston then forces this metal out of the gooseneck into the die.

The advantages of this system include fast cycle times (approximately 15 cycles a minute) and the convenience of melting the metal in the casting machine. The disadvantages of this system are that highmelting point metals cannot be utilized and aluminium cannot be used because it picks up some of the iron while in the molten pool. Due to this, hot-chamber machines are primarily used with zinc, tin, and lead based alloys.

Cold-chamber machine works by melting the material, first, in a separate furnace. Then a precise amount of molten metal is transported to the cold-chamber machine where it is fed into an unheated shot chamber (or injection cylinder). This shot is then driven into the die by a hydraulic or mechanical piston.

This biggest disadvantage of this system is the slower cycle time due to the need to transfer the molten metal from the furnace to the coldchamber machine. Cold-chamber machines are used the alloys include aluminium, magnesium, copper, and zinc alloys with a large composition of aluminium.

Die casting hot chamber machine

Pressure: 34.5~103.5.5Pa Use: low melting point metal heavy section Advantages: less shrinkage compact structure smooth mold filling Disadvantages: high cost low efficiency

Gravity die casting is suitable for mass production and for fully mechanised casting.

Vacuum casting process is one of the most important new technologies in the future to seek. Advantages: eliminate defects like blowhole, cold shut, flow line and misrun; low metal pressure prolongs die life; good parts can be easily obtained

Disadvantages: shot interferes shutting valve when metal dreg that stuck at value Sheet.

In the process, liquid metal is introduced into an open die, just as in a closed die forging process. The dies are then closed. During the final stages of closure, the liquid is displaced into the further parts of the die.

Die casting vs. plastic molding - Die casting produces stronger parts with closer tolerances that have greater stability and durability. Die cast parts have greater resistance to temperature extremes and superior electrical properties. Die casting vs. sand casting - Die casting produces parts with thinner walls, closer dimensional limits and smoother surfaces. Production is faster and labor costs per casting are lower. Finishing costs are also less.

Die casting vs. permanent mold - Die casting offers the same advantages versus permanent molding as it does compared with sand casting. Die casting vs. forging - Die casting produces more complex shapes with closer tolerances, thinner walls and lower finishing costs. Cast coring holes are not available with forging.

Excellent dimensional accuracy (dependent on casting material, but typically 0.1 mm for the first 2.5 cm (0.005 in. for the first inch) and 0.02 mm for each additional centimeter (0.002 in. for each additional inch). Smooth cast surfaces (1-2.5 m). Thinner walls can be cast as compared to sand and permanent mold casting (approximately 0.75 mm).

Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing surfaces). Reduces or eliminates secondary machining operations. Rapid production rates. Casting tensile strength as high as 415 MPa .

Casting weight must be between 30 g and 10 kg. Casting must be smaller than 600 mm. High initial cost. Limited to high-fluidity metals. A certain amount of porosity is common. Thickest section should be less than 13 mm. A large production volume is needed to make this an economical alternative to other processes.

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