HOUSING FOR LIGHT FITTING IN

TRAIN BY DIE CASTING METHOD

ENROLLMENT NO.:- 150490728006

Prepared By : Misal Gandhi
Branch : M.E. (Production)
Guided By : Mr. Hardik Naik

CONTENTS
Objective
Introduction
Industry Profile
Process Cycle
Equipments
Machine Specification
Suitable Material
Advantages-Disadvantages & Application
Video
Conclusion
Future Scope

OBJECTIVE
Within 2 minute faster casting product
Higher Production Rate
Less Human Errors
Faster Products due to Semi Automatic Die
Casting Process
Highly Customer Satisfaction of Quality Product

INDUSTRY PROFILE

Nandratan Foundry manufactures ferrous and

nonferrous castings (as cast or with machining),
Plant based in Sarigam, Gujarat and 160 kms
from Mumbai casting and fabrication.

INDUSTRY PRODUCTS
Ferrous Castings
Ductile iron (SGCI) castings like valve bodies,
spools, flanges, links, levers, water connection
kits, boxes, dampers, oil seals, housings to name
a few.
Nonferrous Castings
Aluminum base product like gear cases, housing
for light fittings, venturies, housing for
automobile components, electrical motor housing,
transmission line components etc.

PLANT LAYOUTS- EQUIPMENTS

Plant & Machinery

Foundry
150 kW medium frequency induction furnace
with 250 kg crucible
3 oil fired pit furnaces
2 coke fired pit furnaces
Molding machine
Fettling Shop
Shot blasting machine
Swing frame grinders

PLANT LAYOUTS- EQUIPMENTS

Machine Shop
Heavy duty lathes
Milling machines
Drilling machines
Tapping machines
Facing machines
Fabrication Shop
Heat treatment furnace
Rolling mill
Hydraulic & pneumatic power presses
Shearing machines
Pedestal grinders
Welding equipments

INTRODUCTION

Die casting is a manufacturing process that can

produce geometrically complex metal parts through
the use of reusable molds, called dies.
The die casting process involves the use of a furnace,
metal, die casting machine, and die.
The metal, typically a nonferrous alloy such as
aluminum or zinc, is melted in the furnace and then
injected into the dies in the die casting machine.
There are two main types of die casting machines hot
chamber machines (used for alloys with low melting
temperatures, such as zinc) and cold chamber
machines (used for alloys with high melting
temperatures, such as aluminum).

DIE CASTING HOT CHAMBER MACHINE

DIE CASTING COLD CHAMBER MACHINE

DIE CASTING M/C USED IN INDUSTRY

PRODUCT PROCESS CYCLE

General PPC

Clamping
Injection
Cooling
Ejection
Trimming

In Industry PPC

Pouring
Clamping
Cooling
Ejection
Removal of
Core
Trimming

EQUIPMENTS

Cold chamber die casting machine Cold

Open holding pot It place in to furnace
Plunger Powered by Hydraulic or Manually
Induction Furnace
Grinding Machine
Cutting Machine

DIE CASTING WALL THICKNESS

MACHINE SPECIFICATION
Both hot chamber and cold chamber die casting
machines are typically characterized by the
tonnage of the clamp force they provide. The
required clamp force is determined by the
projected area of the parts in the die and the
pressure with which the molten metal is injected.
Also, certain materials that require high injection
pressures may require higher tonnage machines.

MATERIAL
Die casting typically makes use of nonferrous
alloys. The four most common alloys that are die
cast are shown below, along with brief
descriptions of their properties.
Aluminum alloys
Low density
Good corrosion resistance
High thermal and electrical conductivity
High dimensional stability
Relatively easy to cast
Requires use of a cold chamber machine

DESIGN RULES

1.Wall thickness:
Incorrect

Non-uniform wall thickness.

Correct

Uniform wall thickness.

2.Corner:
Incorrect

Sharp corner.

Correct

Rounded corner.

3.Draft:
Incorrect

No draft angle.

Correct

With draft angle.

4.Undercuts:
Incorrect

Die cannot separate.

Correct

Die easily separet.

POSSIBLE DEFECTS
Flash-

Due to injection pressure too high

& clamp force too low.
Hot tearing- Due to non-uniform cooling
rate.
Bubbles- Due to very high injection
temperature & non-uniform cooling rate.
Unfilled sections- Due to slow injection
& low pouring temperature.
Ejector marks- Due to very short
cooling time & high ejection force.

ADVANTAGES OF DIE
Very

CASTING

high rate of production is achieved.

Close dimensional tolerances of + 0.025 mm is
possible.
Surface finish of o.8 microns can be obtained.
Very thin sections of 0.50 mm can be cast.
Longer die-life is obtained.
Less floor space is required.
Unit cost is minimum.

DISADVANTAGES OF DIE
Only

CASTING

economical for nonferrous alloys.

Not economical for small runs.
Heavy castings cannot be cast.
Cost of die and die casting equipment is high.
Die casting usually contain some porosity due
to the entrapped air.

CONCLUSION

By using this casting method we can get complex

casting shapes at Higher production at minimum
time in less effort.

THANK YOU