Professional Documents
Culture Documents
Unit-3 - Special Moulding Processes PART-2
Unit-3 - Special Moulding Processes PART-2
Hareesha N G
Lecturer
Dept. of Aeronautical Engineering
Steps involved in the process
• The mould is cleaned using wire brush or compressed air to remove dust and other
particles from it.
• It is preheated to a temperature of 200 - 280°C by gas or oil flame and then the
surface is sprayed with a lubricant.
• The lubricant helps to control the temperature of the die thereby increasing its life
and also assist in easy removal of solidified casting.
• The mould is closed tightly and the liquid metal of the desired composition is poured
into the mould under gravity.
• After the metal cools and solidifies, the mould is opened and the casting is removed.
Gating and risering systems are separated from the cast part.
• The mould is sprayed with lubricant and closed for next casting. The mould need not
be preheated since the heat in the previous cast is sufficient to maintain the
temperature.
Advantages
• Good surface finish and close dimensional tolerances can be achieved.
• Suitable for mass production.
• Occupies less floor space.
• Thin sections can be easily cast.
• Eliminates skilled operators.
Disadvantages
• Initial cost for manufacturing moulds (dies) is high.
• Not suitable for steel and high melting point metals/alloys.
• Un-economical for small productions.
10. PRESSURE DIE CASTING
• Pressure die casting often called 'Die casting' is a casting process in which the
molten metal is injected into a 'die' under high pressures.
• The metal being cast must have a low melting point than the die material which is
usually made from steel and other alloys.
• Hence, this process is best suitable for casting non-ferrous materials, although a
few ferrous materials can be cast.
• The two basic methods of die casting include:
a) Hot chamber die casting process
b) Cold chamber die casting process.
10.a. Hot chamber die casting process
• Figure shows a 'goose neck' type of hot chamber die casting machine.
• In this process, the dies are made in two halves: one half called the fixed
die or 'stationary die’ while the other half called 'movable die’.
• The dies are aligned in positions by means of ejector pins which also help
to eject the solidified casting from the dies.