2k20/b12/20

Under the supervision of Mr. R.C singh

Aim: to perform a deep and extended analysis on
die casting processes and machines
By : Armaan singh (2k20/b12/20)

Index:
Introduction
History
What is die casting
How are die castings produced
Types of machines used
Type of dies
Die terminology
Advantages of die casting
Comparison with other products
Die construction
Automation in die casting
 Continuous computerized process
monitoring
 INTRODUCTION

Die casting is a versatile process for producing engineered

metal parts by forcing molten metal under high pressure into
reusable steel molds. These molds, called dies, can be
designed to produce complex shapes with a high degree of
accuracy and repeatability. Parts can be sharply defined, with
smooth or textured surfaces, and are suitable for a wide
variety of attractive and serviceable finishes.

Die castings are among the highest volume, mass-produced

items manufactured by the metalworking industry, and they
can be found in thousands of consumer, commercial and
industrial products. Die cast parts are important components
of products ranging from automobiles to toys. Parts can be as
simple as a zinc faucet or as complex as a connector housing.

Zinc faucet Connector housing

 History
The earliest examples of die casting by pressure
injection – as opposed to casting by gravity pressure –
occurred in the mid-1800s. A patent was awarded to
Sturges in 1849 for the first manually operated machine
for casting printing type. The process was limited to
printer’s type for the next 20 years, but development of
other shapes began to increase toward the end of the
century. By 1892, commercial applications included
parts for phonographs and cash registers, and mass
production of many types of parts began in the early
1900s.

The first die casting alloys were various compositions

of tin and lead, but their use declined with the
introduction of zinc and aluminum alloys in 1914.
Magnesium and copper alloys quickly followed, and by
the 1930s, many of the modern alloys still in use today
became available.
The die casting process has evolved from the original
low-pressure injection method to techniques including
high-pressure casting – at forces exceeding 4500
pounds per square inch – squeeze casting and semi-
solid die casting. These modern processes are capable
of producing high integrity, near net-shape castings
with excellent surface finishes.
What is die casting?

Die casting is a manufacturing process for producing

accurately dimensioned, sharply defined, smooth or
textured-surface metal parts. It is accomplished by
forcing molten metal under high pressure into reusable
metal dies. The process is often described as the
shortest distance between raw material and finished
product. The term “die casting” is also used to describe
the finished part.
The term “gravity die casting” refers to castings made
in metal molds under a gravity head. It is known as
permanent mold casting in the U.S.A. and Canada.
What we call “die casting” here is known as “pressure
die casting” in Europe.
How are die castings produced?

First, a steel mold capable of producing tens of

thousands of castings in rapid succession must be made
in at least two sections to permit removal of castings.
These sections are mounted securely in a machine and
are arranged so that one is stationary (fixed die half)
while the other is moveable (injector die half). To begin
the casting cycle, the two die halves are clamped tightly
together by the die casting machine. Molten metal is
injected into the die cavity where it solidifies quickly.
The die halves are drawn apart and the casting is
ejected. Die casting dies can be simple or complex,
having moveable slides, cores, or other sections
depending on the complexity of the casting.

The complete cycle of the die casting process is by far

the fastest known for producing precise non-ferrous
metal parts. This is in marked contrast to sand casting
which requires a new sand mold for each casting. While
the permanent mold process uses iron or steel molds
instead of sand, it is considerably slower, and not as
precise as die casting.
 Types of machines used
Regardless of the type of machine used, it is essential that die
halves, cores and/or other moveable sections be securely
locked in place during the casting cycle. Generally, the
clamping force of the machine is governed by (a) the
projected surface area of the casting (measured at the die
parting line) and (b) the pressure used to inject metal into
the die. Most machines use toggle type mechanisms actuated
by hydraulic cylinders (sometimes air pressure) to achieve
locking. Others use direct acting hydraulic pressure. Safety
interlock systems are used to prevent the die from opening
during the casting cycles.
Die casting machines, large or small, vary fundamentally only
in the method used to inject molten metal into the die. These
are classified and described as either hot or cold chamber die
casting machines.

Hot chamber machine

Hot chamber machines are used primarily for zinc, and low
melting point alloys which do not readily attack and erode
metal pots, cylinders and plungers. Advanced technology and
development of new, higher temperature materials has
extended the use of this equipment for magnesium alloys.
In the hot chamber machine, the injection mechanism is
immersed in molten metal in a furnace attached to the
machine. As the plunger is raised, a port opens allowing
molten metal to fill the cylinder. As the plunger moves
downward sealing the port, it forces molten metal through
the gooseneck and nozzle into the die. After the metal has
solidified, the plunger is withdrawn, the die opens, and the
resulting casting is ejected.
Hot chamber machines are rapid in operation. Cycle times
vary from less than one second for small components
weighing less than one ounce, to thirty seconds for a casting
of several pounds. Dies are filled quickly (normally between
five and forty milliseconds) and metal is injected at high
pressures (1,500 to over 4,500 psi). Nevertheless, modern
technology gives close control over these values, thus
producing castings with fine detail, close tolerances and high
strength.

Cold chamber machine

Cold chamber machines differ from hot chamber machines primarily

in one respect; the injection plunger and cylinder are not submerged
in molten metal. The molten metal is poured into a “cold chamber”
through a port or pouring slot by a hand or automatic ladle.

In a cold chamber machine, more molten metal is poured into the

chamber than is needed to fill the die cavity. This helps sustain
sufficient pressure to pack the cavity solidly with casting alloy. Excess
metal is ejected along with the casting and is part of the complete
shot.
Operation of a “cold chamber” machine is a little slower than a “hot
chamber” machine because of the ladling operation. A cold chamber
machine is used for high melting point casting alloys because plunger
and cylinder assemblies are less subject to attack since they are not
submerged in molten metal.

Figure: Cold chamber die casting machine

Type of dies
Dies are classified as: single cavity, multiple cavity, combination and
unit dies.
A single cavity die requires no explanation. Multiple cavity dies have
several cavities which are all identical. If a die has cavities of different
shapes, it’s called a combination or family die. A combination die is
used to produce several parts for an assembly. For simple parts, unit
dies might be used to effect tooling and production economies.
Several parts for an assembly, or for different customers, might be
cast at the same time with unit dies. One or more unit dies are
assembled in a common holder and connected by runners to a
common opening or sprue hole. This permits simultaneous filling of
all cavities.
Die terminology
 Sprue holes are tapered with the small end located at the
breaking point when the die is opened. A sprue pin, located in
the ejector half, makes the sprue hollow and deflects metal
entering the die into the runner system.
 Runners are channels located at the parting line to route liquid
metal from the sprue hole to the gate.
 Gates are passages through which metal enters the die cavity.
They have an important function in directing metal flow so that
the cavity is correctly filled. Air is expelled through vents as
molten metal enters the die cavity.
 Guide pins assure proper alignment of die halves and correct
register of cavities.
 Side walls and cores are designed to have a slight taper or draft.
The largest diameter or cross section of a cavity must be
located at the parting line (unless slides are used) so the casting
can be removed from the die. As molten metal in a die cavity
 solidifies, it shrinks away from walls onto core pins and other
projections. The design of the die must permit withdrawal of
core pins, and ejection without applying too much pressure
which could cause deformation to the die casting.
 Cores, fixed or moveable, as well as “loose pieces,” must be
positioned to facilitate removal either mechanically or by hand.
Loose pieces used to form undercuts must be positioned by the
operator. This requires extra labor, and usually slows the
casting cycle.
 Inserts can be cast integrally to provide special characteristics.
Most dies are cooled by water circulating through channels drilled
for that purpose.
Advantages of die casting

High-speed production – Die casting provides complex shapes within

closer tolerances than many other mass production processes. Little
or no machining is required and thousands of identical castings can
be produced before additional tooling is required.
Dimensional accuracy and stability – Die casting produces parts that
are durable and dimensionally stable, while maintaining close
tolerances. They are also heat resistant.
Strength and weight – Die cast parts are stronger than plastic
injection moldings having the same dimensions. Thin wall castings
are stronger and lighter than those possible with other casting
methods. Plus, because die castings do not consist of separate parts
welded or fastened together, the strength is that of the alloy rather
than the joining process.
Multiple finishing techniques – Die cast parts can be produced with
smooth or textured surfaces, and they are easily plated or finished
with a minimum of surface preparation.
Simplified Assembly – Die castings provide integral fastening
elements, such as bosses and studs. Holes can be cored and made to
tap drill sizes, or external threads can be cast.
 Comparison with other products

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.

DIE CASTING VS. STAMPING

Die casting produces complex shapes with variations possible in
section thickness. One casting may replace several stampings,
resulting in reduced assembly time.

DIE CASTING VS. SCREW MACHINE PRODUCTS

Die casting produces shapes that are difficult or impossible from bar
or tubular stock, while maintaining tolerances without tooling
adjustments. Die casting requires fewer operations and reduces
waste and scrap.
 Die construction

Dies, or die casting tooling, are made of alloy tool steels in at least
two sections, the fixed die half, or cover half, and the ejector die half,
to permit removal of castings. Modern dies also may have moveable
slides, cores or other sections to produce holes, threads and other
desired shapes in the casting. Sprue holes in the fixed die half allow
molten metal to enter the die and fill the cavity. The ejector half
usually contains the runners (passageways) and gates (inlets) that
route molten metal to the cavity. Dies also include locking pins to
secure the two halves, ejector pins to help remove the cast part, and
openings for coolant and lubricant.
When the die casting machine closes, the two die halves are locked
and held together by the machine’s hydraulic pressure. The surface
where the ejector and fixed halves of the die meet and lock is
referred to as the “die parting line.” The total projected surface area
of the part being cast, measured at the die parting line, and the
pressure required of the machine to inject metal into the die cavity

governs the clamping force of the machine

Automation in die casting

 “Automation and Mechanization” are terms often used
interchangeably by the die casting industry. Automation of a
manufacturing process is more sophisticated and complicated than
the mechanization of various operations.
A die caster progresses towards automation by mechanizing various
steps of the die casting process. For example:

1. Die lubrication can be accomplished by installing fixed or

reciprocating spray systems.
2. An automatic ladling device can replace the hand ladle.
3. Castings can be removed from the die by extractors or robots,
or by “drop through” to a conveyor below the machine.
4. Die casting machine operation can be integrated to cast,
quench, trim and eject castings and return scrap to the furnace by
conveyor.

Continuous computerized process monitoring

Alarm monitoring — A computerized remote terminal mounted
near the die casting machine continuously monitors the following:
velocity, position, pressures at the accumulator, die lock-up cylinder,
head and rod side of the injection cylinder, temperatures of
hydraulic oil, metal (up to ten locations in the die), and strains on
four tie-bars. Each of these variables is high/low limit checked every
shot. An alarm is sounded or flashed if a casting variable goes out-of-
limits.
Control — Automatic control valves and tie-bar adjusting motors are
installed on the die casting machine and connected to the
computerized remote terminal unit. The computer adjusts controls
to maintain satisfactory die locking force, slow shot velocity,
optimum fill time and proper intensifier timing. The computer may
also be interfaced to a robot and/or a programmable controller.
Data acquisition — After installing computerized remote terminal
units on each machine, a data acquisition system may be formed by
interconnecting these units and communicating all information back
to a master terminal computer in the office. The master computer
prints out a management information report which summarizes the
operation of the entire die casting shop, including which machines
are running, when they stop, shots made (good and bad), which
machines are out-of-limits and what to do. At the master station, the
manager can analyze the process by studying shot profiles on a video
monitor and statistical reports from a high speed printer.
Thank you!