RAJA BALWANT SINGH ENGINEERING
TECHANICAL CAMPUS,BICHPURI,AGRA
INDUSTRIAL INTERNSHIP
PRESENTATION
Submitted By: Rohit kumar
Location: Procast INDIA
Duration:1month
Roll Number : 2000040400019
Branch : ME
Pressure Die
Casting
Pressure Die
casting
•Pressure die casting is a quick,
reliable and cost-effective
manufacturing process for
production of high volume, metal
components that are net-shaped
have tight tolerances.
•The pressure die casting process
consists of injecting under high
pressure a molten metal alloy
into a steel mold (or tool).
This gets solidified rapidly (from
milliseconds to a few seconds) to
form a net shaped component.
Types of Pressure Die Casting
High Pressure Die Casting Low Pressure Die casting
•Used for castings requiring tight Commonly used for larger and non-
tolerance and detailed geometry. critical parts.
•High pressure die casting has wider
application
•Accounts for about 20% of the total
Nearly 50% of all light alloy casting production
production.Low Pressure Die Casting
Rotor die casting
machine
•AUTOMATIC ALUMINIUM
ROTOR DIE- CASTING
MACHINE ROTOR
MAKING MACHINE
Requirements for rotor die casting
1. Rotor lamination drawing
2. Rotor assemble drawing
3. Commutator drawing
4. Shaft drawing
5. Pressing position
6. Required productivity
7. Other technical requirement
COLD CHAMBER DIE CASTING
MACHINE
•Cold-chamber die casting is ideal
for metals such as aluminum which
have a high melting point.
•During this process, metal is
liquefied in a furnace at extremely
high temperatures and then
ladled into a cold chamber to be
injected into the die.
Working principle
(Contd.,)
• During cold-chamber die casting, the molten charge, which consists of more
material than is required to fill the casting, is ladled from the crucible into a
shot sleeve where a hydraulically operated plunger pushes the metal into the
die.
• The extra material is used to force additional metal into the die cavity to
compensate for shrinkage, which takes place during solidification.
• The main components of a cold-chamber die casting machine are shown
below. Injection pressure of over 10,000psi or 70,000KPa can be obtained
from this type of machine.
Working principle
(Contd.,)
•The die is closed and the molten
metal is ladled into the cold-
chamber shot sleeve.
Working principle
•(Contd.,)
The plunger pushes the molten metal into the die cavity where it is held under
pressure until it solidifies
Working principle
(Contd.,)
• The die opens and the plunger advances, to ensure the casting remains in the ejector
die.
Working principle
(Contd.,)
• Ejector pins push the casting out of the ejector half of the die and the plunger
returns to its original position
3000T Die Casting Machine, ZDC- 3000TCM
FEATURE
S
• Locking force: 3000 Ton Die height: 850-2000mm Tie bar
distance: 1700x1700mm Max. weight of shot: 38.9kgf Max.
casting area: 4256~3242cm² Horsepower required: 190KVA
ADVANTAGES
• High speed production can be achieved as the whole
process is completely automated.
•
Possible to obtain fairly complex castings than that
feasible by gravity die casting due to the use of the
movable cores.
• Very small thicknesses can be easily filled as the liquid
metal is injected under high pressure.
DISADVANTAG
E
• Large capital investment is required to set up a
pressure die casting process.
• The die casting machines & tooling costs
are very expensive.
• Cannot be used for large castings as the casting
machine capacity is limited.
Application of Pressure Die Casting
• Automotive parts like wheels, blocks, cylinder heads, manifolds etc.
• Aerospace castings.
• Electric motor housings.
• Kitchen ware such as pressure cooker.
• Cabinets for the electronics industry.
• General hardware appliances, pump parts, plumbing parts.
T h a n k you
