CDie casting
- 1. 2012-13 VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY NAGPUR DEPARTMENT OF MECHANICAL ENGINEERING SEMINAR ON “AUTOMATION IN DIE CASTING PROCESS” GUIDED BY: PROF. Y. M. PURI CAD/CAD ENGG. PREPARED BY: NIRAJCHANDRA P. GODE CAD/CAM ENGG. FIRST SEM
- 2. DIE CASTING PROCESS A TYPE OF CASTING PROCESS MOLTEN METAL IS FORCED TO INCERT IN A DIE TO CREATE PRESSURE PLUNGER IS USED CASTING SHAPE DEPENDS UPON THE SHAPE OF DIES USED FASTER THAN OTHER CASTING PROCESSES DIES PLUNGER SYSTEM MOLTEN METAL TABLE
- 3. MATERIAL HANDLIG SYSTEM PREPARATION OF SAND MOULDING MACHINES TYPES OF CASTINGS INSPECTION SYSTEM ENTRY EXIT PREPARATION OF MOLTEN METAL SCOPE FOR AUTOMATION IN CASTING INDUSTRY TABLE
- 4. WHY AUTOMATION MATERIAL HANDLINGIN •MORE TIME SPAN IS REQUIRED FOR-- --TRASPORTATION OF CASTING ON WORK FLOORE ITSELF --MOVING MOLTEN METAL TO MOULD CAVITIES •MANUAL HANDLING MAY RESULT IN ACCIDENTS •MANUAL OPERATIONS AT HIGH TEMPERATURE ZONE MAY BE HAZARDOUS •SOMETIMES WEIGTH OF CASTING IS VERY HIGH SO MANUAL HANDLING IS DIFFICULT. HIGH WEIGTH HIGH TEMPERATURE MORE TIME SPAN TABLE
- 5. PREPARATION OF SAND MOULDING MACHINES PREPARATION OF MOLTEN METAL•MANUAL HANDLING IS HAZARDUS •HIGH TEMPERATURES ARE THERE ON WORK FLOORE •HIGH WEIGTH MATERIALS ARE TO BE MOVED •HIGH FORCE IS REQUIERED FOR PREPARATION OF SAND WHILE MIXING HIGH WEIGTH HIGH TEMPERATURE HIGH FORCE TABLE WHY AUTOMATION IN
- 6. INSPECTION SYSTEM TABLE LESS PRODUCTIVITY 2-D VIEW LESS FLEXIBILITY •CONVENTIONAL INSPECTION PROCESS TAKES MORE TIME SPAN •IT GIVES 2-D IMAGE ONLY •CONVENTIONAL RADIOGRAPHIC INSPECTION SYSTEM IS HAZARDOUS TO HUMANS •VERY LESS FLXIBILITY IS AVAILABLE WHY AUTOMATION IN
- 7. DIE CASTING •MANUAL APPLICATION OF PRESSURE OF THE ORDER OF THOUSANDS OF BAR IS HARDLY POSSIBLE •REMOVAL OF HIGH TEMPERATURE CASTING THROUGH DIE IS QUITE DANGEROUS IN MANUAL OPERATION •WORKING SPACE IN DIE CASTING PROCESS IS HIGH TEMPERATURE ZONE HIGH PRESSURE HIGH TEMPERATURE CASTING REMOVAL PROBLEM TABLE WHY AUTOMATION IN
- 8. TYPES OF DIE CASTING HOT CHAMBER DIE CASTING COLD CHAMBER DIE CASTING TABLE ZINC AND METALS HAVING LOW MELTING POINT ALUMINIUM AND METALS HAVING HIGH MELTING POINT MOLTEN METAL AND PLUNGER ARE EMBEDED MOLTEN METAL AND PLUNGER ARE AT DIFFERENT POSITIONS LADLE SYSTEM IS REQUIREDLADLE SYSTEM IS NOT REQUIRED METALS INSERTION LADLE SYSTEM DIFFERENCE
- 9. HOT CHAMBER DIE CASTING MACHINE COLD CHAMBER DIE CASTING MACHINE DIFFERENCE TABLE
- 10. AUTOMATION OF METAL INJECTION SYSTEM AUTOMATION OF LADLE SYSTEM IN COLD CHAMBER DIE CASTING AUTOMATION OF CASTING REMOVAL SYSTEM AUTOMATION OF CLAMPING SYSTEM AUTOMATION IN DIE CASTING UNIT DEALS WITH MAINLY…….. INJECTION SYSTEM CLAMPING SYSTEM LADLE SYSTEM DIE ASSEMBLY TABLE
- 12. TABLE
- 13. HOT CHAMBER DIE CASTING MACHINE MODEL-BMC R88 BAOYANG MACHINARY CO.LIMITED TABLE
- 14. COLD CHAMBER DIE CASTING MACHINE MODEL-AMC 32 NADCA ORGANISATION TABLE
- 15. COMPONENTS OF MACHINE 2) DIE CLOSING AND OPENNING 4) INJECTION SYSTEM1) DUEL PUMPS 5) CONTROL SYSTEM 3) LUBRICATION DEVICE 6) CLAMPING DEVICES TABLE ……GENERALLY REQUIRES FOR AUTOMATION
- 16. COMPONENTS OF MACHINE DIE CLOSING AND OPENNING SYSTEM PURPOSE: TO OPEN AND CLOSE DIE AT THE TIME OF INJECTIONOF METAL AND REMOVAL OF CASTING HYDRAULICALY ACTUATED PROPERTIES OF SYSTEM: HIGH STRENGTH CAST STEEL TAILSTOCK PLATEN AND WEAR RESISTANCE HIGH TENSILE STRENGTH CHROMIUM-PLATED STEEL ALLOY TIE BAR TABLE
- 17. LUBRICATION DEVICE COMPONENTS OF MACHINE PURPOSE: LUBRICATION OF ALL MOVING COMPONENTS OF SYSTEM PROVISION OF COOLING SYSTEM PUMP CIRCULATING AND FILTERING SYSTEMS ARE ATTACHED SYSTEM PROPERTIES: PLC CONTROLLED, AUTOMATIC LUBRICANT DELIVERY AND PRESSURE DISCHARGE TYPE TABLE
- 18. INJECTION SYSTEM COMPONENTS OF MACHINE PURPOSE: INJECTION OF METAL INTO DIE WITH PRESSURE HYDRAULICALY ACTUATED SYSTEM PROPERTIES: MINIMISED PRESSURE LOSS, HIGH TEMPERATURE RESISTANCE PROPERTY LESS REACTION TIME DIFFERENCE TABLE
- 19. DUEL PUMPS COMPONENTS OF MACHINE PURPOSE: TO PROVIDE PRESSURIED FLUID AT VARIOUS PARTS TO ACTUATE MOTION ELECTRICALLY ACTUATED SYSTEM PROPERTIES: QUICK MECHANISM ACTION STABLE, STABLE AT HIGH TEMPERATURE HYDRAULIC SYSTEM TABLE
- 20. CONTROL SYSTEM COMPONENTS OF MACHINE PURPOSE: CONTROL OF ALL PROCESSES TAKING PLACE AT WORK SPACE COMPONENTS: CONTROLLERS SOFTWARE AND HARDWARE PACKAGES MICROCOMPUTERS SENSORS TABLE
- 21. CLAMPING DEVICES COMPONENTS OF MACHINE PURPOSE: TO CLAMP VARIOUS ATTACHABLE PARTS AT VARIOUS TIME INTERVALS AS REQUIRED HYDRAULICALY OR ELECTRICALY ACTUATED SYSTEM PROPERTIES: ACCURATE AND PRICISE PROPER GRIPPING FORCE TABLE
- 22. CIRCUIT DIAGRAM INJECTION SYSTEM DIE MOVEMENT SYSTEM LUBRICATION SYSTEM CLAMPING SYSTEM TABLE HOT CHAMBER
- 23. PROCESS CYCLE CLAMPING INJECTION COOLING REMOVAL POST PROCESSES TWO HALVES OF DIE ARE CLAMPED TOGETHER MOLTEN METAL IS INJECTED IN DIE CASTING IN DIES ARE ALLOWED TO COOL REMOVAL OF CASTING THROUGH DIE PROCESSES SUCH AS TRIMMING, GRINDING ARE DONE EACH PROCESS CYCLE TIME 2 TO 3 SECONDS TABLE
- 24. DIE CAST PARTS REMOVED BY PROCESSES GRINDING CUTTING TRIMMING CAST PART WITH RUNNERS AND SPRUE TABLE
- 25. Defect Causes Flash Injection pressure too high Clamp force too low Unfilled sections Insufficient shot volume Slow injection Low pouring temperature Bubbles Injection temperature too high Non-uniform cooling rate Hot tearing Non-uniform cooling rate Ejector marks Cooling time too short Ejection force too high DEFECTS AND THEIR CAUSES TABLE
- 26. ADVANTAGES OF AUTOMATION TIME SAVING HIGH ACCURACY BETTER HANDLING HIGH REAPETABILITY NO EFFECT OF HIGH TEMPERATURE LESS HAZARDOUS LESS MAN POWER FAST WORK TABLE
- 27. PROBLEMS FACED IN THESE INDUSTRIES LUBRICATION OF MOVING PARTS AT HIGH TEMPERATURE LUBRICATION PROBLEM COOLING OF MOLTEN METAL DUE TO DISTANCE FACTOR COOLING OF MOLTEN METAL HIGH TEMPERATURE SUSTAINABLE MATERIAL HIGH TEMPERATURE AFFETCS THE MACHINE MATERIAL TABLE
- 28. RECENT DEVELOPMENTS VACCUM ASSISTED DIE CASTING •REDUCES GAS ENTRAPMENT DURING METAL INJECTION •DECREASES POROSITY IN THE CASTING •HIGHER LEVEL OF QUALITY ADVANTAGES: VACCUM PUMP IS ATTACHED AT OTHER END OF DIE ASSEMBLY PROCESS: TABLE
- 29. RECENT DEVELOPMENTS ACTIVE COOLING CHANNELS PROCESS: COOLING CHANNELS ARE PROVIDED AT OTHER SIDE OF DIE ASSEMBLY ADVANTAGES: • REDUCES IJECTOR MARKS • HIGH PRODUCTION RATE • HIGH VOLUME JOBS TABLE
- 30. RECENT DEVELOPMENTS DIE SPRAYING PROCESS: DIES ARE COOLED BETWEEN SHOTS BY SPRAYING COOLING SOLUTIONS ON THE FACES OF THE DIES ADVANTAGES: •ACT AS LUBRICANTS FOR CASTING SEPARATION AND EJECTION •COOL DIES IMPROVE QUALITY OF PRODUCTION TABLE
- 31. MANUFACTURERS OF AUTOMATIC CASTING EQUIPEMENTS 1) CAST LINE REIS - Robots and Systems 2) RIMROCK INUSTRIES Machines And Controls 3) APPLIED MANUFACTURING TECHNOLOGIES Study And Analysis 4) ABB—SERVICES Software And Solutions 5) KUKA ROBOTICS Robot Supplier 6) BAOYANG MACHINARY CO.LIMITED Machine Manufacturer TABLE 7) NADCA ORGANISATION Machine Setup And Manufacturer 8) KENNEDY DIE CASTING Machine Manufacturer
- 32. REFERENCES/BIBLIOGRAPHY •BOOK TITLE “MANUFACTURING TECHNOLOGY” (VOL-2) BY P N RAO (TMH PUBLICATIONS ND) •DESIGN MANUAL ON “SYSTEM AUTOMATION” BY KUKA ROBOTICS (NY) AND ABB SERVICES (TEXAS) •COMPANY MANUAL (ON WEBSITE) BY BAYOYANG MANUFACTURING LIMITED (CHINA) •BOOK TITLE “FUNDAMENTALS OF DIE CASTING” BY GENICK BAR (Minneapolis) •WEBSITES- www.howstuffworks.com www.wikipedia.com www.youtube.com www.substech.com FOR CONCEPT OF TOPIC FOR AUTOMATION CONCEPT IN TOPIC FOR FIGURES AND MACHINE STRUCTURE FOR DESIGN OF MACHINE PARAMETERS FOR VIDEOS AND OTHER STUFFS TABLE
- 33. VIDEO ON “AUTOMATION IN DIE CASTING PROCESSES” TABLE
- 34. THANK YOU TABLE
- 35. TABLE OF CONTENTS POINTS DIE CASTING SCOPE WIDE SCOPE EXPLANATION AUTOMATION IN DIE CASTING TYPES OF DIE CASTING FULL VIEW MACHINE FRAGMENTATION IN DIE CASTING MACHINES DIFFERENCE COMPONETS OF MACHINE COMPONENTS OF MACHINE EXPLANATION CIRCUIT DIAGRAM PROCESS CYCLE DIE CASTING PARTS DEFECTS ADVANTAGES OF AUTOMATION PROBLEMS FACED IN INDUSTRY MANUFACTURERS DEVELOPMENT VIDEO REFERENCES
- 36. THANK YOU TABLE
Editor's Notes
- #24: ROUG