CDie casting
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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
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Transcript of CDie casting
2012-13
VISVESVARAYA NATIONAL INSTITUTE OF TECHNOLOGY NAGPUR
DEPARTMENT OF MECHANICAL ENGINEERING
SEMINAR ON
“AUTOMATION IN DIE CASTING PROCESS”
GUIDED BY:PROF. Y. M. PURICAD/CAD ENGG.
PREPARED BY: NIRAJCHANDRA P. GODECAD/CAM ENGG.FIRST SEM
DIE CASTING PROCESS
A TYPE OF CASTING PROCESS
MOLTEN METAL IS FORCED TOINCERT IN A DIE
TO CREATE PRESSURE PLUNGER ISUSED
CASTING SHAPE DEPENDS UPONTHE SHAPE OF DIES USED
FASTER THAN OTHER CASTINGPROCESSES
DIES PLUNGER SYSTEM
MOLTEN METAL
TABLE
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
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 WEIGTHHIGH
TEMPERATUREMORE TIME
SPAN
TABLE
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 WEIGTHHIGH
TEMPERATUREHIGH FORCE
TABLE
WHY AUTOMATION
IN
INSPECTION SYSTEM
TABLE
LESS
PRODUCTIVITY
2-D
VIEW
LESSFLEXIBILITY
•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
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
TYPES OF DIE CASTING
HOT CHAMBER DIE CASTING COLD CHAMBER DIE CASTING
TABLE
ZINC AND METALS HAVINGLOW MELTING POINT
ALUMINIUM AND METALS HAVINGHIGH MELTING POINT
MOLTEN METAL AND PLUNGERARE EMBEDED
MOLTEN METAL AND PLUNGERARE AT DIFFERENT POSITIONS
LADLE SYSTEM IS REQUIREDLADLE SYSTEM IS NOT REQUIRED
METALS
INSERTION
LADLESYSTEM
DIFFERENCE
HOT CHAMBER DIE CASTING MACHINE COLD CHAMBER DIE CASTING MACHINE
DIFFERENCE
TABLE
AUTOMATION OF METAL INJECTION SYSTEM
AUTOMATION OF LADLE SYSTEMIN 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
LADLESYSTEM
DIEASSEMBLY
TABLE
FRAGMENTATIONOF
DIE CASTING MACHINES
TABLE
TABLE
HOT CHAMBER DIE CASTING MACHINEMODEL-BMC R88BAOYANG MACHINARY CO.LIMITED
TABLE
COLD CHAMBER DIE CASTING MACHINEMODEL-AMC 32NADCA ORGANISATION
TABLE
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
COMPONENTS OF MACHINE
DIE CLOSING AND OPENNING SYSTEM
PURPOSE:TO OPEN AND CLOSE DIE AT THE TIME OF INJECTIONOF METALAND REMOVAL OF CASTING
HYDRAULICALY ACTUATED
PROPERTIES OF SYSTEM:HIGH STRENGTH CAST STEEL TAILSTOCKPLATEN AND WEAR RESISTANCE HIGH TENSILE STRENGTH CHROMIUM-PLATED STEEL ALLOY TIE BAR
TABLE
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
INJECTION SYSTEM
COMPONENTS OF MACHINE
PURPOSE:INJECTION OF METAL INTO DIEWITH PRESSURE
HYDRAULICALY ACTUATED
SYSTEM PROPERTIES:MINIMISED PRESSURE LOSS,HIGH TEMPERATURE RESISTANCE PROPERTYLESS REACTION TIME DIFFERENCE
TABLE
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
CONTROL SYSTEM
COMPONENTS OF MACHINE
PURPOSE:CONTROL OF ALL PROCESSES TAKINGPLACE AT WORK SPACE
COMPONENTS: CONTROLLERS SOFTWARE AND HARDWARE PACKAGES MICROCOMPUTERS SENSORS
TABLE
CLAMPING DEVICES
COMPONENTS OF MACHINE
PURPOSE:TO CLAMP VARIOUS ATTACHABLE PARTS AT VARIOUS TIME INTERVALSAS REQUIRED
HYDRAULICALY OR ELECTRICALY ACTUATED
SYSTEM PROPERTIES:ACCURATE AND PRICISEPROPER GRIPPING FORCE
TABLE
CIRCUIT DIAGRAM
INJECTION SYSTEM
DIE MOVEMENT SYSTEMLUBRICATION SYSTEM
CLAMPING SYSTEM
TABLE
HOT CHAMBER
PROCESS CYCLE
CLAMPING INJECTION COOLING
REMOVAL
POST PROCESSES
TWO HALVES OFDIE ARE CLAMPED
TOGETHER
MOLTEN METALIS INJECTED
IN DIE
CASTING IN DIESARE ALLOWED TO
COOL
REMOVAL OF CASTING THROUGH
DIE
PROCESSES SUCHAS TRIMMING,
GRINDING ARE DONE
EACHPROCESS CYCLE
TIME2 TO 3 SECONDS
TABLE
DIE CAST PARTS
REMOVEDBY PROCESSES
GRINDING
CUTTING
TRIMMING
CAST PART WITHRUNNERS AND SPRUE
TABLE
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
ADVANTAGES OF
AUTOMATION
TIME SAVING
HIGHACCURACY
BETTER HANDLING HIGH
REAPETABILITY
NO EFFECT OF
HIGH TEMPERATURE
LESSHAZARDOUS
LESS MAN POWER
FAST WORK
TABLE
PROBLEMS FACED IN THESE INDUSTRIES
LUBRICATION OF MOVING PARTS AT HIGH TEMPERATURELUBRICATION
PROBLEM
COOLING OF MOLTEN METAL DUE TO DISTANCE FACTORCOOLING OF
MOLTEN METAL
HIGH TEMPERATURESUSTAINABLE MATERIAL HIGH TEMPERATURE AFFETCS THE MACHINE MATERIAL
TABLE
RECENT DEVELOPMENTS
VACCUM ASSISTED DIE CASTING
•REDUCES GAS ENTRAPMENTDURING METAL INJECTION
•DECREASES POROSITYIN THE CASTING
•HIGHER LEVEL OF QUALITY
ADVANTAGES:
VACCUM PUMP IS ATTACHED ATOTHER END OF DIE ASSEMBLY
PROCESS:
TABLE
RECENT DEVELOPMENTS
ACTIVE COOLING CHANNELS
PROCESS:
COOLING CHANNELS ARE PROVIDED ATOTHER SIDE OF DIE ASSEMBLY
ADVANTAGES:
• REDUCES IJECTOR MARKS
• HIGH PRODUCTION RATE
• HIGH VOLUME JOBS
TABLE
RECENT DEVELOPMENTS
DIE SPRAYING
PROCESS:
DIES ARE COOLED BETWEEN SHOTSBY SPRAYING COOLING SOLUTIONS ON THEFACES OF THE DIES
ADVANTAGES:
•ACT AS LUBRICANTS FOR CASTINGSEPARATION AND EJECTION
•COOL DIES IMPROVE QUALITY OFPRODUCTION
TABLE
MANUFACTURERS OF AUTOMATIC CASTING EQUIPEMENTS
1) CAST LINEREIS - Robots and Systems
2) RIMROCK INUSTRIESMachines And Controls
3) APPLIED MANUFACTURING TECHNOLOGIESStudy And Analysis
4) ABB—SERVICESSoftware And Solutions
5) KUKA ROBOTICSRobot Supplier
6) BAOYANG MACHINARY CO.LIMITEDMachine Manufacturer
TABLE
7) NADCA ORGANISATIONMachine Setup And Manufacturer
8) KENNEDY DIE CASTINGMachine Manufacturer
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.comwww.wikipedia.com www.youtube.comwww.substech.com
FOR CONCEPTOF TOPIC
FOR AUTOMATIONCONCEPT IN TOPIC
FOR FIGURES ANDMACHINE STRUCTURE
FOR DESIGN OF MACHINE PARAMETERS
FOR VIDEOS AND OTHER STUFFS
TABLE
VIDEO ON “AUTOMATION IN DIE CASTING PROCESSES”
TABLE
T H A N K Y O U
TABLE
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
T H A N K Y O U
TABLE
