Detailed Project Report (DPR) on Pressure Die Casting

PRESSURE DIE CASTING

[EIRI/EDPR/1588] J.C. 386US$

INTRODUCTION

Die casting is a popular manufacturing process for casting metal products. There are two main die casting process types and several variations in process design.  When molten metal is forced into mold cavities at high pressure, it is known as die casting. The process is best suited for speedy production of bulk metallic parts that require minimal post-production machining.

Types of Die Casting Processes

All die casting process types are designed with the same goal in mind—cast a mold using injected molten metal. Depending on the type of melted metal, part geometry and part size, different die casting processes can deliver superior results over alternative methods. The two main types of die casting processes are hot-chamber and cold-chamber die casting. Variations on these two types of die casting include:

• Low-pressure die casting 

• Vacuum die casting 

• Squeeze die casting

• Semi-solid die casting 

The Hot-Chamber Die Casting Process 

Hot-chamber die casting, sometimes called gooseneck casting, is the more popular of the two die casting processes. In this process, the cylinder chamber of the injection mechanism is completely immersed in the molten metal bath. A gooseneck metal feed system draws the molten metal into the die cavity.

While direct immersion in the molten bath allows for quick and convenient mold injection, it also results in increased corrosion susceptibility. Due to this fact, the hot-chamber die casting process is best suited for applications that utilize metals with low melting points and high fluidity. Good metals for the hot-chamber die casting process include lead, magnesium, zinc and copper. 

The Cold-Chamber Die Casting Process 

The cold-chamber die casting process is very similar to hot-chamber die casting. With a design that focuses on minimizing machine corrosion rather than production efficiency, the melted metal is automatically- or hand-ladled into the injection system. This eliminates the necessity for the injection mechanism to be immersed in the molten metal bath.

For applications that are too corrosive for the immersion design of hot-chamber die casting, the cold-chamber process can be an excellent alternative. These applications include the casting of metals with high melting temperatures, such as aluminum and aluminum alloys. 

The Low-Pressure Die Casting Process

Low-pressure die casting is a process best suited for aluminum components that are symmetric around an axis of rotation. Vehicle wheels, for example, are often fabricated through low-pressure die casting. In this type of process, the mold is situated vertically above the molten metal bath and connected via a riser tube. When the chamber is pressurized (usually between 20 and 100kPa), the metal is pulled upward and into the mold. The elimination of feeders from this type of die casting process delivers the high casting yields. 

The Vacuum Die Casting Process

Vacuum pressure casting (VPC) is a relatively new die casting process that delivers enhanced strength and minimal porosity. This process is similar to low-pressure die casting, except the locations of the die cast mold and molten metal bath are reversed. The cylinder chamber can become a vacuum, which forces the molten metal into the mold cavity. This design reduces turbulence and limits the amount of gas inclusions. Vacuum die casting is especially beneficial in applications destined for post-casting heat treatment. 

The Squeeze Die Casting Process

Squeeze casting was created as a workable solution for casting metals and alloys with low fluidity. In this process, the molten metal fills up an open die, which then squeezes closed, forcing the metal into the recessed portions of the molding. The squeeze casting process delivers extremely dense products and is a complementary process to subsequent heat-treating. The process is most often associated with molten aluminum, and is used in applications that call for fiber reinforcement. 

COST ESTIMATION

Plant Capacity            2 MT/Day

Land & Building (4000 sq.mt.)    US$ 6.06 Lac

Plant & Machinery                    US$ 1.83 Lac

Working Capital for 2 Months    US$ 3.29 Lac

Total Capital Investment          US$ 11.63 Lac

Rate of Return                          26%

Break Even Point                      60%

CONTENTS

INTRODUCTION

USES AND APPLICATION

PROPERTIES

B.I.S SPECIFICATION

MARKET SURVEY

EMPLOYMENT OPPORTUNITIES FOR CITIZENS IN THE ALUMINUM INDUSTRY

OVERVIEW OF ALUMINIUM IN MIDDLE EAST

PRODUCTION OF PRESSURE DIE CASTING IN MIDDLE EAST

IMPORT AND EXPORT OF PRESSURE DIE CASTING IN MIDDLE EAST

DEMAND AND SUPPLY POSITION OF ALUMINIUM DIE CASTING (PRESSURE DIE CASTING) IN MIDDLE EAST

EXPORT & IMPORT OF ALUMINIUM AND ALLOY INCLUDING SCRAP FROM UAE

CHINA S DIE CASTING INDUSTRY TO UPGRADE GROWTH REVIEW

COMBINATION OF MOLD AND DIE CASTING MACHINE FOR CASTING ENTERPRISES IN CHINA TO OPEN NEW IDEAS

ALUMINIUM PRODUCING COUNTRIES

TREND OF ALUMINIUM INDUSTRY IN MIDDLE EAST

THE CASTING MARKET IN ITALY

SHIPMENT DETAILS

LIST OF BUYERS

LIST OF AIRCRAFT AND ENGINE MRO COMPANIES IN THE UAE

MANUFACTURING PROCESS

QUALITY CONTROL

PROCESS FLOW CHART

PLANT LAYOUT

SUPPLIER PLANT AND MACHINERIES

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINUM PRESSURE DIE CASTING COMPONENTS

SUPPLIERS OF ALUMINIUM INGOT

SUPPLIERS OF PICKLING ACIDS

SUPPLIERS OF DIE-CASTING MACHINES

SUPPLIERS OF DRILLING AND LATHE MACHINE

SUPPLIERS OF MACINE SHOP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)