PRESSURE DIE CASTING (ALUMINIUM)
[EIRI/EDPR/4420] J.C.: 2622XL
INTRODUCTION
The pressure die casting processes consume almost twice as many tons of aluminium alloys as all other casting processes combined. These processes are especially suited to the production of large quantities of relatively small parts. Aluminium die cast parts may weigh up to around 5 kilograms.
Pressure die casting in aluminum alloy offers means for very rapid production of engineering and other related component even or intricate design. The technique has obvious advantages when a component is required in large quantities. However, for aeronautic space, defence and automotive applications, mechanical properties and durability are of primary importance It is, therefore, essential that the best features of design should be employed and optimum casting technique with minimum cost be adopted. Pressure die cast products are used in the form of components of various electrical electronic, mechanical instruments and appliances used in domestic as well as industrial field.
Types of Aluminum Alloys for Die Casting Applications
In this eBook, we shall focus on 7 different types of aluminum alloys that are die cast in most industrial setup.
These alloys include the following:
The K-alloy; this aluminum allow is known to possess the following key properties: resistance to corrosion improved cooling and zero post die casting operations.
Alloy 413; superior die casting properties and it possess good fluidity and guarantee better pressure tightness.
Alloy 383; it possesses the following key properties: dimension stability, ease of casting and good mechanical properties. It has superior corrosion resistance too.
Alloy B390; it is known for its superior wear resistance and high hardness. They are mainly used to die cast the internal combustion engine pistons.
The A360; it is mainly used to cast aluminum parts where pressure tightness and fluidity is a priority. It maintains corrosion resistance and strength even at elevated temperature.
Alloy A413; its properties are similar to that of the alloy A360. This alloy is mainly used to die cast hydraulic cylinder components.
Alloy A380; it has good thermal and mechanical properties. Their performance property is similar to most alloys listed above.
COST ESTIMATION
Plant Capacity 3 MT/Day
Land & Building (5360 sq.mt.) Rs. 4.86 Cr
Plant & Machinery Rs. 9.97 Cr
Working Capital for 1 Month Rs. 2.31 Cr
Total Capital Investment Rs. 17.98 Cr
Rate of Return 27%
Break Even Point 58%
CONTENTS
INTRODUCTION
TYPES OF ALUMINUM ALLOYS FOR DIE CASTING APPLICATIONS
THESE ALLOYS INCLUDE THE FOLLOWING:
PRESSURE DIE CASTING
ADVANTAGES OF PRESSURE DIE CASTING:
TYPES OF PRESSURE DIE CASTING
HIGH PRESSURE DIE CASTING
TYPES OF HIGH PRESSURE DIE CASTING:
HOT CHAMBER PROCESS
COLD CHAMBER PROCESS
ADVANTAGES
LOW PRESSURE DIE CASTING
ADVANTAGES
USES/APPLICATIONS
BIS SPECIFICATION
PRESSURE DIE CASTING PROCESS
HIGH-PRESSURE DIE-CASTING (HPDC)
PROCESS CYCLE
A. CLAMPING
B. INJECTION
C. COOLING
D. EJECTION
E. TRIMMING
(I) HOT CHAMBER TYPE
(II) COLD CHAMBER TYPE
HOT CHAMBER DIE-CASTING
COLD CHAMBER DIE CASTING
ADVANTAGES
DISADVANTAGES
APPLICATIONS
THE MAIN ADVANTAGES OF LOW-PRESSURE DIE-CASTING ARE GIVEN AS:
THERE ARE SEVERAL STEPS DURING THE PRODUCTION OF ALUMINUM CASTING ALLOY WHEEL.
THERE ARE SEVERAL STEPS DURING THE PRODUCTION OF ALUMINUM CASTING ALLOY WHEEL WHICH IS GIVEN BELOW:
MELTING PROCESS
MELTING DOWN OF VIRGIN INGOT
MELT PREPARATION
THE PRIMARY PURPOSE OF MELT TREATMENT IS
(A) DEGASSING
DEGASSING PROCESS
MEASURING HYDROGEN CONCENTRATION
REDUCED PRESSURE TEST (STRAUBE-PFEIFFER)
QUANTITATIVE REDUCED PRESSURE TEST (SEVERN SCIENCE)
DENSITY MEASUREMENTS
INITIAL BUBBLE TEST (HYCON TEST)
RECIRCULATING GAS TEST (TELGAS, ALSCAN)
(B) FLUXING
X-RAY INSPECTION (REAL TIME RADIOSCOPIC INSPECTION)
QUALITY CONTROL
FINISHING PROCESS
PAINTING
TESTING
PROCESS FLOW
PRESSURE DIE CASTING MACHINE AND EQUIPMENTS
DIE CASTING MACHINES
ALL THESE AIM AT IMPROVING:
THE PRESSURE DIE CASTING MACHINES
THERE ARE TWO MAIN TYPES OF PRESSURE DIE CASTING MACHINES AND THEY INCLUDE:
THE HOT CHAMBER PRESSURE DIE CASTING MACHINES;
THE COLD CHAMBER DIES CASTING MACHINES;
DIE CASTING MOLD
SUPPLIERS OF ALUMINIUM PRESSURE DI-CASTING
SUPPLIERS OF RAW MATERIALS
ALUMINIUM ALLOY INGOT
SUPPLIERS OF PICKLING ACIDS
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS PRESSURE DIE CASTING MACHINE
SUPPLIERS OF ALUMINIUM MELTING FURNACE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF PAINTING EQUIPMENTS
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
MARKET OVERVIEW
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
UTILITIES PER MONTH (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY LAYOUT
CONCLUSIONS
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)
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