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Introduction:
Prize for one who has made the most number of mistakes in the design of die cast components! Japanese methodology OET Compilation of design rules how to design die cast components without tears PDC Part design: ~ 80% Science & some 20% art!
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
10 Commandments?
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
100%
100%
0%
Fig.1
- Proto -Proto
Dr. N. Ramanj
-Proto
0% Time
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100%
QUALITY PARADOX
For a PDC Die
Knowledge / Expertise of our own casting ! Cost of Change !
100%
0%
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MANUFACTURING (MIDSTREAM)
SEA Fig.3
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Fig 4.One-piece chassis for a high-speed electronic printer replaced 82 separate components and fasteners in the forerunner assembly. Drilling and tapping have been eliminated by incorporating cored holes, which receive thread-forming screws for fastening. 11
School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
5. Rib the part to add strength and stiffness & Reduce weight: Ribs to reinforce part structurally Minimum increase in weight Replacing heavy sections that would be otherwise necessary. Fig.5
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Think Ribs:
Ribs fairly easy to incorporate into an existing hardened die! When?
Fig.5School of Postgraduate Studies, NTTF, Bangalore
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Dr. N. Ramanj Design for Pressure Die Casting
FIGURE 6.Castings for two-wheeler engines show how good design can provide ribs where needed for strength and cored holes for fastening while maintaining fairly constant wall thickness.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
FIGURE 7. Aluminum components for a weighing scale demonstrate intelligent use of ribbing to promote strength and stiffness.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
incorporating internal ribs that run the full depth of the part. Corners reinforced by radiusing to avoid corner fractures in the casting 16
School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Fig.9 Where there would normally be a heavy section adjacent to a cored area, introduce further coring to create ribs, thereby removing mass & obtaining uniform wall thickness
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
3 >> 4 >> 6
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Acute-angle intersections cause the die to overheat in the area between the ribs. Multiple intersections of radial ribs should be avoided; otherwise, the intersection will contain porosity.
Fig.10
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Dr. N. Ramanj Design for Pressure Die Casting School of Postgraduate Studies, NTTF, Bangalore
Much improved rib design(Only 3 ribs intersect at each point) 3 >> 4 >> 6
Fig.13
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Dr. N. Ramanj Design for Pressure Die Casting School of Postgraduate Studies, NTTF, Bangalore
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Dr. N. Ramanj
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Sharp corners cause uneven cooling, while rounded corners permit uniform cooling with much less stress; Rounded corners that maintain uniform wall thickness provide the best results
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Dr. N. Ramanj Design for Pressure Die Casting
Fig.15
Fig.16
Sharp edges on cores are difficult to maintain because they are points of heat concentration, with resulting premature erosion of the die 28 material.
Dr. N. Ramanj Design for Pressure Die Casting
Fig.17
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Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Typical W.T? *Fine-grained dense structure, devoid of porosity, thus making the skin the strongest part 32 of wall thickness (?)
Dr. N. Ramanj Design for Pressure Die Casting
Max Strength/Weight is achieved with 0.8 - 1.3 W.T Strength Weight Ratio
Fig.19
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Dr. N. Ramanj Design for Pressure Die Casting
Fig.20
Intersection of two walls should be at right 34 angles to avoid sharp corner hot spots
Dr. N. Ramanj
the boss and connect it to the wall with a short rib. The ribs should be no wider than the 35 thickness of the casting wall
School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj
Fig.22 When the draft angle is abnormally small, even the slightest depression in the drafted surface of the die will prevent ejection causing drag marks in the surface of the casting 36
School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
If possible, the part should be designed so that it can be made in a simple two-piece die.
Fig.25 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
14.Think of shopman :
Through-wall cored holes for tapping should be countersunk on both sides to avoid deburring; Holes for tapping should be cored rather than drilled. A drilling operation is eliminated, and the tap will cut into dense material for a higher-quality thread. 40
Dr. N. Ramanj Design for Pressure Die Casting
SC Should never be designed to intersect the opposite die half, since imperfect die closure (possibly the result of flash at the parting plane not being fully removed) would result in a damaged die.
Fig.27 of Postgraduate Studies, NTTF, Bangalore School
Dr. N. Ramanj
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Dr. N. Ramanj Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
16.Know Limitations of Cast Threads: It is possible to die-cast internal threads in zinc parts only by using techniques that involve either unscrewing the casting from a threaded core or rotating the core out of the casting during ejection.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Design of bush type inserts:(To resist both axial and rotational forces).
Insert with knurled circumference (Positive location within the die must be provided to prevent insert movement during the casting cycle)
Fig.29 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
Insert Machined & U/C square (insert's threads must be kept away from the casting face)
Fig.31 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
Deeper cuts could open up unsightly subsurface porosity and possibly affect function.
Fig.35 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
19. Specify explicitly location of ejector pins: If an area to be machined covers ejector-pin locations, their impressions should be 0 to 0.4 mm depressed-so that they are removed in machining.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Avoid an angled junction of an external wall with the parting line.It is preferable to add a minimumdraft shoulder at the parting line, so that most of the gate material will come away in trimming.
Fig.36 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
Trimming tool to match intricate geometry would be expensive and hard to maintain. Advisable to add a shoulder between wall detail and parting line to allow for use of a single trimming die or a lathe-turning operation to remove gates and flash. 55
Dr. N. Ramanj Design for Pressure Die Casting
If the casting is designed with convex features in outside walls,it is a straightforward job to mill the corresponding concavities into the steel.
Fig.38 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
On Lettering If the designer wants the economy of raised characters but does not wish them to project above the surrounding surface, a raised pad can be incorporated into the die to form a depressed area in the casting. Then when the pad is engraved, the lettering will come out flush.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
How will you design a spherical shaped handle for a door? Zinc only!
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Dr. N. Ramanj Design for Pressure Die Casting
Zinc only!
Fig.39 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
25.Know limitations of dimensions & Tolerances The as cast dimensional variations of a die casting depend on part size. This dependency is largely due to thermal expansion and contraction of both the die and the casting. The die expands at operating temperatures, and the casting shrinks after it leaves the die. Variations in die operating temperatures and the temperature of the molten metal entering the die add to the need for a design tolerance on diecasting dimensions.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
25.Know limitations of dimensions & Tolerances Tolerances across the parting line and between core slides and main die blocks must be greater because of the clearances that are incorporated into these features in the die to enable them to function at elevated temperatures. Recommended tolerances also allow for gradual wear in die components over the life of tooling. This is a significant factor. Another is warpage.
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Outside view of Motor Body Housing Casting ~ 180 dia; ~100mm deep; 800gm
Fig. 40
Nominal Wall thickness ~ 2 mm CI Insert for bearing Problem: Non-filling of window portions 68
Dr. N. Ramanj Design for Pressure Die Casting
What to do?
Fig. 42 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
Fig. 43
Fig. 44
Fig. 45
Runner
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Subrunner
Runner
Fig. 46
School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj
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Design for Pressure Die Casting
NTTF
How did they solve the problem of Part sticking to the cavity? (You guessed it right)
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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Motor Housing Non-drive End Cracks below opening Location of runners near heavy sections
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Design for Pressure Die Casting
gm
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Fig. 53
Fan Casting
Fig. 54
Fan Casting
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Design for Pressure Die Casting
Family die for Flange & Bearing Cover 50dia 5mm thick; 8gm
20mm thick; 30 gm
Dr. N. Ramanj
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Family die for Flange & Bearing Cover Problem: Only one set of good parts obtained out of each shot Severe Blow-holes Analysis: Severe unbalanced Mass-flow; C.f. : 46gm Vs 68gm
Fig. 56 of Postgraduate Studies, NTTF, Bangalore School
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Dr. N. Ramanj Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
Solution: Progressively reducing runner width Increase radii for improved flow;
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School Fig.58 of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
NTTF
Lesson learnt: For optimum results, the degree of imbalance between the two sides of a family die should not exceed + / - 10%
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
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Subrunner added
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Dr. N. Ramanj Design for Pressure Die Casting
Ribs?
Not Filling
Not Filling
Dr. N. Ramanj
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Design for Pressure Die Casting
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Dr. N. Ramanj Design for Pressure Die Casting
Non- Filling
Wafer-thin wall
Fig. 66 of Postgraduate Studies, NTTF, Bangalore School
Dr. N. Ramanj
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Conclusion:
20 % 80 % 80 % 20 %
Cause Fig. 67
School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj
NTTF
Have always the simple mind of a student, because on the simplest of foundations are built the most wonderful works of nature. Dr.W.A.J.Chapman
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
NTTF
References: 1.Die casting book by Dr.Arthur Street 2.Metals Hand book Volumes 5A,5B,15 SME 3.Principles of Metal Casting By Richard W.Heine 4.Design for Manufacturability By James Bralla
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting
Thank You
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School of Postgraduate Studies, NTTF, Bangalore Dr. N. Ramanj Design for Pressure Die Casting