THIS SLIP CONTAIN ABOUT INDUSTRIAL TRAINING SLIP

1. INTERNSHIP PROJECT EXPERIENCE
AT
VIHAN MOTORS MUZAFFARNAGAR
PRESENTED BY : MUKUL TYAGI

2. COLLEGE OF ENGINEERING ROORKEE
NAME: MUKUL TYAGI
B.TECH IN MECHANICAL ENGINEERING
UNIVERSITY ROLL NO: 1700601040
YEAR: 4th YEAR

3. SUBMITTED TO:
Mr. Mohit Kumar Sengar Sir
Assistant Professor
College of Engineering Roorkee

4. TOPIC – PROCESS FLOW FOR BODY OUTER.
PROCESS OF ZINC CASTING
 Raw Material :- ZAMAK3
 Metal is heated in furnace in the range of 420°C-440°C.
 Poured through ladle in shot sleeve.
 Material injected in die.
 Shape take as made in a die.
 Material cooled.
 Parts ejected.
 Degating.
 Secondary operation like Buffing, Turning, Tapping.
 Dispatched to paint shop.

5. DIE CASTING
 Die casting is a moulding process in which the molten metal is
injected under high pressure and velocity into a split mould die. It is
also called pressure die casting.
 The split mould used under this type of casting is reusable. Die
casting is categorized two types namely- hot chamber and cold
chamber.
 Metals like Zinc, tin and lead alloys are casted in hot chamber die
casting having melting point below 3900C whereas aluminum alloys
are casted in cold chamber die casting machine.
 Aluminum dissolves ferrous parts in the die chamber and hence
preferred to be used in cold chamber die casting.
 Continuous contact of molten metal is avoided by using a ladle for
introducing molten metal directly to the machine.

7. RAW MATERIAL :- ZAMAK-3
Zamak3
is an
alloy of
zinc.

8. Composition of ZAMAK-3
Aluminium = 3.5 to 4.3%
Copper = 0.25 %
Magnesium = 0.02-0.05 %
Iron = 0.1 %
Tin = 0.003 %
Zinc= Balanced
Lead= 0.005%
Cadmium=0.004%

9. MECHANICAL PROPERTIES OF ZAMAK-3
Excellent finishing characteristics for
plating, painting, and chromate
treatments.
It has more ductility (increased
elongation) than ZAMAK-5.
Tensile strength of ZAMAK-3=283MPa.
Yield strength of ZAMAK-3=221MPa.

10. PHYSICAL PROPERTIES OF ZAMAK-3
Density:- 6.6gm/cm³
Melting point:- 384°C

11. MACHINE USED:- PRODUCER 130 TONS
Hot chamber machines are used for alloys with low
melting temperatures, such as zinc, tin, and lead.
 The temperatures required to melt other alloys would
damage the pump, which is in direct contact with the
molten metal.
The metal is contained in an open holding pot which is
placed into a furnace, where it is melted to the
necessary temperature.

12. Typical injection pressures for a hot chamber
die casting machine are between 1000 and
5000 psi.
In this machine, the furnace is with the hot
chamber in which the metal is converted into
molten metal.

13. Features:
Locking force: 130 tons
Die height: 90-495 mm
Tie bar diameter: 80×6 mm
Maximum weight of shot: 1.61 kgf
Maximum casting area: 533 cm²
Horsepower required: 18 KVA

14. MACHINE SPECIFICATIONS
Models P130
Clamping force(At 90kg/cm²) ton 130
Tie bar Diameter mm 80×6
Die platen size(H×V) mm 680×634
Between tie bar(H×V) mm 400×400
Maximum die stroke mm 293
Die height mm 90~495
Nozzle Touch force ton 5.4
Nozzle break stroke mm 180
Dia. Injection cylinder mm Ø100
Maximum injection force (at 70kg/cm²) ton 6.6
Maximum injection stroke mm 190
Standard plunger tip dia. mm 60
Total net injection amount(Zn) gr 2700
Melting pot capacity(zn) kg 500
Nozzle position(Center lower part) mm 0,-80
Maximum casting area cm² 533
Casting Pressure kg/cm² 195
Intensifier pressure kg/cm² 100
Ejection force ton 6
Ejection Stroke mm 90
Casting Cycle nh 800
working pressure kg/cm² 120
Accumalator(bladder type) L/pcs 20×1
Oil tank capacity L 350
Machine weight ton 8.7
Over all dimensions m 4.8×2.1×2.3
Injection system 2 stage injection
2.3
ection

17. HOT CHAMBER DIE CASTING PROCESS
Hot chamber die casting can be used with zinc,
magnesium, and other low melting alloys using either
our proprietary multi-slide or conventional tooling.
The hot chamber machine contains the melting pot,
while the cold chamber melt pot is separate and the
molten metal has to be ladled into the shot sleeve.
With the internal mechanism, it makes the hot
chamber the faster of the two processes.

18. THE BASIC COMPONENTS OF THE HOT
CHAMBER DIE CASTING MACHINE
The injection mechanism of a hot chamber
machine is immersed in the molten metal. The
furnace is attached to the machine by a metal
feed system called a gooseneck.

20.  The die is closed and the piston rises, opening the port, allowing
molten metal to fill the cylinder.

21. Next, the plunger seals the port, pushing the molten
metal through the gooseneck and nozzle into the die
cavity where it is held under pressure until it
solidifies.

22.  The die opens and the cores, if any, retract. The casting
remains in only one die half – the ejector side. The plunger
then returns, allowing residual molten metal to flow back
through the nozzle and gooseneck.

23. Ejector pins push the casting out of the ejector die.
As the plunger uncovers the filling hole, molten metal
flows through the inlet to refill the gooseneck.

24. After the completion of body outer tool casting
process, it is degated and the extra waste
material is removed from the body outer tool.
Then some secondary operation are performed
over body outer tool like buffing, making its
surface smooth and good surface finish, turning,
tapping, etc.
Then after the making of whole outer body tool,
it is dispatched to paint shop, where it is painted
and after the painting it can’t be scratched and
it's surface can’t get rough on scratching.

25. BODY OUTER TOOL

26. HOT CHAMBER COMPONENTS
A Frame
Suspends shot components above and in the
furnace; mounted to stationary platen.
Shot cylinder
Actuates vertically; metal is injected with downward
stroke on the cylinder.
Coupling
Connects shot cylinder to plunger rod and tip.

27. Plunger rod and tip
Pumps the metal; piston tip has 2 or 3
grooves in it for piston rings.

28. DIE CHANNELS
 The flow of molten metal into the
part cavity requires several
channels that are integrated into
the die and differs slightly for a
cold chamber.
 In a cold chamber machine, the
molten metal enters through
injection sleeve. After entering the
die, in either type of machine, the
molten metal flows through a
series of runners and enters the
part cavities through gates, which
direct the flow.

29.  Often, the cavities
will contain extra
space called
overflow wells,
which provide an
additional source of
molten metal during
solidification.
 When the casting
cools the molten
metal will shrink
and the additional
material is needed.

30.  Lastly, small channels are
included that run from
the cavity to the exterior
of the die. These
channels act as venting
holes to allow air escape
from the die cavity.
 The molten metal that
flows through all of these
channels will solidify
attached to the casting
and must be separated
from the part after it is
ejected.

31. One type of channel that doesn’t fill with material is a
cooling channel. these channels allow water or oil to
flow through the die, adjacent to the cavity and
remove heat from the die.

32. Defects that may arise in DIE casting:-
Flash
Unified sections
Bubbles
Hot tearing
Ejector marks
 Injection pressure too high.
 Clamp force too low.
 Insufficient shot volume.
 Slow injection.
 Low pouring temperature.
 Injection pressure too high.
 Non uniform cooling rate.
 Non uniform cooling rate.
 Cooling time too short.
 Ejection force too high.

33. SPECIFIC DIE DESIGN
Wall thickness:
 Sharp changes in sectional area and heavy sections
over 6 mm thickness should be avoided if possible.
Uniform wall thickness need to be maintained so as
to achieve a minimum porous die casted product.
 The injected liquid metal cools rapidly on contact
with the die casting surface resulting in a fine grained
dense structure (the surface is termed as skin)
generally devoid of porosity and is considered to be
the strongest region of the die casted product.

34. Depending upon the casting size, the recommended skin measures
between 0.38 and 0.63 as mentioned in the Table

35. Draft:
 The side wall of the die casting and other features
perpendicular to the parting line must be tapered or
drafted as much as possible to easy removal from the
die.
 Draft angles depend upon the type of alloy is used.
For the case of outside wall, the recommended draft
angel should be the half of the draft angle used in
the inside wall.

36. THANKYOU