This document outlines a student project to design and fabricate a gravity die for casting flat plates and cylinders. It will involve designing the die parts using software, machining the die from H11 tool steel using CNC machines, and testing the die through a casting process using 6063 aluminum alloy. The project aims to produce complex shapes through die casting and provide experience with die design, machining, casting techniques and evaluating final products.

1. ME6612-DESIGN &
FABRICATION PROJECT
BATCH-5
GUIDED BY,
1. DR. M. SANTHANAKUMAR M.E., Ph.D.,
2. MR. H. RAVIKUMAR M.Tech., (Ph.D)

2. ME6612 - DESIGN AND
FABRICATION OF GRAVITY DIE
FOR FLAT PLATE & CYLINDER
1.RAGHUL GK (212216114150)
2.SABARI GIRI VASAN JK (212216114163)
3.SACHIN AK (212216114164)

3. CONTENTS
INTRODUCTION
WHAT IS DIE CASTING
?
ABSTRACT
TYPES OF CASTING
METHODS
WHY GRAVITY DIE/
PERMANENT MOULD
CASTING?
LITERATURE SURVEY/
PROBLEM
IDENYIFICATION &
SOLUTION
PROJECT PLANNING
CONTENTS

4. CONTENTS
DESIGN NOMENCLATURE
EXPLANATION
NOMENCLATURE MATERIALS USED
PROPERTIES OF
THE MATERIAL
FABRICATION
CONTENTS

5. CONTENTS
FIGURES OF
MATERIALS
FINISHED
PRODUCT
CASTING
PROCESS OF
CASTING OF
OUR PRODUCT
SAMPLE
OUTPUT
BILL OF
MATERIAL
REFERENCES
CONTENTS

6. Die casting is a
method to produce
the components
made of ferrous,
non-ferrous metals
in a larger quantity.
INTRODUCTION

7. Die casting is a metal casting process that is characterized by
forcing molten metal under high pressure into a mold cavity. The mold
cavity is created using two hardened tool steel dies which have been
machined into shape and work similarly to an injection mold during
the process. Most die castings are made from non-ferrous metals,
specifically zinc, copper, aluminum, magnesium, lead, pewter, and tin-
based alloys.
WHAT IS DIE CASTING ?

8. Basically, Die casting is a type of casting which is used to
produce complex shapes. They use vacuum, high pressure,
etc.. Methods to produce a material. Here we are going to
design a pattern with a material which withstand the
properties of the cast metal to make a perfect die. The
ultimate aim of this project is to design & fabricate die
castings of complex shapes using softwares, G-Codes, M-
Codes, & CNC machines.
ABSTRACT

9. TYPES OF
CASTING
METHODS
GRAVITY DIE
CASTING
INJECTION
MOULDING
CENTRIFUGAL
CASTING
SAND CASTING
CASTING METHODS

10. DIE CASTING
GRAVITY DIE
CASTING
VACCUM DIE
CASTING
SQUEEZE DIE
CASTING
SEMI SOLID DIE
CASTING
TYPES OF DIE CASTING

11. In gravity die casting
we can be able
produce more
product in a short
span of time with
regular intervals.
We can also
produce complex
shape products with
in a short span with
a perfect size &
clarity.
WHY GRAVITY DIE CASTING ?

12. Compared to “SAND CASTING” this die can be used again and again for many
times , whereas the sand in sand casting is destroyed after single use.
The mould is designed and created machined properly, whereas a match
plate is placed in sand and mould is created.
Where as in the gravity die casting production quantity & quality is also high.
This why the gravity die casting method is preffered than other casting
methods
LITERATURE SURVEY / PROBLEM
IDENTIFICATION & SOLUTION

13. SELECTION OF PROJECT
PROBLEM IDENTIFICATION & SOLUTION
DESIGN
MATERIAL SELECTION
DESIGN CORRECTION
BUYING MATERIAL & BUDJET PLANNING
MACHINING
CASTING
RESULT
PROJECT PLANNING

14. DESIGN OF DIE FOR CYLINDER
IIt has a mirror part image

15. DESIGN OF DIE FOR FLAT PLATE (PART 1)
IIt has a mirror part image

16. NOMENCLATURE OF DIE (CYLINDER)
SPRUE WELL
RISER
MOULD
CAVITY
FILTER FOR DENSE CASTING
METAL
SPRU
E
POURING
CUP
RUNNE
R

17. NOMENCLATURE OF DIE (FLAT PLATE)
POURING BASIN
RISER
MOULD
CAVITY
SPRU
E

18. MOULD CAVITY:
It is place where molten metal is filled. In other words it is the desired pattern or shape which is to be
taken out after casting.
POURING BASIN:
It is the place where the molten metal start its flow. In other words in the funnel.
SPRUE:
It is the tapered section where it is used to equal flow of molten metal into the cavity.
SPRUE WELL:
It is used to avoid faster solidification purposes
NOMENCLATURE EXPLANATION

19. FILTER FOR DENSE MOLTEN METAL:
The title itself says the purpose of this filter.
RUNNER:
It is the part like the sprue which final part of the gate & attached directly with the mould cavity.
GATE:
Here, we used INGATE system for both cylinder & flat plate.
RISER:
We used side riser with shape of cylinder because it is more efficient & easy to manufacture than
the spherical riser & blind riser.
NOMENCLATURE EXPLANATION

20. S.
NO
MATERIALS USED QUANTITY PURPOSE
1. H11 HOTWORKING
TOOL STEEL
46Kg MAKING DIE
2. ALUMINIUM 6063
ALLOY
5Kg CAST METAL
3. DOVEL PIN 4(PIECES) ASSEMBLING OF DIE
4. ALLIGN KEY 1(M10 SIZE) ASSEMBLING OF DIE
5. ALLIGN SCREW 4(M10 SIZE) ASSEMBLING OF DIE
MATERIALS USED

21. AISI H11 HOTWORKING TOOL
STEEL

22. CHEMICAL PROPERTIES H11 TOOL STEEL:
PROPERTIES OF MATERIALS USED
Element Content (%)
Carbon, C 0.33-0.43
Manganese, Mn 0.20-0.50
Silicon, Si 0.80-1.20
Chromium, Cr 4.75-5.50
Nickel, Ni 0.3
Molybdenum, Mo 1.10-1.60
Vanadium, V 0.30-0.60
Copper, Cu 0.25
Phosphorous, P 0.03
Sulfur, S 0.03
Iron, Fe Balance

23. PHYSICAL PROPERTIES:
PROPERTIES OF THE MATERIALS USED
Properties Metric Imperial
Density 7.81 g/cm3 0.282 lb/in3
Melting point 1427°C 2600°F

24. MECHANICAL PROPERTIES:
PROPERTIES OF THE MATERIALS USED
Properties Metric Imperial
Hardness, Rockwell C (air cooled from
982°C, 45 mins)
52.5 52.5
Hardness, Rockwell C (air cooled from
1010°C, 45 mins)
56 56
Hardness, Rockwell C (air cooled from
1038°C, 45 mins)
57 57
Modulus of elasticity 207 GPa 30000 ksi
Modulus of elasticity (@538°C/1000°F) 159 GPa 23000 ksi
Modulus of elasticity (@204°C/400°F) 190 GPa 27500 ksi
Charpy impact (V-notch; air cooled from
1010°C;535°C temper temperature)
13.6 J 10.0 ft-lb
Charpy impact (V-notch; air cooled from
1010°C;650°C temper temperature)
27.1 J 20.0 ft-lb
Charpy impact (V-notch; air cooled from
1010°C;370°C temper temperature)
33.9 J 25.0 ft-lb
Machinability (1% carbon steel) 75.0 - 80.0% 75.0 - 80.0%
Poisson's ratio 0.27-0.30 0.27-0.30

25. THERMAL PROPERTIES:
PROPERTIES OF THE MATERIAL USED
Properties
Metric
Imperial
Thermal expansion (@20-
100ºC/68-212ºF)
11.9 x 10-6/ºC 6.63 µin/in°F
Thermal conductivity
(@100ºC/212ºF)
42.2 W/mK 292.9 in/hr.ft².°F

26. ALUMINIUM ALLOY 6063

27. CHEMICAL COMPOSITION:
PROPERTIES OF THE MATERIAL USED
Element 6063 % Present 6063A % Present
Si 0.2 to 0.6 0.3 to 0.6
Fe 0.0 to 0.35 0.15 to 0.35
Cu 0.0 to 0.1 0.1
Mn 0.0 to 0.1 0.15
Mg 0.45 to 0.9 0.6 to 0.9
Zn 0.0 to 0.1 0.0 to 0.15
Ti 0.0 to 0.1 0.1
Cr 0.1 max 0.05
Al Balance Balance

28. PROPERTIES OF THE MATERIAL USED
MECHANICAL PROPERTIES:
Property 6063-T5 6063-T6 6063-T832
Yield Strength
145 MPa | 21000
psi
214 MPa | 31000
psi
269 MPa | 39000
psi
Tensile Strength
186 MPa | 27000
psi
241 MPa | 35000
psi
290 MPa | 42000
psi
Modulus of
Elasticity
68.9 GPa | 10000
ksi
68.9 GPa | 10000
ksi
69.0 GPa | 10000
ksi

29. PHYSICAL PROPERTIES:
PROPERTIES OF THE MATERIAL USED
Property Value
Density 2700 kg/m3
Melting Point 615°C

30. THERMAL PROPERTIES:
PROPERTIES OF THE MATERIAL USED
Property 6063-T5 6063-T6 6063-T832
Coefficient of Thermal
Expansion @ 20.0 -
100 °C Temp
21.8 μm/m-°C | 12.1
μin/in-°F
21.8 μm/m-°C | 12.1
μin/in-°F
21.8 μm/m-°C | 12.1
μin/in-°F
Thermal Conductivity
209 W/m-K | 1450
BTU-in/hr-ft²-°F
200 W/m-K | 1390
BTU-in/hr-ft²-°F
200 W/m-K | 1390
BTU-in/hr-ft²-°F

31. The fabrication of the die is done by these following machines
1. LATHE
2.MILLING MACHINE
3.GRINDING MACHINE
4.CNC
It is done by the following process also they are listed below
1.MILLING
2.GROOVING
3.GRINDING
4.CHAMFERING
5.POLISHING
FABRICATION

32. BEFORE MACHINING
SIZE: 40(T)*204(L)*204(B)- 2QTY
SIZE: 40(T)*205(L)*110(B)- 2QTY
AFTER MACHING
SIZE: 40(T)*200(L)*200(B)- 2QTY
SIZE: 40(T)*200(L)*100(B)- 2QTY
FIGURES OF THE MATERIALS

33. DOVEL PIN
SIZE : 8(D)*16(L) IN mm
ALLIGN SCREW
SIZE : M10 (TVS)
FIGURES OF THE MATERIAL

34. FINISHED PRODUCT CYLINDER (DIE)

35. FINISHED PRODUCT FLAT PLATE (DIE)

36. ASSEMBLED DIE (CYLINDER, FLATE PLATE)

37. It is the final step of
preparation of the
product where the cast
metal is melted in the
furnace at the melting
temperature of the cast
metal
CASTING

38. CLEAN & TURN ON THE FURNACE
DROP THE CAST METAL IN HEATING AREA
WAIT TILL THE METALS GETS MELTED
TAKE THE MOLTEN METAL
POUR THEM INTO THE DIE
SOLIDIFICATION
DESIRED PRODUCT
PROCESS OF CASTING

39. VIDEO DEMONSTRATION OF CASTING

40. SAMPLE OUTPUT PRODUCT

41. SAMPLE OUTPUT PRODUCT

42. S.
N
O
MATERIALS
USED
QUANTITY/HRS WORKED PURPOSE COST
(Rs)
1. H11
HOTWORKING
TOOL STEEL
46Kg
(200*200*40) (2PCS)
(200*100*40) (2PCS)
MAKING DIE 10,373
2. ALUMINIUM 6063
ALLOY
5Kg CAST METAL 750
3. DOVEL PIN 4(PIECES) ASSEMBLING OF DIE 20
4. ALLIGN KEY 1(M10 SIZE) ASSEMBLING OF DIE 40
5. ALLIGN SCREW 4(M10 SIZE) ASSEMBLING OF DIE 40
6. CNC MACHING 20HRS MACHINING 8,000
7. TRANSPORT PETROL 1200
8. TOTAL 20,423
BILL OF MATERIAL

43. 1. youtube.com
2. workshop technology by harsha chowdry
3.wikipedia
REFERENCES