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Introduction to casting industry
- 1. Presented by Advait D. Athavale Process Engineer Quality Engineer & Program Manager (at Ryobi Die casting) (at Magna International) 1
- 2. Where are “castings” in your life? • Hundreds of things around us are made by casting technique. It is a very basic manufacturing process, used from ancient times • Melt something, pour it in something, cool it down and take it out • From water bottles to cars, lot of things are casted 2
- 3. Training Outline • Part 1: Introduction to High Pressure Die Casting (HPDC) ▫ Casting process ▫ Plant tour ▫ Flow simulation ▫ Cooling simulation ▫ Die design • Part 2: Whats’ in it for me? ▫ Engineering roles in HPDC industry. ▫ Where can one fit it, and how. 3
- 4. HPDC Process - Animation Die Cast Process Die close Slow shot Fast shot Cooling Die open Ejection Extraction Spray cycle 4
- 5. Plant Tour ! On an actual die cast machine, many processes happen at same time, hand-in-hand • Shot end, tip lube • Spray robot • Cooling, JIT • Squeeze pins • Ejector pins • Extraction robot • Quenching cycle • Trimming cycle • Engraving, traceability • Inspection • packaging 5
- 6. Flow Simulation – Multiple Cavities • Simultaneously make more than one part each shot • Cavities may be LH-RH pairs • May be couple of pairs clubbed together • Though similar looking, every cavity’s cooling pattern is different; and thus defects are different 6
- 7. Cooling Simulation • Thin walls cool first; and obviously thicker sections take longer • Idea is to keep molten metal pushing in thicker sections to compensate for shrinkage • Cooling lines should be designed accordingly 7
- 8. Die design • Material H-13, fast heat dissipating + cost effective • Cover half, ejector half • Top, bottom, operator side, helper side • Gating design, in gate, venting gates, Vacuum valve • Waterlines placement • Core pins • Squeeze pin/s • Datum placement based on machining and assembly datum structure • Flash 8
- 9. Exercise- Cooling Design • Where will you place the water line in below casting? Hot Cooling gradually Cold / Frozen Runner Gate Metal IN Biscuit Metal OUT Just in time cooling Big water line Small water line 9
- 10. Post Processing- After Part is Casted • X-Ray inspection • Shot blast • Heat treatment • Machining 10
- 11. Find Your Role in Die Cast Industry 11
- 12. Find Your Role in Die Cast Industry • Process engineer • Manufacturing / Industrial engineer • Value stream engineer • product engineer • Tooling engineer • Die Design engineer / simulation engineer • Quality engineer 12
- 13. Process Engineer • Key role in making good finished product • Defect free casting • Low / no scrap • Design process parameters during product launch • Maintain dies, keep quality within customer qualifications • Cycle time improvement over product life • Can you fit in this role? 13
- 14. Industrial Engineer / Value Stream Engineer • Set up die cast cell layout • Design product flow within shop floor / KANBAN ▫ Raw metal storage ▫ In-process inventory management • Ensure adequate facilities on floor • Cycle time study / through-put improvement • Ergonomics • Can you fit in this role? 14
- 15. Product Engineer • Study customer drawing/s and specifications • Study product cast-ability • Suggest design changes (if needed) for better quality • Can you fit in this role? 15
- 16. Tooling Engineer • Die design / use 3D software ▫ Die material ▫ waterlines ▫ gating ▫ flow simulations • Increase die life • Maintain tooling: pouring, shot end, gating, die • Can you fit in this role? 16
- 17. Quality Engineer • King of all / thorny crown • Responsible for final product quality • Set-up quality system • Quality inspection at each process • Respond to customer quality concerns • Can you fit in this role? 17
- 18. Enhance Your Resume • CAD course • Six sigma certification • Supply chain course • KANBAN expert 18
- 19. Stay Updated • Die cast Industry is/will dive into structural castings in future • Battery tray for electric vehicles • Technology advances for better pricing, better quality, better lifestyle …. Stay tuned 19
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Editor's Notes
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- Lesson descriptions should be brief.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.
- How presentation will benefit audience: Adult learners are more interested in a subject if they know how or why it is important to them. Presenter’s level of expertise in the subject: Briefly state your credentials in this area, or explain why participants should listen to you.