BY

• RAVIKANT B. PATIL
(2011143)
SEMESTER PROJECT REPORT 2
 WORK ORDER NO. - 1423451
 CUSTOMER - ENDURANCE
 COMPONENT - CANYSTER
 MATERIAL - ALUMINIUM

SEMESTER PROJECT REPORT 3

1. INTRODUCTION TO PDC DIE
2. COMPONENT DETAILS
3. PART DETAILS
4. TOOL DATA
5. CALCULATION
6. ASSEMBLY DETAILS
7. CONCLUSION
SEMESTER PROJECT REPORT 5
 As the name “Pressure Die Casting” implies,
injection of the molten metal into the mould or
die cavity is done under pressure.
 The thin walls, as well as the various bends
around the corners and the edges of complicated
die castings, offer considerable resistance to
complete filling of the mould or die.
 The air present in the cavity has to be displaced
by the entering metal. The air could be displaced
by providing air vents in the die or by connecting
the cavity to vacuum before the metal is injected
into the die
 Casting is broadly divided into two types:-
1. Temporary casting process &
2. Permanent casting process.
 Permanent casting process are further divided
into Pressure die casting dies(PDCD), Gravity
die casting dies, Centrifugal die casting dies,
etc.
 PDCD are further subdivided into Hot
Chamber PDCD & Cold Chamber PDCD

SEMESTER PROJECT REPORT 7

 Materials with melting point less than 450°c
(such as zinc, tin and lead alloys) are casted
in this process.
 The melting furnace is attached to the
machine itself.
 This prevents the loss of superheat.
 They have shorter cycle time than that of cold
chamber PDCD.

SEMESTER PROJECT REPORT 8

SEMESTER PROJECT REPORT 9
 Materials with melting point 450°c to 800°c (such
as Aluminium, Magnesium and Copper alloys)
are casted in this process.
 The melting furnace is not attached to the
machine.
 The molten metal is fed into machine with the
help of ladle or any other auxiliary method.
 This process have a problem of loss of
superheat.
 They have longer cycle time than that of hot
chamber PDCD.

SEMESTER PROJECT REPORT 10

SEMESTER PROJECT REPORT 11
SEMESTER PROJECT REPORT 12
SEMESTER PROJECT REPORT 13
SELECTION OF PARTING LINE IS VERY IMPORTANT
ASPECT IN ORDER TO ACHIEVE PROPER CAVITY
FILLING AND POSITIVE EJECTION OF COMPONENT
FROM THE DIE.

PARTING LINE
PARTING PLANE

SEMESTER PROJECT REPORT 14

SEMESTER PROJECT REPORT 15
 DESIGN
 PART DRAWING RELEASE
 RAW MATERIAL
 MATERIAL PREPARATION
 PREMACHINING
 BENCH WORK
 PRECISION MACHINING (BEFORE HT)
 HEAT TREATMENT
 GRINDING
 PRECISION MACHINING (AFTER HT)
 POLISHING
 INSPECTION (Q.C)
 ASSEMBLY
SEMESTER PROJECT REPORT 17
 Material :- Aluminium-Nickel alloy
 Density :- 2.71 g/cu. cm.
 Shrinkage :- 6%
 Weight :- 406 gm.
 Average wall thickness :- 3.21 mm.
 Projected area for casting :- 46.44 sq. cm.

SEMESTER PROJECT REPORT 18

•Projected area of component(s)= 92.89 sq. cm.
•Projected area of casting(component + overflows)
=120.43 sq.cm.
•Projected area of (casting + feed systems) = 144.51 sq.
cm.
•Thickness of casting =4.5mm
•Weight of component (s) = 812 gm.
•Weight of casting = 1055 gm.
•Weight of shot = 1266 gm.
SEMESTER PROJECT REPORT 19
 Depth of overflow = 3 x wall thickness
= 3x 3.5
= 10.5 mm.

 Width of overflow = 2 x depth of overflow

 = 2 x 10.5
= 21mm.

 Length of overflow = 2 x Width of overflow

= 2 x 21
= 42mm
 • Locking Force = A x P x FOS
1000
= 155.71 tons
• Gate area = Q = 100 mm2
Vg
Gate thickness =t/3
= 8.5 / 3
=2.83mm

 Volume of metal through gate, Vp

= 234615 mm3 x1.3
= 304999 cm3
SEMESTER PROJECT REPORT 21
• Runner area = 50 mm
• Runner depth = 20mm
• Width of Runner = 30mm
• Length of Runner = 100 mm

SEMESTER PROJECT REPORT 22

•Ejector pin Calculations:
•Ejector pin area = 4% of Projected area of
compo.
= 3.51 sq. cm.

•No. of Ejector pins = 4% of Projected area

Area of one pin(Ø6)
= 9.53
≈ 10 pins

SEMESTER PROJECT REPORT 23

 As we get inspected parts the assembly of the tool
proceeds.
 After inspections of finish parts, mating parts are
assembled in there respective positions this is
carried out in sequential stages
 Alignment of housing

 Spotting of core(moving) & cavity(fixed) inserts

 Alignment Ejector box

 Ejector box assembly

 ASSEMBLY
 Spotting of local inserts & guide pins
and their assembly.
 Assembly of sprue spreader and sprue
bush.
 Checking whether all ejector pins are at
their positions .
 Connecting water jackets and hose
connectors.
 Fit the elbows, pipes, nozzles.
 Cross check all parts are to be clamped
 Guide pillars fitting diameter had
to finish on cylindrical grinding.
 Fixed insert had to be surface
grinded
 Ejector pin length had to be
maintained
 Hose pipe slots was not machined
 Sprue bush collar was grinded.
 Fixed and moving inserts were
needed to polish
 The project was a medium for us to
enhance our knowledge in the field of tool &
Die Designing & Manufacturing. It helped us
a lot in better understanding of the
concepts of plastic mould manufacturing.
 During the project we had to communicate
with various departments and authorities to
solve the problems and difficulties around in
between. It has helped to improve our
abilities to work as a team.
 It was a nice opportunity for us to learn
about such a tool, thus enhancing our
knowledge
SEMESTER PROJECT REPORT 28