CMF335 Design of Tooling for Die Casting Syllabus:
CMF335 Design of Tooling for Die Casting Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
At the end of this course the student should be able to
• Understand the different types of alloys and its properties.
• Identify the type of casting process, machine and feed system for the components.
• Demonstrate the elements and working principle of different dies.
• Design the Die casting tool for metallic components.
UNIT I INTRODUCTION
Material Properties: Pouring, Turbulence, Fluidity. Casting material selection, Classification of Casting process, Sand casting, Plaster mould casting, Ceramic mould casting, Shell mould casting, Vacuum mould casing, Expandable polystyrene casting, Investment casting, Slush casting, Metal mould castings, Vacuum permanent mould casting, Centrifugal casting, Continuous casting, Pressure die casting, Die casting, Advantages of Die casting over other process. Die Casting Alloys Low fusion alloys, High fusion alloys, Chemical compositions, Properties, Casting Defects.
UNIT II DIE CASTING MACHINES
History of die casting machines, Hot chamber machine, cold chamber machine, Horizontal machine, Vertical machine, Die locking, Toggle locking, Hydraulic locking, Injection systems, knock out pins and plates, ejection unit, loading of metal into hot chamber.
UNIT III DIE CONSTRUCTION
Cores, Cavities, pillars and bushes, ejectors, bolster plates, Shot weight, Clamping force, Injection pressure, Shut height and day light, parting surface, relief and venting.
Feed System: Gates, Runners, Taper tangent runner system, Precession layout, Spreader, shot sleeve, shot weight, PQ2 Diagram and calculations etc.
Cooling System: Core cooling, Cavity cooling, cooling of shot sleeve, cooling of spreader, baffles, cooling calculations.
UNIT IV TYPES OF DIES
Single cavity dies, Multi cavity dies, combination dies, unit dies, trimming and finishing of components, Inspection of components, safety, SPC & visual control techniques – Construction, Actuation of side cores, defects and remedies.
UNIT V DESIGN OF DIE
Design of Cold chamber, Hot chamber, Single cavity, Multi cavity die-casting dies, and Dies with side cores and splits.
TOTAL : 45 PERIODS
COURSE OUTCOMES:
Upon the completion of this course the students will be able to
• Explain casting processes for different components and materials
• Analyse the casting process for design of feed system, ejection, cooling and parting surfaces.
• Design of Dies for the casting of components
• Solve industrial problems related to casting of metallic components
TEXT BOOKS:
1. Do Ehler H.A, “Die Casting”, New York -McGraw Hill Book Co-Inc. International Student Ed. 2000. ISBN- 0471497479
2. Genick Bar–Meir, Fundamentals of Die Casting Design, Version 0.1.4, 2012
REFERENCES:
1. Street. C. Arthur, “The Die Casting Book”, England Portcullis Press Ltd., 2nd Ed. 1986, ISBN-0-408-10717-0
2. William Andresen, “Die Cast Engineering: A Hydraulic, Thermal, and Mechanical Process”, CRC Press, 2004, ISBN 9780824759353
3. Edward J. Vinarcik, “High Integrity Die Casting Processes”, Wiley publications, 2002, ISBN: 978-0-471-20131-1
4. William Andresen, Die Casting Engineering : A Hydraulic, Thermal, and Mechanical Process, Marcel Dekker, 2010