Chapter 1.

Objectives of project.

1. OBJECTIVES
Casting is a manufacturing process by which a liquid material is usually poured into a
mould, which contains a hollow cavity of the desired shape, and then allowed to solidify.
The solidified part is also known as casting. There are three manufacturing process, 1.
Machining, 2. Casting, 3. Forging. But casting is cheapest process of manufacturing.
Casting is a simple and economical process for batch production. Main problems in
casting are Gas porosity, shrinkage, misrun etc. Gas porosity occurs because most liquid
materials can hold a large amount of dissolved gas, but the solid form of the same
material cannot, so the gas forms bubbles within the material as it cools. It may present
itself on the surface of the casting which reduces the strength of the part. When casting
are solidify before completely filling mould cavity then it is called MISRUN. A misrun
occurs when the liquid metal doesnt completely feel the cavity, leaving unfilled portion.
Misrun occurs because of either lack of fluidity in the molten metal or cross section that
are too narrow. Our objective is to remove the above mentioned problem by observation
of the process and environmental condition.

1.1 HOT DIE CASTING

DC 20 Ton
DC 40 Ton
DC 66 Ton
DC 88 Ton

1.2 COLD DIE CASTING

DC 20 Ton

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Chapter 2.

Selection, description and working of project.

2.1 INTRODUCTION
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,
aluminium, magnesium, lead, pewter and tin based alloys. Depending on the type of metal
being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and this tends to limit
the process to high volume production. Manufacture of parts using die casting is relatively
simple, involving only four main steps, which keeps the incremental cost per item low. It is
especially suited for a large quantity of small to medium-sized castings, which is why die
casting produces more castings than any other casting process.
Die castings are characterized by a very good surface finish (by casting standards) and
dimensional consistency.Two variants are pore-free die casting, which is used to eliminate
gas porosity defects; and direct injection die casting, which is used with zinc castings to
reduce scrap and increase yield.

2.2 CAST METALS

Zinc: the easiest metal to cast; high ductility; high impact strength; easily plated;
economical for small parts; promotes long die life.
Aluminium: lightweight; high dimensional stability for complex shapes and thin
walls; good corrosion resistance; good mechanical properties; high thermal and
electrical conductivity; retains strength at high temperatures.
Magnesium: the easiest metal to machine; excellent strength-to-weight ratio; lightest
alloy commonly die cast.
Copper: high hardness; high corrosion resistance; highest mechanical properties of
alloys die cast; excellent wear resistance; excellent dimensional stability; strength
approaching that of steel parts.

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Silicon tombac: alloy made of copper, zinc and silicon. Often used as an alternative
for investment casted steel parts.
Lead and tin: high density; extremely close dimensional accuracy; used for special
forms of corrosion resistance. Such alloys are not used in foodservice applications for
public health reasons. Type metal, an alloy of Lead, Tin and Antimony (with
sometimes traces of Copper) is used for casting hand set type in letterpress printing
and hot foil blocking.

2.3 MAIN PARTS OF THE DIESEL FIRE CASTING MACHINE

Base (Fabrication body).
CRC Plate.
3 Plates.
1 Railing.
2 3lug.
2 2lug.
2 Toggle.
4 Seven.
1 Cross Slide.
2 Support Plate.
1 Body Top.
2 Nozzle Cylinder.
1 Injection Cylinder.
1 Injector Cylinder.
1 Locking Cylinder.
4 Tai rod.
1 Goose Neck.
1 Accumulator.
Electronic Panel.(PLC)
1 Hydraulic Mini Block 1.
1 Hydraulic Pump.
1 Oil Cooler.
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1 Hydraulic Mini Block 2.

1 Hydraulic Mini Block 3.
1420 L and Key Bolt.
1 Melting Furnace.
Oil Furnace.
1 Lubricator.

2.4 DESCRIPTION OF THE MACHINE PARTS

2.4.1 Base: First the assembly of the body is done with the base. Base is made up from cast
iron plate. The thickness of the plate is 5mm. The base is also known as Fabrication
Body. The Fabrication Body is shown below.

Fig 2.4.1 Base

2.4.2 Three Lug: It is shown in the below photo. They are used to support the machine.
They are made up of the mild steel. High grade steel is used in it. After that
machining is done on it.

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Fig 2.4.2 Three Lug

2.4.3 CRC Plate: It is used to make the fabrication body. It is an important part of the
fabrication body. It is needed for the construction of the body.

2.4.4 Nozzle Cylinder: The nozzle cylinder is important part of the machine. Through
the nozzle cylinder injection of the mould is shot into the die. Nozzle cylinder is
attached with the plate 1. It is prepared by casting.

Fig 2.4.4 Nozzle Cylinder

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2.4.5 Plate 2: There are 3 plates used in the assembly of the machine. The plate 2 is used
in the middle. It joins the nozzle cylinder and the die. The plate is prepared by casting.
First the model of the plate is prepared from thermocol. Then it is prepared from the
mild steel. The plate has four holes in which the 4 tai rods are placed. This 4 tai rods
help in holding the other plates.

Fig 2.4.5 Plate 2

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2.4.6 PLC Circuit: The PLC Circuit is the main component of the machine. Without the
PLC Circuit the machine cannot start and it cannot perform the proper functions
without the circuit. The circuit has many MCB which regulates the function.

Fig 2.4.6 PLC Circuit

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2.4.7 L and Key Nut and Bolts: The above photo is of the nut bolts used in the
assembly and joining of the machine. Without the nut and bolts machine cannot be
joined. Various types of nut bolts are used. Nut and bolts are of different shapes and
sizes which are used in the machine. Standard shape and size are used.

Fig 2.4.7 L and Key Nut Bolts

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2.4.8 Water Cooling Pipes: These pipes are used to cool down the temperature of the
die. When the temperature of the die rises more than the required temperature the
water starts flowing through the pipes cooling the die.

Fig 2.4.8 Water Cooling Pipes

2.4.9 Support Plate:

Fig 2.4.9 Support Plate

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2.4.9 Seven

Fig 2.4.10 Seven

2.5

FURNACES USED IN CASTING MACHINE

2.5.1 Oil Furnace:

Fig 2.5.1 Oil Furnace

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2.5.2 Melting Furnace:

Fig 2.5.2 Melting Furnace

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2.6 ASSEMBLY PROCESS

The process of fitting all the machine parts at their proper place and making the
machine ready for working is known as assembly. The above all parts are used in
the assembly of the machine.
In assembly of the machine various L and Key Nut Bolts are used. In total fitting
of the machine 1420 nuts and bolts are used.
There are three plates used. All the plates are arranged in the order according to
their function. The plates are made from casting process. They have four holes in
which tai rods are used to connect all the three plates.
In between the plates parts like nozzle cylinder are fitted. The injection cylinder
and ejector cylinder are also placed between the plates.
The machine consists of accumulator in which nitrogen gas is present. Nitrogen
pressurizes the piston due to which molten metal passes through the die gate and
enters into the die.
As the temperature of the melting furnace is 450 C the heat can be transferred to
machine also, so the system of water cooling is arranged. Water cools the die so
the temperature is maintained.
For the proper working of the parts lubricating pump is provided. It provides
lubrication to all the parts automatically so the machine works properly. If
lubrication is not provided then it causes wear and tear. Friction is generated.
Control Panel Circuit is provided to control the functions of the machine. Without
the control panel machine does not start. So the various functions are performed
by the machine.
So the whole machine is shown below.

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2.6.1 Die Casting Machine:

Fig 2.6.1 Die Casting Machine

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Chapter 3. Plant layout of industry visited.

3.1 Plant layout of SHREE HARIKRUPA TRADING.

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Chapter 4. Flow process chart.

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Chapter 5. Cost estimation of product

Assumption :Density of cast iron =7.25 gm/
Rate of power =Rs. 9 per unit
Labor cost =Rs. 30 per kg
Raw material cost = As per required part.
Overhead charges =25%
Total volume = 118080 + 75248.20
= 193328.2
= 193.33
Total weight = volume x density
= 193.33 x 7.25
= 1401.62 kg
Raw material cost
1. Base (Fabrication Body) = 4 Lakhs Rs.
2. CRC Plate =48Rs/kg
3. 3 plates= 78Rs/kg
4. 1 Railing= 1.5 Lakhs Rs.
5. 2 Three Lug= 78Rs/kg
6. 2 Two Lug=78Rs/kg
7. 2 Toggle= 78Rs/kg
8. 4 Seven=78Rs/kg
9. 1 Cross Slide=78Rs/kg
10. 2 Support Plate=78Rs/kg
11. 1 Body Top= 78Rs/kg
12. 2 Nozzle Cylinder= 35000 Rs.
13. 1 Injection Cylinder= 48000 Rs.
14. 1 Injector Cylinder= 18000 Rs.
15. 1 Locking Cylinder= 24000 Rs.
16. 4 Tai Rods= 85000 Rs.
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17. 1 Goose Neck= 30500 Rs.

18. 1 Accumulator= 80000 Rs.
19. Electronic Panel= 75000 Rs
20. Hydraulic Mini Blocks= 75000 Rs.
21. Hydraulic Pump = 103000 Rs.
22. Oil Cooler= 28000 Rs.
23. 1420 L and Key Bolts= 19400 Rs.
24. Melting Furnace= 95000 Rs.
25. Oil Furnace= 95000 Rs.
26. Lubricator= 34000 Rs.

Total Raw Material Cost = 3000000 Rs.

Labour cost = Rs. 30 per kg
= 42030 Rs.
Labour of Paint = 25000 Rs.
Total Labour Charges = 42030 + 25000
= 67030 Rs.
Power cost
For miller machine
o Torque (T) =

=
= 14323 N.m
o Power (P) =
=
= 450 kwh
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o Power per piece = 450 kw

o Power cost = 450 x 8
= 3600Rs.

For grinding machine

o Torque (T) =

=
= 1278 N.m
o Power (P) =

=
= 274 kw
o Power per piece = 274 kw
o Power cost = 274 x 8
= 2192 Rs.

Total Power cost =Power cost of miller machine + Power cost of grinding machine
= 3600 + 2192
= 5792 Rs.

Total cost = Raw material cost + Labour cost + Overhead charges +

Power cost
= 3000000 + 67030 + 5000 + 5792
= Rs 30,77,822
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Chapter 6. Problems And Solutions Of Process.

6.1 GAS POROSITY
Porosity may be the most persistent and common complaint of casting users. Forgings,
machined parts and fabrications are able to avoid porosity with ingot cast feedstock,
mechanical processing and automated inspection of simple shapes. Porosity in castings
contributes directly to customer concerns about reliability and quality. Controlling porosity
depends on understanding its sources and causes. Significant improvements in product
quality, component performance, and design reliability can be achieved if porosity in castings
can be controlled or eliminated.
Porosity in castings is due to bubbles being trapped during solidification. Porosity sources
include entrapped air

during filling, centerline shrinkage that occurs during the final

solidification, blowholes from unvented cores, reactions at the mold wall, dissolved gases
from melting and dross or slag containing gas porosity.
To prevent gas porosity the material may be melted in a vacuum, in an environment of lowsolubility gases, such as argon or carbon dioxide or under a flux that prevents contact with
the air. To minimize gas solubility the super heat temperatures can be kept low. Turbulence
from pouring the liquid metal into the mold can introduce gases, so the molds are often
streamlined to minimize such turbulence. Other methods include vacuum degassing gas
flushing or precipitation. Precipitation involves reacting the gas with another element to form
a compound that will form a dross that floats to the top.

Fig 6.1 Gas Porosity

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6.1.1 Causes of Gas Porosity

1. The metal may have been overheated.
2. Inadequate burnout.
3. Scrap re-used too many times.
4. Too much oxygen in torch flame.
5. Pin holes on the surface.

1. The metal may have been overheated

Solution - Reduce metal temperature during casting. If the metal is overheated and
introduced in to the mould too hot it takes longer to solidify and is in contact with the
sand for longer. This can increase the risk of reaction and therefore gas entrapment from
the sand. The solution is to reduce the metal temperature and therefore reduce the amount
of time the liquid metal is in contact with the sand.

2. Inadequate burnout
Solution - Increase the time at the top temperature. Any carbon residue that may be left
over from the sand could react with the metal on entering the mould and create gases.
These gases will then be trapped under the skin of the metal as it solidifies leading to gas
porosity.

3. Scrap re-used too many times

Solution - Refine metal or only use a maximum of 50% old metal. By introducing re-used
metal there is a possibility of introducing old casting as well as other impurities into the
melt. These impurities can cause a direct gas reaction leading to gas porosity.

4. Too much oxygen in torch flame

Solution - Use a reducing flame when melting with a torch. Oxygen levels that are set too
high within the torch flame will cause an oxidizing reaction of the metal. It is important
therefore to make sure that the oxygen levels are moderate. There is also a possibility for
the unskilled caster to overheat the metal.

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5. Pin holes on the surface

Solution - If used alloy scrap such as feeders is remelted, it must be thoroughly cleaned
to remove any mould material as this can react with the alloy, leading to the formation of
sulphides. Used alloy from castings with severe porosity should not be remelted again but
refined.

6.2 MIS-RUN
A misrun occurs when the liquid metal does not completely fill the mold cavity, leaving an
unfilled portion. Cold shuts occur when two fronts of liquid metal do not fuse properly in the
mould cavity, leaving a weak spot. Both are caused by either a lack of fluidity in the molten
metal or cross-sections that are too narrow. The fluidity can be increased by changing the
chemical composition of the metal or by increasing the pouring temperature. Another
possible cause is back pressure from improperly vented mold cavities.
Misruns and cold shuts are closely related and both involve the material freezing before it
completely fills the mold cavity .These types of defects are serious because the area
surrounding the defect is significantly weaker than intended.
The castability and viscosity of the material can be important factors with these problems.
Fluidity affects the minimum section thickness that can be cast, the maximum length of thin
sections, fineness of feasibly cast details, and the accuracy of filling mold extremities.

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Fig 6.2 Mis-Run

6.2.1 Solution
There are a number of ways to reduce the concentration of inclusions. In order to reduce
oxide formation the metal can be melted with a flux, in a vacuum, or in an inert
atmosphere.
Other ingredients can be added to the mixture to cause the dross to float to the top where
it can be skimmed off before the metal is poured into the mold. If this is not practical,
then a special ladle that pours the metal from the bottom can be used.
Another option is to install ceramic filters into the gating system. Otherwise swirl gates
can be formed which swirl the liquid metal as it is poured in.
Adjust proper pouring temperature.
Modify design.
Modify gating system.

6.3 SHRINKAGE
Shrinkage defects occur when feed metal is not available to compensate for shrinkage as the
metal solidifies. Shrinkage defects can be split into two different types: open shrinkage
defects and closed shrinkage defects. Open shrinkage defects are open to the atmosphere,
therefore as the shrinkage cavity forms air compensates. There are two types of open air
defects: pipes and caved surfaces. Pipes form at the surface of the casting and burrow into the
casting, while caved surfaces are shallow cavities that form across the surface of the casting.
Closed shrinkage defects, also known as shrinkage porosity, are defects that form within the
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casting. Isolated pools of liquid form inside solidified metal, which are called hot spots. The
shrinkage defect usually forms at the top of the hot spots. They require a nucleation point, so
impurities and dissolved gas can induce closed shrinkage defects. The defects are broken up
into macro porosity and micro porosity (or micro shrinkage), where macro porosity can be
seen by the naked eye and micro porosity cannot.

Fig 6.3 Mis-Run

6.3.1 Solution
The general technique for eliminating shrinkage porosity is to ensure that liquid metal
under pressure continues to flow into the voids as they form.
Avoid heavy isolated casting sections that are difficult to feed.
Design the part with a progressive change in casting thickness
Design the gating and feeding system to provide for directional solidification back to
the risers.
For gray and ductile irons, increase carbon and silicon content as allowed, to decrease
volumetric contraction of the metal during solidification
Limit the pouring temperature so that the liquid contraction is minimized.

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Chapter 7. References
1. http://www.srsltd.co.uk/support/downloads/problem_solving/p_solving_gas_po
rosity.pdf
2. http://www.leekeegroup.com/eng/company/pdf/paper1_070718.pdf
3. http://rastgar.com/rec/papers/Porosity%20in%20Castings.pdf
4. http://en.wikipedia.org/wiki/Casting_defect
5. Book :- Work shop technology, manufacturing process.(Author:- S.K. Garg)
Laxmi Publication pvt. Ltd.
6. http://www.shreeharikrupadiecasting.com/hot66.htm
http://en.wikipedia.org/wiki/Cupola_%28ISS_module%29#Specifications

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Chapter 8. Moment at work photograph in action.

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