Detailed Project Report on Pressure Die Casting (Aluminium)

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PRESSURE DIE CASTING (ALUMINIUM)

[EIRI/EDPR/4420] J.C.: 2622XL

INTRODUCTION

The pressure die casting processes consume almost twice as many tons of aluminium alloys as all other casting processes combined. These processes are especially suited to the production of large quantities of relatively small parts. Aluminium die cast parts may weigh up to around 5 kilograms.

Pressure die casting in aluminum alloy offers means for very rapid production of engineering and other related component even or intricate design. The technique has obvious advantages when a component is required in large quantities. However, for aeronautic space, defence and automotive applications, mechanical properties and durability are of primary importance It is, therefore, essential that the best features of design should be employed and optimum casting technique with minimum cost be adopted. Pressure die cast products are used in the form of components of various electrical electronic, mechanical instruments and appliances used in domestic as well as industrial field.

Types of Aluminum Alloys for Die Casting Applications

In this eBook, we shall focus on 7 different types of aluminum alloys that are die cast in most industrial setup.

These alloys include the following:

The K-alloy; this aluminum allow is known to possess the following key properties: resistance to corrosion improved cooling and zero post die casting operations.

Alloy 413; superior die casting properties and it possess good fluidity and guarantee better pressure tightness.

Alloy 383; it possesses the following key properties: dimension stability, ease of casting and good mechanical properties. It has superior corrosion resistance too.

Alloy B390; it is known for its superior wear resistance and high hardness. They are mainly used to die cast the internal combustion engine pistons.

The A360; it is mainly used to cast aluminum parts where pressure tightness and fluidity is a priority. It maintains corrosion resistance and strength even at elevated temperature.

Alloy A413; its properties are similar to that of the alloy A360. This alloy is mainly used to die cast hydraulic cylinder components.

Alloy A380; it has good thermal and mechanical properties. Their performance property is similar to most alloys listed above.

COST ESTIMATION

Plant Capacity 3 MT/Day

Land & Building (5360 sq.mt.) Rs. 4.86 Cr

Plant & Machinery Rs. 9.97 Cr

Working Capital for 1 Month Rs. 2.31 Cr

Total Capital Investment Rs. 17.98 Cr

Rate of Return 27%

Break Even Point 58%

CONTENTS

INTRODUCTION

TYPES OF ALUMINUM ALLOYS FOR DIE CASTING APPLICATIONS

THESE ALLOYS INCLUDE THE FOLLOWING:

PRESSURE DIE CASTING

ADVANTAGES OF PRESSURE DIE CASTING:

TYPES OF PRESSURE DIE CASTING

HIGH PRESSURE DIE CASTING

TYPES OF HIGH PRESSURE DIE CASTING:

HOT CHAMBER PROCESS

COLD CHAMBER PROCESS

ADVANTAGES

LOW PRESSURE DIE CASTING

ADVANTAGES

USES/APPLICATIONS

BIS SPECIFICATION

PRESSURE DIE CASTING PROCESS

HIGH-PRESSURE DIE-CASTING (HPDC)

PROCESS CYCLE

A. CLAMPING

B. INJECTION

C. COOLING

D. EJECTION

E. TRIMMING

(I) HOT CHAMBER TYPE

(II) COLD CHAMBER TYPE

HOT CHAMBER DIE-CASTING

COLD CHAMBER DIE CASTING

ADVANTAGES

DISADVANTAGES

APPLICATIONS

THE MAIN ADVANTAGES OF LOW-PRESSURE DIE-CASTING ARE GIVEN AS:

THERE ARE SEVERAL STEPS DURING THE PRODUCTION OF ALUMINUM CASTING ALLOY WHEEL.

THERE ARE SEVERAL STEPS DURING THE PRODUCTION OF ALUMINUM CASTING ALLOY WHEEL WHICH IS GIVEN BELOW:

MELTING PROCESS

MELTING DOWN OF VIRGIN INGOT

MELT PREPARATION

THE PRIMARY PURPOSE OF MELT TREATMENT IS

(A) DEGASSING

DEGASSING PROCESS

MEASURING HYDROGEN CONCENTRATION

REDUCED PRESSURE TEST (STRAUBE-PFEIFFER)

QUANTITATIVE REDUCED PRESSURE TEST (SEVERN SCIENCE)

DENSITY MEASUREMENTS

INITIAL BUBBLE TEST (HYCON TEST)

RECIRCULATING GAS TEST (TELGAS, ALSCAN)

(B) FLUXING

X-RAY INSPECTION (REAL TIME RADIOSCOPIC INSPECTION)

QUALITY CONTROL

FINISHING PROCESS

PAINTING

TESTING

PROCESS FLOW

PRESSURE DIE CASTING MACHINE AND EQUIPMENTS

DIE CASTING MACHINES

ALL THESE AIM AT IMPROVING:

THE PRESSURE DIE CASTING MACHINES

THERE ARE TWO MAIN TYPES OF PRESSURE DIE CASTING MACHINES AND THEY INCLUDE:

THE HOT CHAMBER PRESSURE DIE CASTING MACHINES;

THE COLD CHAMBER DIES CASTING MACHINES;

DIE CASTING MOLD

SUPPLIERS OF ALUMINIUM PRESSURE DI-CASTING

SUPPLIERS OF RAW MATERIALS

ALUMINIUM ALLOY INGOT

SUPPLIERS OF PICKLING ACIDS

SUPPLIERS OF PACKING MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS PRESSURE DIE CASTING MACHINE

SUPPLIERS OF ALUMINIUM MELTING FURNACE

SUPPLIERS OF CNC LATHE MACHINE

SUPPLIERS OF PAINTING EQUIPMENTS

SUPPLIERS OF DG SETS

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

MARKET OVERVIEW

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

UTILITIES PER MONTH (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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