Detailed Project Report on Pressure Die Casting (Aluminium)

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PRESSURE DIE CASTING (ALUMINIUM)

[CODE NO.4048]

The pressure die casting processes consume almost twice as many tones 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.

In summary, by the end of this section, you need to understand the basic properties of all the possible aluminum die casting alloys.

This is important when you need a specific aluminum alloy for a given application.

COST ESTIMATION

Plant Capacity 2 MT/Day

Land & Building (4000 sq.mt.) Rs. 4.64 Cr

Plant & Machinery Rs. 1.52 Cr

Working Capital for 2 Months Rs. 2.29 Cr

Total Capital Investment Rs. 8.84 Cr

Rate of Return 17%

Break Even Point 68%

INTRODUCTION

TYPES OF ALUMINUM ALLOYS FOR DIE CASTING APPLICATIONS

THESE ALLOYS INCLUDE THE FOLLOWING

PRESSURE DIE CASTING

ADVANTAGES OF PRESSURE DIE CASTING

DISADVANTAGES OF PRESSURE DIE CASTING

TYPES OF PRESSURE DIE CASTING

1. HIGH PRESSURE DIE CASTING

HIGH PRESSURE DIE CASTING PROCESS

TYPES OF HIGH PRESSURE DIE CASTING

HOT CHAMBER PROCESS

COLD CHAMBER PROCESS

ADVANTAGES

DISADVANTAGES

2. LOW PRESSURE DIE CASTING

LOW PRESSURE DIE CASTING PROCESS

ADVANTAGES

DISADVANTAGES

USES AND APPLICATION

APPLICATION OF PRESSURE DIE CASTING

B.I.S. SPECIFICATION

PROCESS FLOW CHART

PRESSURE DIE CASTING PROCESS

(1) 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

FIG. 13.3 AIR BLOWN OR GOOSE NECK TYPE DIE CASTING SETUP

COLD CHAMBER DIE CASTING

ADVANTAGES

DISADVANTAGES

APPLICATIONS

MELTING PROCESS

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

PRESSURE DIE CASTING MACHINE AND EQUIPMENTS

DIE CASTING MACHINES

ALL THESE AIM AT IMPROVING

CONSIDERATIONS WHEN BUYING DIE CASTING MACHINES

THE CRITICAL PARTS TO CONSIDER IN A MACHINE INCLUDE

THE FOLLOWING

THE PRESSURE DIE CASTING MACHINES

1. THE HOT CHAMBER PRESSURE DIE CASTING MACHINES;

2. THE COLD CHAMBER DIES CASTING MACHINES;

DIE CASTING MOLD

MARKET POSITION

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE

SERVICE ARE

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY

2. MARKETS

3. POWER AND FUEL SUPPLY

4. WATER SUPPLY

5. CLIMATE

6. TRANSPORTATION

7. WASTE DISPOSAL

8. LABOR

9. REGULATORY LAWS

10. TAXES

11. SITE CHARACTERISTICS

12. COMMUNITY FACTORS

13. VULNERABILITY TO WARTIME ATTACK

14. FLOOD AND FIRE CONTROL

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION

2. FIXED ASSETS

3. WORKING CAPITAL

4. BREAK-EVEN POINT

5. OTHER FIXED EXPENSES

6. MARGIN MONEY

7. TOTAL LOAD

8. LAND AREA/MAN POWER RATIO

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

PLANT LAYOUT

SUPPLIERS OF ALUMINIUM PRESSURE DI-CASTING

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM ALLOY INGOT

SUPPLIERS OF PICKLING ACIDS

SUPPLIERS OF PACKING MATERIALS

SUPPLIERS OF PAINT

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF 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 COOLING TOWER

SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)

SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS

SUPPLIERS OF AIR CONDITIONING EQUIPMENTS

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

SUPPLIERS OF SUBMERSIBLE WATER PUMP

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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