IOSR Journal of Engineering (IOSR JEN) www.iosrjen.

org
ISSN (e): 2250-3021, ISSN (p): 2278-8719,
|| Special Issue || June-2019, || PP 58-62 ||

Rejection Analysis of High Pressure Die Casting Component By

Reverse Engineering
Khairnar Y.S1, Amale N.M2, Bake Rahul.S3, Bandal O. N3, Shendage S.R4
1
(Assistant professor, Department Of Mechanical Engineering JSPM Narhe Technical Campus, Pune, India)
2, 3, 4
(Student, Department Of Mechanical Engineering JSPM Narhe Technical Campus, Pune, India)

Abstract: There are number of manufacturing process, but the one of the best manufacturing process used in
the industry is die casting. The die casting also includes various types like hot chamber die casting, cold
chamber die casting and gravity die casting. The die casting process is influenced by parameters like product to
be manufactured, rate of production, quality of production, etc. Depending on these parameters one of the die
casting process is used.An important factor for obtaining defect free pressure diecast parts is good design of the
feeding system. Feeding system is a path of flow of molten alloy during filling of casting. In this project a
systematic approach has been developed to design feeding system for a high pressure die-casting die.This
involved studying current design practices in the industry and translating this into a knowledge base of rules for
machine selection, design of gate, gate-runner, runner, overflows and airvents. The designed feeding system is
evaluated in terms of criteria such as filling, air entrapment, power utilization, yield, and fettling. A defect of
part SCON-200 is analyzed. The main aim of this project is to finding the root cause of the problem and solution
to the specific cause. It includes design of the die, analysis of the die parameter, simulation of the product,
experimental validation of product. Simulation of the product is done in MAGMA software. After that the trails
were conducted on the machine of selected tonnage which gives the accurate result with analytical
methodology.
Keywords: die casting, MAGMA, SCON-200

I. Introduction
Rejection of any component occurs due to some defects contained in it which will affect components
performance. Due to rejection manufacturing organization has to pay for loss in various areas. Common losses
are: loss of material, loss of time, loss of capital which was invested in machine, manpower, etc. Also
continuous more rejection will reduce supply rate of good products to customer. Thereby it will reduce
productivity. So for avoiding all these losses, there should be production of rejection free components. But any
superior machine, method, design, operator manufacturing process cannot manufacture components having zero
defects. Hence the organization tries to reduce the percentage of defects to an minimum level in such a way that
components functional requirement should not get disturbed. And hence minimizing the defects automatically
there is reduction in rejection .The some causes of defects are as follows: due to certain lacunas in design, due to
uncontrolled process, due to defect in material used, due to human errors ,etc. For reducing defects one must
find the root cause of the defect and then try to find the solution for the same. There are various ways of
approaching towards optimum solution such as why-why analysis, brainstorming analysis, etc. In current
situation why-why analysis is used to solve the problem. There are many defects in die casted components due
to various causes like Porosity, blow holes, low temperature, and high temperature these all problems are of die
casting. But the one major problem related to one product called SCON200 was after manufacturing the product
when it reached at customer, there was loosing of Screw, failure of screw, bending of screw and missing of the
screw. These were the major customer complaints issued to the company 4 to 5 times in month. So the purpose
of our project is to find the root cause of the failure and find the solution to the problem and produce the
component defect free. Due to this complaint of the customer should be reduced. So the analysis should be done
to remove this compliant.

Hot Chamber Machines: Hot chamber machines are used primarily for zinc, and low melting point alloys
which, do not readily attack and erode metal pots, cylinders and plungers. Advanced technology and
development of new, higher temperature materials has extended the use of this equipment for magnesium alloys.
In the hot chamber machine, the injection mechanism is immersed in molten metal in a furnace attached to the
machine. As the plunger is raised, a port opens allowing molten metal to fill the cylinder. As the plunger moves
downward sealing the port, it forces molten metal through the gooseneck and nozzle into the die.Alter the metal
has solidified, the plunger is withdrawn, the die opens, and the resultingcasting is ejected. Hot chamber
machines are rapid in operation. Cycle times vary fromless than one second for small components weighing less
than one ounce to thirty seconds for a casting of several pounds. Dies are filled quickly (normally between five
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 Rejection Analysis of High Pressure Die Casting Component By Reverse Engineering

and forty milliseconds) and metal is injected at high pressures (1,500 to over 4,500 psi).Nevertheless, modern
technology gives close control over these values, thus producing castings with line detail, close tolerances and
high strength.

Fig: A Typical High Pressure Die Casting Machine

Cold Chamber Machines: Cold chamber machines differ from hot chamber machines primarily in one respect,
the injection plunger and cylinder are not submerged in molten metal. The molten metal is poured into a "cold
chamber" through a port or pouring slot by a hand or automatic ladle. A hydraulically operated plunger,
advancing forward, seals the port forcing metal into the locked die at high pressures. Injection pressures range
from 3,000 to over 10,000 psi for both aluminum and magnesium alloys, and from 6.000 to over 15,000 psi for
copper base alloys. In a cold chamber machine, more molten metal is poured into the chamber than is needed to
fill the die cavity. This helps sustain sufficient pressure to pack the cavity solidly with casting alloy. Excess
metal is ejected along with the casting and is part of the complete shot.The main difference between cold-
chamber die casting and hot-chamber die casting manufacture is that in the cold-chamber process the molten
metal for the casting is introduced to the shot chamber from an external source, while in the hot chamber
process the source of molten material is attached to the machine.

Fig: A Typical Cold Chamber Die Casting Machine

II. Methodology
 Check the 3D Model and 2D Drawing given by the customer
 Ensure that 3D Model matches with the 2D drawing and make model inspection report

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 Rejection Analysis of High Pressure Die Casting Component By Reverse Engineering

 Identify critical and major dimensions

 Check for design feasibility and decide parting line
 Get customer approval for the selected parting line
 Add drafts to the model considering tolerances for MMC
 Add shrinkage to the mode
 Generate surface as per the decided parting line
 Split core and cavity considering the manufacturing aspects
 Check for draft analysis and clearance analysis Optimize feed system as per the filling pattern shown by
MAGMA
 Create model base Provide ejector positions in the component and inserts Create cooling holes.
 Conduct concept design review meeting.
 Change the model or layout based on the review output Freeze the layout.
 Prepare detail drawings of inserts and mold base elements
 Checking of the detail drawing
 Release drawings to manufacturing
 Check for any design non-conformity with the assembly division.

Calculations:
Gate and Runner calculations:
PART NAME: SCON-200 PART MATL: ZAMAK-3
1) Component weight= 143 gms
2) No of cavities = 2
3) Component material = ZAMAK-3
4) Over flow weight= 25% of component weight = 35 gms
5)Material through gate = Component weight + O/F. weight =178.75 gms
6) Density of material to cast= 6.7gms/cc
7) Volume of material through gate = material through gate/density of material to cast=26.86cc
8) Minimum wall thickness = 1.1 mm.
9) Velocity of gate = 4300 cm/sec
10)Cavity fill time = 0.007 sec.
11)Gate thickness = 0.5 mm.
12)Fill rate = Volume of material through gate/cavity fill time = 3811.30 cc/sec
13) Area of gate = Fill rate/velocity of gate = 88.63 mm sq.
14)Length of gate = Area of gate/ Thickness of gate = 177.27 mm.
15) Area of runner = 4 X Gate area = 354.54 mm sq.
16) Width of runner = SQRT 2 X Area of runner = 26.63 mm.
17)Depth of runner = Width of runner/2 = 13.31 mm.
Selection of Die Casting Machine:
18) Component projected area = 8700 mm sq.
19) Projected area of runner, O/F and biscuit =50% X component projected area. =4350 mm sq
20) Total projected area = 1.3 X Component Projected area = 26100 mm sq
21) Die opening force = Total projected area X Specific Inj. Pressure = 104.40 ton
22) Die locking force = 1.2 X Die opening force = 125.28 ton
23) Machine to be used = 400 ton
Plunger Size Calculations
24) Shot weight =2 X Component weightX Number of castings = 572 gms
25) Plunger diameter = 60 mm

Scope: Alloy pressure die castings are finding applications in major three types of market viz. Primary market
Replacement market and Substitution market. The automobiles component and fittings, telephone industry,
electrical appliances, electronic components and builder hardware & fittings etc. are the major market for Al.
Pressure Die Castings. The requirement of defense, aeronautic and space is also there, where mechanical
properties and durability are of prime importance, therefore it is essential that the best features of design should
be employed and optimum casting technique with minimum cost be adopted. The primary market is expected to
continue as the leading market, with demand growth in requirement as the field like, builder hardware,
automobile components, electrical appliances, electronic components, telephone industry are growing to meet
the demand of more and more urbanization and change of life style. The technological developments are
opening up the new field of application of the Pressure Die cast components.

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 Rejection Analysis of High Pressure Die Casting Component By Reverse Engineering

III. Conclusion
After calculating all the design parameters like gate velocity, Gate area, metal temperature and cavity
fill time .Total number of air vents is decided by back pressure analysis in magma soft. According to the
standard if the value of back pressure of entrapped air in casting cavity is more than 2 bar then it will lead to air
porosity after machining of casting.After finalizing all the parameters of the die. The casting die has been
manufactured. For validating the manual design calculations and analysis with magma soft, test has been
performed on the first component manufactured from die. The result of this project work is design the parts of
die casting that parts are shown in below

Figure: Moving Side Housing

Figure: Fixed Side Housing

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 Rejection Analysis of High Pressure Die Casting Component By Reverse Engineering

Figure: SCON-200

Figure: SCON-200 with runner and gate

References
[1]. Die Design and Analysis of High Pressure Die Casting Die for Oil Pan Anuj Chaudhary and Pardeep Rana
[2]. Calculation of the Die Cast Parameters of the Thin Wall Aluminum Die Cast Part A. Reikher
[3]. Design and Development of a High Pressure Die Casting Technique for Manufacturing Heavy Vehicle Engine Components
[4]. Design and Validation of a Casting Die Priyanka Vispute#1 , Digambarchaudhari, Reeti Mukherjee.
[5]. Application of an Integrated CAD/CAE/CAM system for die casting dies
[6]. Prediction and Validation of shape distortations in the simulation of high pressure die casting
[7]. Computer Aided Engineering CAE simulation For the Design Optimization Of The Gate System On High Pressure Die Casting
Process.
[8]. Innovative Support System For Casting Defect Analysis- A Need Of Time
[9]. A Study On Joining Magnesium Alloy High Pressure Die Casting Components With Thread Forming Fasteners
[10]. Manufacturing Porous Ceramic Materials By Tape Casting

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