THE DIE CASTING MACHINES

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Classification Of Die Casting Machines

Based on Placement of injection chamber or metal feeding system

 Hot Chamber Die Casting Machine

 Cold Chamber Die Casting Machine

The Cold Chamber Die Casting Machine is classified as,

a. Horizontal Cold Chamber Die Casting Machine

b. Vertical Cold Chamber Die Casting Machine

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Classification Of Die Casting Machines
Based on Placement of injection chamber or metal feeding system

Hot Chamber M/C

Loading chamber: Goose Neck

Cold Chamber M/C

Loading chamber Shot Cylinder
or Shot Sleeve

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Hot Chamber Die Casting Machine
Used for alloys with low melting temperatures
1. Zn
2. Sn
3. Pb
Temperatures required to melt other alloys would
damage pump, in direct contact with molten metal

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Hot Chamber Die Casting Machine

Metal contained in open holding pot, placed into furnace where it melts to necessary
temperature

Molten metal flows into shot chamber through inlet & plunger, powered by hydraulic
pressure, forcing molten metal through gooseneck channel into die

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Hot Chamber Die Casting Machine

Typical injection pressures for a hot chamber die casting machine

are between 1000 and 5000 psi (7 – 35 MPa)

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Cold Chamber Die Casting Machine

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Cold Chamber Die Casting Machine
Metal contained in open holding pot, placed into furnace where
it melts to necessary temperature

Holding pot kept separately from the die casting machine.

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Cold Chamber Die Casting Machine

 Plunger powered by hydraulic cylinder, forcing molten metal through shot

chamber - into the injection sleeve of the die.

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Cold Chamber Die Casting Machine

Typical injection pressures for cold chamber die casting machine –

between 2000 and 20000 psi

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Cold Chamber Die Casting Machine

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Mechanical Systems of Die Casting Machines

1. Clamp System

2. Ejection System

3. Metal Injection i.e. Shot System

4. Machine Control System

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Mechanical Systems of Die Casting Machines

Functions of Clamp System

•Open & close die on straight line keeping parting surfaces parallel

•Provide clamping force

•Hydraulic power for moving cores in die

•Hydraulic / mechanical actuation of ejection

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Three Functions of The Shot System

•Provide plunger velocity

•Provide a position to change the plunger velocity

•Provide a pressure or force.

HPDC - MACHINE
PDC MACHINE
 HPDC MACHINE – MAIN PARTS FOR INJECTION

SHOT SLEEVE
Material : steel SKD61/H13
Hardness/Density : 45-50, 55-65HRC

PLUNGER TIP
Generally made from
a high-temperature tool
steel -SKD-61 or
beryllium copper.

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HPDC MACHINE – MAIN PARTS FOR INJECTION

PLUNGER FOR HOT CHAMBER

DIE CASTING M/C

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HPDC MACHINE – MAIN PARTS FOR INJECTION

Material : H13, CR45

Hardness : 25HRC

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HPDC MACHINE – MAIN PARTS FOR INJECTION

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HPDC MACHINE – MAIN PARTS FOR INJECTION

Accumulators
Intensifier
Tie bars.

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 HPDC MACHINE – MAIN PARTS FOR INJECTION

Die Casting Terminology. Accumulator: A pressure vessel in a hydraulic system in which

hydraulic fluid is stored under nitrogen gas pressure, serving as a rapid source of hydraulic

power when needed (fast shot, die close and core operations).

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Hydraulic Accumulator

 A hydraulic accumulator is an energy storage device.

 It pressure storage reservoir in which non-compressible hydraulic fluid is
held under pressure by an external source.
 That external source can be a spring, a raised weight, or compressed gas

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HPDC MACHINE – MAIN PARTS FOR INJECTION
The Accumulator:

In order to keep injection system performing well,

Injection line pressures must be kept constant;

 Valve settings & gas pressures must be checked regularly.

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Hydraulic Accumulator

Why nitrogen gas is used in hydraulic cylinder?

Nitrogen is used in hydraulic accumulators because it is an inert gas

that does not react with other materials in the system.

Additionally, it is relatively inexpensive and readily available.

Nitrogen also has a relatively low solubility in liquids, making it an

effective means of pressurizing a hydraulic accumulator.

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Hydraulic Accumulator

What are the benefits of using nitrogen over other

gases?
There are several benefits to using nitrogen over other gases in hydraulic accumulators:

1. Inertness: Nitrogen is an inert gas, meaning it does not react with other materials in the
system. This reduces the risk of corrosion or contamination of the hydraulic fluid.

2. Low solubility: Nitrogen has a relatively low solubility in hydraulic fluids, which means it
does not dissolve into the fluid and cause problems such as foaming or reduced lubrication.

3. High compressibility: Nitrogen has a high compressibility, which allows it to store a large
amount of energy in a small volume. This makes it an effective means of providing a
cushion of pressurized gas that can be used to absorb shocks or store energy.

4. Safety: Nitrogen is a non-flammable and non-toxic gas, which makes it a safe choice for
use in hydraulic systems.

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Hydraulic: Intensifier

Intensification is a controlled increase of the metal pressure at the end of the die
cast "shot" immediately following impact or "cavity full".

It is accomplished by increasing the hydraulic pressure above the "nominal"

pressure by one of the following means:

 Shifting to alternate relief valves,

 Opening high pressure accumulators,
 Operating "multipliers" also called cylinder intensifiers

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Hydraulic: Intensifier

Purpose:
• To reduce "gas and shrinkage porosity" to its minimum level

• Intensification does not eliminate porosity, merely compresses

it to an acceptable level.
•Hydraulic device that increases hydraulic fluid pressure at end of injection
stroke
•This high pressure dramatically increases the metal pressure to:

•Squeeze additional metal into the die

cavity as the metal shrinks

•Further compress trapped gases

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Tie Bars.

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 Tie Bars.
Tie bars serve to hold the machine together

Attached to the front plate & back plate with nuts on both side

Travelling plate attached to rear plate with linkage & suitable

guide rails

Tie bars are sized to provide the proper amount of stretch at

clamping load

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Actual applied load on tie bar must not exceed 110% of the rated
tonnage (different manufacturers have different recommendations)

Example, each tie bar on 800 tones machine has rated loading - 200
tonnes.

 So each tie bar should ever be loaded to over 220 tones.

 Properly operated within this limit the tie bar will not break

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COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING

DIE CASTING INJECTION MOULD

• Die casting - manufacturing process that involves Injection moulding is similar to die casting, with
casting metal under extreme force. The process significant difference being the material used. It uses
involves heating metals into their molten form. plastics and other polymers. It is perhaps the most
Then, the liquefied metal is casted under high- common manufacturing process adopted for
pressure conditions. fabricating plastics.

Raw material –is essentially non-ferrous metals Polymers commonly used are polyethylene, ABS,
nylon polypropylene, PS, etc.
Aluminium, Zinc, Copper, Brass Magnesium, Lead
& Tin
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING

DIE CASTING
INJECTION MOULD
• Die casting involves heating metals in furnace & melted Injection molding process involves melting plastics in barrel
to required temperature. This molten metal is transferred of injection molding machine. Melted plastics are passed
to shot sleeve of die casting machine & forced into die by into the mold cavity in this molten state, pushed by screw
means of plunger under high pressure. M M cools &
During injection molding process, plastic resin cools and
solidifies taking shape of die used
solidifies, taking form of mold used. Therefore, you need an
• Suitable for manufacturing geometrically complex parts. injection molding machine, plastic material, and a mold to
Equipment needed for the method includes a die casting carry out this process.
machine with a built-in or separate furnace, where the
raw material is heated to liquid
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING
DIE CASTING
INJECTION MOULD
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING
DIE CASTING
INJECTION MOULD

Insert Material Insert Material

Hot die steel : H13 – T35Cr5MoV1
Hot die steel : H13 – T35Cr5MoV1
P20
UHB – ORVAR - SUPREME
IMPAX – 718S – SUPREME & IMPAX 718 H –
ASSAB – 8407 - SUPREME These are modified P20 steel
QR – 90 SUPREME – Modified version of H13 ASSAB – 8407 – SUPREME
Stavax - S136 pre hardened steel.
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING
DIE CASTING
INJECTION MOULD
INJECTION PRESSURE INJECTION PRESSURE

Injection pressures for a hot chamber die Injection pressures for Injection molding
casting machine are between 1000 and 5000 psi machine between 70 to 112 Mpa or 715kg/cm²
(7 – 35 MPa) or 70kg/cm² to 351kg/cm² to 1142kg/cm²
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING
DIE CASTING
INJECTION MOULD
Process Cycle
Process Cycle

1. Mold preparation
2. Filling
3. Ejection
4. De-gating
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING
DIE CASTING
ADVANTAGES
INJECTION MOULD ADVANTAGES

• Accurate shape and tighter tolerance • Plastic injection molded parts are cheaper than
• Stronger designs with a more stable structure metal parts
• More stable and heat resistant than injection • Flexibility to accommodate various plastic
molding designs materials
• Fully resistant to UV rays and weather changes • Fillers can be injected to increase the strength of
the material
• Ideal for complex designs and shapes
• The pieces created with plastic injection molds
are good electrical insulators
COMPARISION BETWEEN DIE CASTING & INJECTION
MOULDING

WHICH IS BETTER?
While evaluating the difference between die
casting and injection molding, you must know the
materials required for the products, tooling cost,
and timeline. Both methods come with their
qualities and limitations. Choose the right
manufacturer so that the process gets more
profitable.