Types of Die Casting on basis of Pressure

1. Pressure Die Casting

2. Pressure Die Casting
• Pressure die casting is a quick, reliable and cost-effective
manufacturing process for production of high volume, metal
components that are net-shaped have tight tolerances.
• The pressure die casting process consists of injecting under
high pressure a molten metal alloy into a steel mold (or tool).
• This gets solidified rapidly (from milliseconds to a few
seconds) to form a net shaped component.

3. Types of Pressure Die Casting
High Pressure Die Casting
• Used for castings requiring tight
tolerance and detailed
geometry.
• High pressure die casting has
wider application
• Nearly 50% of all light alloy
casting production.
Low Pressure Die Casting
• Commonly used for larger and
non-critical parts.
• Accounts for about 20% of the
total production

4. Rotor die casting machine
• AUTOMATIC ALUMINIUM ROTOR DIE-
CASTING MACHINE ROTOR MAKING
MACHINE

5. Working Principle
• ROTOR DIE CASTING MACHINE_HD.mp4

6. Specification

7. Requirements for rotor die casting
1. Rotor lamination drawing
2. Rotor assemble drawing
3. Commutator drawing
4. Shaft drawing
5. Pressing position
6. Required productivity
7. Other technical requirement

8. COLD CHAMBER DIE CASTING
MACHINE
• Cold-chamber die casting is ideal for metals such as
aluminum which have a high melting point.
• During this process, metal is liquefied in a furnace at
extremely high temperatures and then ladled into a cold
chamber to be injected into the die.

9. Working principle

10. Working principle (Contd.,)
• During cold-chamber die casting, the molten charge, which
consists of more material than is required to fill the casting, is
ladled from the crucible into a shot sleeve where a
hydraulically operated plunger pushes the metal into the die.
• The extra material is used to force additional metal into the
die cavity to compensate for shrinkage, which takes place
during solidification.
• The main components of a cold-chamber die casting machine
are shown below. Injection pressure of over 10,000psi or
70,000KPa can be obtained from this type of machine.

11. Working principle (Contd.,)
• The die is closed and the
molten metal is ladled into
the cold-chamber shot sleeve.

12. Working principle (Contd.,)
• The plunger pushes the
molten metal into the die
cavity where it is held under
pressure until it solidifies.

13. Working principle (Contd.,)
• The die opens and the
plunger advances, to ensure
the casting remains in the
ejector die.

14. Working principle (Contd.,)
• Ejector pins push the casting
out of the ejector half of the
die and the plunger returns
to its original position.

15. 3000T Die Casting Machine, ZDC-
3000TCM

16. Features
Locking force: 3000Ton
Die height: 850-2000mm
Tie bar distance: 1700x1700mm
Max. weight of shot: 38.9kgf
Max. casting area: 4256~3242cm2
Horsepower required: 190KVA

17. Specifications

18. Specifications (Contd..)

19. Advantages
• High speed production can be achieved as the whole process
is completely automated.
• Possible to obtain fairly complex castings than that feasible
by gravity die casting due to the use of the movable cores.
• Very small thicknesses can be easily filled as the liquid metal
is injected under high pressure.

20. • Very good surface finish can be obtained &most of pressure
die castings can be directly electroplated without any further
processing.
• Closer dimensional tolerances & better mechanical properties
can be obtained compared to sand casting.
• Very economical for large scale production.
Advantages (Cont.)

21. Disadvantages
• Large capital investment is required to set up a pressure die
casting process.
• The die casting machines & tooling costs are very expensive.
• Cannot be used for large castings as the casting machine
capacity is limited.

22. • It is not suitable for all materials because of the limitations of
the die materials & the alloys used must have allow melting
point.
• High porosity is common & heat treatment is difficult.
Disadvantages (Contd..)

23. Application of Pressure Die Casting
• Automotive parts like wheels, blocks, cylinder heads,
manifolds etc.
• Aerospace castings.
• Electric motor housings.
• Kitchen ware such as pressure cooker.
• Cabinets for the electronics industry.
• General hardware appliances, pump parts, plumbing parts.