Global Journal of Researches in Engineering: A

Mechanical and Mechanics Engineering

Design and Analysis of Pressure Die Casting Die for

Automobile Component
By Y. Abdulfatah Abdu, T. M. Shafii, K. K. Dubey & Prof U. K. Gupta
Kampala International University
Abstract- This paper describes one of the ways for the design and analysis of the die of the
technology of pressure die casting process. This paper is to maintain the closest tolerances,
reduced all machining and can make the process the optimum choice for small volume
production as well. Such exact and light parts are one of the premises for the automobile
industry, parts with a lightweight design and exact products directly influence the fuel
consumption of an automobile and consequently the users are satisfied. These requirements are
met using aluminium alloys, high strength steels and fibre reinforced for the structural
components. In this work a die was designed based on factors to be considered in the critical
dimensions and filling analysis is used to determine the size, location and to ensure a complete
and balanced filling of the part while designing for proper runner system. This work uses different
software such as Solid Works, 3-Diamesional Flow, Pro-Engineer respectively. The design,
analysis, and testing work are carried at Automotive Private Limited, Gurgaon, Haryana.
Keywords: pressure die casting, automobile industry, aluminium alloys, solid works, 3-diamensional flow,
pro-engineer.

GJRE-A Classification : FOR Code: 091399

DesignandAnalysisofPressureDieCastingDieforAutomobileComponent
Strictly as per the compliance and regulations of:

© 2016. Y. Abdulfatah Abdu, T. M. Shafii, K. K. Dubey & Prof U. K. Gupta. This is a research/review paper, distributed under the
terms of the Creative Commons Attribution-Noncommercial 3.0 Unported License http://creativecommons.org/licenses/by-
nc/3.0/), permitting all non commercial use, distribution, and reproduction inany medium, provided the original work is properly
cited.
 Design and Analysis of Pressure Die Casting Die for Automobile Component

designing the core and cavity after adding material the core is the male part of the die and forms internal
shrinkage value to the component geometry. The core shape of the component, and the cavity is the female
and cavity are the parts of the die that provide the part of the die it forms the external shape of the
internal and external shape of the component in which component.
Table 1: Component Details
COMPONENT NAME CYLINDER HEAD COVER
Quantity required 20,000 per month
Material ADC 12
Density 2.7 g/cm3

Shrinkage 0.5%
Volume of the component 217.553cm3 = 217,553 mm3
Weight of the component 330.0 g
2016

Projected area 7900.0 mm2

Year

Draft angle 5 degrees

Function Closing the top of the cylinder head
2
a) Methods Number of component per shot = 4000/ (3x960)
Global Journal of Researches in Engineering ( A ) Volume XVI Issue III Version I

These are the following steps used while = 1.0

designing the component: Hence we have to use a single cavity die.
1. The component is identified and all relevant
information required for design is collected.  Tonnage Requirement
2. The number of cavities is decided based on yearly Projected area of the component = 7900mm2
requirement. Projected area including overflows and feed system
3. Identical components are grouped in the unit die. = 7900 x 1.5
4. The design calculations are done to find the
suitable machine = 11850mm2
5. Details of machine are collected Specific Injection pressure = 600 kgf/cm2 = 600 x 10-2
6. Component parting line was being decided based kgf/ mm2
on part geometry, ejection, and aesthetics. Total force acting on the die plate = Projected
7. The runner, gate dimensions and type are area x Injection Pressure
selected based on the part geometry, cavity = 7900x 600 x 10-2
location.
8. The type of ejection will be selected based on = 47400 kgf
aesthetics, parting line location, part geometry,
etc. = 47.4 T
9. The amount of heat being injected into the die will
be calculated and the suitable cooling system is Considering machine efficiency of 80%, Locking
provided. tonnage required = 47.4 x 1.2
10. 3-Diamensional modelling of the die, gate design, = 57T
and core cavity extraction will be conducted using Hence according to locking tonnage ranges, we can
Solidworks software by considering shrinkage of select 80 T machine.
material.  Shot Weight
11. Assembly and part drawings are to be made in 2- Component volume = 217,553 mm3
Diamensional using Solidworks software. Volume of component + Volume of overflow and feed
12. Part drawings will be carefully checked at the end system (excluding Biscuit)
and approved.
= 217,553 x 1.2
i. Design Calculations
 Number of Cavities = 261,063.6 mm3
Production required per month: 20,000 per month (Die Actual shot volume = 261,063.6 + πd2 h/4
will be loading only for 5days) Where h is biscuit thickness, and d is the plunger
Number of component per day: 4000 diameter Stroke length for 80 T machine = 250 mm
Number of shifts per day: 3 Effective stroke length = 250 – biscuit thickness
Number of shots per shift = 8 x 60 / Cycle time.
= 250 – 25
= 8 x 60 /0.5
= 960 shots = 225 mm

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 Design and Analysis of Pressure Die Casting Die for Automobile Component

Assume fill ratio = 0.50  Dry Shot Flow Rate

Volume delivered by machine = (Plunger Dia)2 x π x DSV/4
= π d2 x (225/4) x 0.5 = (55)2 x π x 4.5 x 103/4
261,063.6 + πd2 x (225/4) 0.5 = πd2 x (225/4) = 10,692,618.75 mm3/sec
261,063.6 = 88.40625 d2 = 10,692.62 cm3/sec
d2 = 2953 mm2  Max. Metal Pressure (lines)
d = 54.3 mm = Density x Gv2
Available plunger sizes in 80 T machines are 35, 45, and 2g x Cd2
55 mm Hence we can select 55 mm plunger tip Where
Shot volume = 261,063.6 +πd2 h/4 Gv is maximum gate velocity = 400cm/s
= 261,063.6 +π (54.3)2 x 25/4 (recommended)
= 261,063.6 +π (54.3)2 x 25/4 g is acceleration due to gravity = 981 cm/sec

2016
= 261,063.6 + 57,900.97 Cd is coefficient of discharge = 0.4
= 318,964.57 mm3 = 2.58 x (4000)2

Year
Shot weight = Shot volume x density 2 x 981 x (0.4)2
= 131,498.5 gf/cm2
= 318,964.57 x 2.7 x 10-3 3
= 131.5 kgf/cm2
= 861.2g = 0.9kg
 Min. Metal Pressure (lines)

Global Journal of Researches in Engineering ( A ) Volume XVI Issue III Version I

 Fill Ratio = Density x Gv2
2g x Cd2
Fill ratio = Shot sleeve volume Gv is the minimum gate velocity = 2500cm/s (NADCA
Metal volume
recommended)
318,964.57 = π (55)2 x (225/4) x y y = 0.6 = 2.58 x (2500)2
This value for fill ratio is acceptable for the process 2 x 981 x (0.4)2
 Fill Time = 51,366.6 gf/cm2
Fill Time = K[Ti – Tf + sz] T = 51.4 kgf/cm2
[ Tf – Td ]  Flow rate (fill rate), Q
Where (A theoretical minimum fill rate that can be used to
k empirically derived constant = 0.0346 produce the highest quality casting)
Ti, Temperature of molten metal as it enters the die = = Volume (casting and overflow) of metal (passing)
6500c through Gate /Fill time
Tf, Minimum flow temperature of metal = 5700c = 261,063.6 / 0.054
Td, Temperature of die cavity surface just before the = 4,834,511.111 mm3 /sec
metal enters = 2000c  Runner Design
S, percent solid fraction allowable in the metal at the end Runner Area (A) = 1.3Ag
of filling = 30% = 69 x 1.3
Z, Units conversion factor = 3.8
T, casting wall thickness = 3 mm = 86.7 mm2
Depth (D) = √(Α/0.8)
t = 0.0346[650 – 570 + 30 x 3.8] x3
[570 – 200] = 10.42mm
= 0.054 second Width = 2D = 20.84 m
= 54 milli seconds P-Q2 GRAPH
ii. PQ2 Calculations
Maximum (Hydraulic) Accumulator Pressure
= 150kgf/cm2
Diameter of (hydraulic) cylinder = 130 mm
Plunger diameter = 55 mm
Dry Shot Velocity (DSV) = 4.5 m/sec
 Maximum Static Metal Pressure
2
= MAP x (Cylinder Dia)2
(Plunger Dia)
= 150 x (130)2/(55)2

= 838.02kgf/cm2

© 2016 Global Journals Inc. (US)

 Design and Analysis of Pressure Die Casting Die for Automobile Component
2016 Year

4
Global Journal of Researches in Engineering ( A ) Volume XVI Issue III Version I

FLOW RATE Q (cm3/s)

Figure 2.1 : P-Q2 Diagram

From PQ2 graph,

P = 91.5 kgf/ cm2
Q = 7,255.7 cm3/sec
Therefore Ag = Q/ Cd√(p*2g/ρ)
= 7255.7/0.4 √(91.5x2x981/2.58)
= 0.6877 cm2
= 69 mm2
Therefore area of the gate = 69 mm2
Gate thickness = 3mm (will produce atomization)
Gate length hence = 23mm

iii. Cooling Calculation

Heat input = hGn Heat accumulated = 12,267 x 50/100
h is the heat factor = 145 Kcal/kg for Aluminum
n is the number of shots = 120 per hour = 6,133.5 kcal/hr
G is weight of casting, overflow and feed system Heat removing capacity = 35 kcal/hr
= 705g
= 0.705kg Length of cooling line = 6,133.5/35
Therefore Heat input = 145 x 0.705 x 120 = 175 mm
= 12,267 kcal/hr
50 % of heat is lost by convection to atmosphere and by
spray cooling

© 2016 Global Journals Inc. (US)

Design and Analysis of Pressure Die Casting Die for Automobile Component

2016 Year
5

Global Journal of Researches in Engineering ( A ) Volume XVI Issue III Version I

Figure 2.1.1 : Core Insert Figure 2.1.2 : Cavity Insert

Figure 2.1.3 : Tool Cavity & Core Assembly

© 2016 Global Journals Inc. (US)

 Design and Analysis of Pressure Die Casting Die for Automobile Component
2016 Year

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Global Journal of Researches in Engineering ( A ) Volume XVI Issue III Version I

Figure 2.1.4 : Assembled Die Tool

III. Analysis while casting. The geometrical, structural, dimensional

and superficial requests are considered as a waste if the
A comprehensive analysis of each factor casting which doesn't fulfil the factors to be considered.
entering in the die casting process is needed to be done In this case, a short with vertical and horizontal part ribs
since each factor is susceptible to affect the ready arrangement was considered in which the 3Dflow
casting in a negative way. The die casting technology behaviours was analysed. The following results at the
makes the thin-walled castings having a high different filling time were observed when the process
dimensional and geometrical precision. These are to started.
handle the whole die casting process to control all
aspect associated with the process to prevent wastage

Figure 3.01 : Vertical Arrangements of Part Figure 3.02 : Horizontal Arrangements of Part

© 2016 Global Journals Inc. (US)

 Design and Analysis of Pressure Die Casting Die for Automobile Component

IV. Results and Discussion motion of the plunger, the shot sleeve dimensions and
the initial amount of metal in the sleeve all affect the
The process started at initial for both cases and types of waves which are created during the process.
terminated at 3.810 and 4.214 seconds for vertical The results summary of the tool design parameters
arrangement and a horizontal one. The analysis shows which are the multiple functions of other design
that the air porosity defect rate is more in the vertical parameters upon which the design was made in Table 2
arrangement than the horizontal arrangement. The below.
outstanding volume of the shot sleeve is filled with air.
Both design and analysis research shows that the
Table 2 : Results Summary
NO. OF CAVITIES 1

TONNAGE REQUIREMENT 80 T

SHOT WEIGHT 0.9kg

FILL RATIO 0.6

FILL TIME 54 milliseconds

MAX. STATIC PRESSURE 838.02kgf/cm2

DRY SHOT FLOW RATE 10,692.62 cm3/sec

MAX. METAL PRESSURE 131.5 kgf/cm2

MIN. METAL PRESSURE 51.4 kgf/cm2

FLOW RATE 4,834.5 cm3/sec

METAL PRESSURE (P) P = 91.5 kgf/ cm2

FLOW RATE (Q) Q = 7,255.7 cm3/sec

GATE AREA 69 mm2

GATE LENTH 23mm

RUNNER SIZE L=86.7 mm2, D= 10.42mm, W= 20.84 mm