Die Casting - 3

Institute for Design of Electrical Measuring Instruments, Mumbai – 22.
121
Fig. 12.25 Single cavity die casting die for Cover Mission - Kinetic scooter part.
Designed to suit cold-chamber HMT 180 T M/c.
with multilevel parting line (see next page)
Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Institute for Design of Electrical Measuring Instruments, Mumbai – 22. 122
3D Model of Cavity block – Fixed side made by CNC machining
Fig. 12.26 . 3D Model of Core block – Movable side made by CNC machining
Single cavity die casting die for Cover Mission – Kinetic

Fig. 12.27 Two cavities die casting die for LPG Regulator Cover-Jumbo.

Photograph of die casting die for LPG Regulator Cover-Jumbo.
Fig. 12.28 Photograph of die casting part for LPG Regulator Cover-Jumbo

Fig. 12.29 Two cavity die casting die for Limit Switch Housing – ESSEN DEINKI
Designed to suit cold-chamber HMT 120 M/c. with sliding cores mechanism.

Fig. 12.30 Single cavity die casting die for Manifold – PILOT spray gun part.
Designed to suit cold chamber HMT 180 T M/c.
With multiple sliding cores (see next page)

3D Model of Manifold – PILOT spray gun
Fig. 12.31 3D Model of Cavity block – Movable side

Made by CNC machining for Single cavity die casting die for
Manifold – PILOT spray gun

Fig. 12.32 Single cavity die casting die for Fr. Wheel Hub - Kinetic scooter part.

Fig. 12.33 Eckwinkel 90 – Export item

Fig. 12.34 Four cavity die casting die for Eckwinkel 90 – Export item

3D Model of Manifold HVLP – 06 PILOT spray gun
Fig. 12.35 3D Model of Cavity block – Movable side

Manifold HVLP – 06 PILOT spray gun

Fig. 12.36 Single cavity die casting die for Manifold Pilot HVLP-06 – Spray Gun item

Fig. 12.37 3D Model of Cavity block – Movable side and Slides

Pacman – Export item

Fig. 12.38 Two cavity die casting die for Pacman – Export item
Designed to suit Hot-chamber M/c.

Motor Housing
M/s. Crompton Greaves
Fig. 12.39 Motor Cover

Fig. 12.40 Family die casting die for Motor Housing and Cover

Fig. 12.41 Family die casting die for Terminal Block – M/s. Crompton Greaves
Fig. 12.42 Two cavity die casting die for Piston Plate – M/s. Larson & Toubro

Fig. 12.43 Family die casting die for Terminal Block – M/s. Crompton Greaves

Chapter 13
Model Questions on Die Casting Dies
1) What is Pressure Die Casting?

2) What is hot chamber system?
3) What is cold chamber system?
4) What are the advantages of die casting process?
5) What are the advantages with cold Chamber machines?
6) What are the disadvantages with cold chamber machines?
7) What are the advantages with hot chamber machines?
8) What are the disadvantages with hot chamber machines?
9) How the die locking mechanism systems works in die casting machine?
10) How ejection Systems works in die casting machine?
11) What are the parameters are considered while selecting of die casting machine?
12) What is the purpose of knockout system in die casting machine?
13) What is meant by slides in die casting dies?
14) What is meant by runners and gates in die casting dies?
15) What is meant by vents in die casting dies?
16) What application of overflow in die casting dies?
17) Why cooling is required in die casting dies?
18) When single cavity die-casting dies are used?
19) What is the multiple cavity die casting die?
20) What is meant by family die casting dies?
21) What are the parameters to be considered during die design of die casting dies?
22) What shrinkage allowance considered for aluminum and zinc alloys and Why?
23) Why draft is needed in die cavity and cores?
24) How the parting line is considered in die casting die?
25) Give description on slides.
26) Give description on cores.
27) Write short note on ejection?
28) How gating system is useful in die casting dies?
29) Give values of gate thick nesses for aluminum and zinc die cast parts considering
class of thickness as very thin, thin, medium and thick?
30) Give Locking force formula?

31) Give ratio of width to depth for runner cross section view.
32) Give short note of bents.
33) Where overflows are required?
34) Which material to be used for core & cavity housing in die casting dies?
35) Which material to be used for cavity and core die block, die inserts, core pin,
spreader, runner blocks etc.
36) Give details of different materials and their harnesses used in die-casting?
37) Give description on Standard moulds units and its advantages in die casting dies?
38) Give details of cycle time in die-casting?
39) Give names of casting defect in die-casting?
40) What is ‘blisters’ in die cast defect and how it can be prevented?
41) What is die soldering in die-casting and how it can be prevented?
42) What is ‘cold shuts’ in die-casting and how it can be prevented?

APPENDIX
DESIGN DATA
1) Roughness Chart.
2) Hole Base Tolerance System Chart.
3) Shaft Base Tolerance System Chart.
4) Standard Threads Form.
5) Standard Screws sizes and accessories.
6) Die Casting Machine Details.
a) HMT / BUHLER H – 50
b) HMT DC – 60 / 80
c) HMT DC – 120
d) HMT H– 160 – D
e) HMT H – 250 – D2
f) HMT H – 400 – D2
g) HMT H – 660 – D
h) Hot Chamber M/c. Z – 160 – d2























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Institute for Design of Electrical Measuring Instruments, Mumbai – 22.

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

3D Model of Cavity block – Fixed side made by CNC machining

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Photograph of die casting die for LPG Regulator Cover-Jumbo.

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

3D Model of Manifold – PILOT spray gun

Fig. 12.31 3D Model of Cavity block – Movable side

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Fig. 12.33 Eckwinkel 90 – Export item

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

3D Model of Manifold HVLP – 06 PILOT spray gun

Fig. 12.35 3D Model of Cavity block – Movable side

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Fig. 12.37 3D Model of Cavity block – Movable side and Slides

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Fig. 12.39 Motor Cover

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

1) What is Pressure Die Casting?

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

2) Hole Base Tolerance System Chart.

3) Shaft Base Tolerance System Chart.

4) Standard Threads Form.

5) Standard Screws sizes and accessories.

6) Die Casting Machine Details.

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

Die Casting Dies: Notes compiled by S. V. RASAL – Principal Director

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