DIE CASTING DEPARTMENT
Mr. Vijay Kumar : Head of Die Casting department
Mr. Manoj Kumar : Manager (D.C Prod.)
Mr. Tarjender Singh : Manager (.P Prod.)
Mr. Deeraj gupta : !ssit. Manager (D.C Pord.)
Mr. C.P Saini : !ssit. Manager (D.C Prod.)
Mr. Parampa" : !ssit. Manager (.P Prod.)
QUALITY DEPARTMENT
Mr. #eeraj Pan$ha" : Manager
Mr. Vi%e& Singh : !ssit. Manager
Mr. !mandeep Pan$ha" : !ssit. Manager
CASTING
SHOP
Me"ting furna$e
Holding furnace
CASTING
Casting is pro$ess in 'hi$h mo"ten meta" (a"uminum) is poured in the mou"d to gi%e the
mo"ten meta" into desired shape ( si)e.
TYPES O CASTING
High Pressure Die $asting: High Pressure Die Casting pro%ides the shortest route
from mo"ten meta" to $omp"eted $omponent. *y inje$ting mo"ten meta" ('hether it
+e a"uminium die $asting or )in$ dies $asting) into a hardened too" stee" mou"d and
a""o'ing it to so"idify under pressure +efore eje$tion.
o' Pressure Die $asting: o' pressure $asting is a de%e"opment of the permanent
mou"d pro$ess, in 'hi$h the meta" is introdu$ed into the $hi"" mou"d from +e"o'. -as
pressure ho"ds the meta" in the die unti" it so"idifies.
.errous Casting: / 0n ferrous $asting iron +ased meta" are used "i&e stee", $ast iron,
tungestan et$.
#on .errous Casting: / 0n non ferrous $asting non iron +ased meta" are used "i&e
a"uminium, $opper, +rass et$.
0n 1amaha motors non ferrous $asting is done. !nd is made of a""oy of a"uminum
This produ$es "ight 'eight parts.
.irst of a"" the !"uminum a""oy ingot (1D22!S for D.C) are tested +y Quali!"
de#ar!$en! +y Spe$trometer.
SPECTROMETER TEST
This test is used to $he$& 3 of a""oy e"ements if not the ingot "ot is reje$ted.
!rgon gas is used for measuring the 3of a""oy e"ements.
0n 4pti$a" 5mission Spe$trometer spar& is produ$ed on the surfa$e of ingot &ept
on the +en$h inside.
!rgon gas produ$es +end 'idth of different si)e for different meta".
These +end 'idth is then $on%erted to $orresponding fre6uen$y 'hi$h is
$on%erted into 3 $omposition +y $omputer soft'are.
7 7
*!#D 80DTH .95:;5#C1 34. C4MP4S0T04# 0#-4T
% CHEMICAL COMPOSITION
Si : </2= Cr : .2 Ma>
.e : .?/.<@ P+ : .2Ma>
Cu : 2.@/A Sn : .2Ma>
Mn : .@ Ma> Ti : .2Ma>
Mg : .AMa> Ca : .BB@Ma>
Cn : .D/.<@ S+ : .2Ma>
#i : .@ Ma> !" : 9emaining
MELTING URNACE
.urna$e is the p"a$e 'here the !"uminum ingot is $on%erted into mo"ten state.
Put EB3 return and FB3 %irgin in the furna$e
8hen the temp. 9ea$hes ?@B deg mi>es the a""oy proper"y.
#o' spread $o%era"" on the meta" surfa$e proper"y.
9emo%e the dross and $"ean the meta" $omp"ete"y +e assured that !"uminum
shou"d not $ome out a"ong 'ith dross.
!dd degasser 'ith the he"p of perforated pot.
!fter fe' minutes, ta&e samp"e and send to SP5CT94 !* for $omposition
testing.
!fter %erifying the $omposition, send the meta" to ho"ding furna$e.
0n 1amaha Motors H41M5S1 H4D0#- .;9#!C5 are used of $apa$ity .@
T4# and 2.@ T4#.
The Ho"ymesy Ho"ding .urna$e are 'ide"y used for me"ting the non/ferrous
meta" "i&e a"uminum.
0t $onsists of a $y"inder made of stee".
The me"ting temp. ies form @@B/FBB
B
C.
CH490#5 Ta+"ets are added to remo%e f"u> "i&e paint ( greas, impurity.
H= -as remo%es a"" "eft impurity +y o>idi)e
GENERAL MACHINE CHARACTERISTICS&
2. ! ma$hine has a +ed on 'hi$h is mounted a fi> p"aten and a rear (thrust) p"aten.
=. Goining the p"aten is four tie +ars.
A. 4n fi> p"aten inje$tion system is mounted.
E. 4n rear (thrust) p"aten "o$&ing arm is mounted.
@. *et'een fi> and rear(thrust) p"atens is a mo%ing p"aten 'hi$h s"ides on the +ed of
the ma$hine and is guided +y four tie +ar
F. The mo%ing p"aten is atta$hed to the thrust p"aten and the "o$&ing me$hanism +y
me$hani$a" "ea%ers $a""ed T4--5S, 'hi$h $ause the mo%ing p"aten to mo%e as
re6uired.
?. Die ha"%es are mounted on fi> and mo%ing p"atens.
D. !fter "o$&ing the die, a $asting is made.
<. M!CH0#5 849KS 4# H1D9!;0C S1ST5MS.
URNACE
C4MP4#5#T 4. .;9#!C5
C'arging Door&(
The so"id materia" enters through $harging door into $harging f"oor and there it gets
$harged into the furna$e.
)ind *o+&(
!ir for $om+ustion is de"i%ered from +"o'er and enters a $ham+er $a""ed 8ind *o>.
Ta# Hole&(
0t is used for getting the mo"ten meta" form furna$e.
COM*USTION ,ONE
0n this )one fue" are +urnt ( o>ygen is $onsumed from the atmosphere. Heat is
generated in this )one.
MELTING ,ONE
0n this )one the meta" starts me"ting through to fue" of +ottom of the furna$e.
STAC- ,ONE
This )one e>ists on the top of the furna$e. 0t "ea%es a"" the gas from $om+ustion
$ham+er to the atmosphere.
[Link]
0ts $ontinuous operation.
o' $ost of operation.
5asy to operate.
Temp. Can +e $ontro""ed.
.94M H595 M4T!# M5T! 0S T!K5# *1 C9;C0*5, 8H0CH 0S
P95H5!T5D T4 95C50V5 M4T!# M5T!.!#D D0..595#T P94C5D;95S
!95 .4485D .49 48 ( H0-H P95SS;95 C!ST0#-.
HIGH PRESSURE DIES CASTING&
.4480#- 0S TH5 P94C5SS .48 D0!-9!M 4. H0-H P95SS;95 D05
C!ST0#-.
H(9T C!ST0#- P!-5 2, A, PH4T4ST!T5)
P;#-59 94D
Meta" is inje$ted in die the through shot s"ee%e 'ith the he"p of p"unger tip ( p"unger rod.
PLUNGER ROD
PLUNGER
WATER INLET
WATER OUTLET
O RING
Cu TUBE
!DD5
Meta" is poured in shot s"ee%e 'ith "adde".
SP9!159
! "ayer of "u+ri$ation oi" is made on die surfa$e 'ith the he"p of sprayer in 'hi$h
die $oat (air is used.
4P59!T0#- P!#5
To operate MI$ a pane" is pro%ided on MI$ side on 'hi$h %arious fun$tion s'it$hes fi>.
H($asting defe$ts)
H(s$an)
T95!TM5#T !.T59 C!ST0#-:/
!.T59 TH!T TH5 C!ST0#- 0S S5#D .49 T90MM0#- 49
.5TT0#- 8H595 -;#S !95 ;S5D T4 95M4V5 *;9 # 5JT9!
M5T! .94M C!ST0#-.
!.T59 TH5# TH5 C!ST0#- 0S S5#D T4 SH4T *!ST0#-:
Shorts of dia .5 ar! "#ast!d for $o%%#!.
B"asting means firing granu"e si)ed parti$"es on a pie$e of meta" for gi%ing
it a good finishing or matte finish, shot +"asting or grit +"asting is done to
$"ean the meta" after the pre%ious pro$ess.
D5*;990#-: / !fter then +ur is remo%ed n e>tra materia" is $ut.
Then fina""y it is $he$&ed and send to dispat$h or paint shop n
then from there it is send to ma$hine shop for further ma$hining
LO) PRESSURE DIE CASTING&(
The mo"ten meta" is &ept in Cru$i+"e 'hi$h $ontains e"ement for &eeping mo"ten
at re6uired temp. (?@B
B
C).
!fter then fo""o'ing steps are ta&en 'ith ma$hine of .P $asting.
.059 P!C5M5#T: / P"a$e the fi""er of a$$urate si)e.
*480#- !09:/*"o' of air on top as 'e"" on +ottom side remo%es the
meta".
P!C5M5#T 4. S!#D C495S:/P"a$e the in"et e>haust air ho"e,
$hainroom, B= $entre $ores in the $a%ity. C"osing the die $ores:/ $"ose the
dies front/+a$&(top/+ottom.
4P5#0#- 4. D05 C495S:/4pen a"" four side dies.
CH5CK0#- TH5 C495S: / Che$& the sand $ores of any +rea&age
espe$ia""y on +a$& side $a%ities and air ho"es $ores.
C4S0#- 4. S0D5 D05:/C"ose the "eft (right side die $a%ities.
*48 4. !09: / *"o' of air from $entre of $ore to'ards outside
+et'een $hains remo%es ($entre $ores.
C4S0#- 4. D05 C495S:/C"osing the +a$& Kfront dies pu$h the to auto
push +utton to start the auto start of the $y$"e ti"" the top die fit on the
+ottom die. P"a$e the $ore for ne>t shot. Che$& the $asting.
C495 K#4CK 4;T:/ Then $asting is send for remo%a" of e>tra materia" n $ore
remo%a" +y %i+rating guns,
H5!T T95!TM5#T:/Then $asting +eing of a"uminium is soft so made hard +y
heat treatment
TH5# C!ST0#- 0S T5ST5D .49 5!K!-5. # 0. 5!K 85D0#- 49
S!#D0#- 0S D4# 50. 95:;095D 49 95G5CT5D.
SH4T *!ST0#-: / short +"asting is done in same manner as a+o%e in high
pressure $asting.
.!T0#- 49 D5*;990#-: / De+urring is, to put it simp"y, a finishing method
used in industria" settings and manufa$turing en%ironments. Meta" is fre6uent"y
ma$hined using many pro$esses in order to $reate pie$es of spe$ifi$ shape and
si)e. .or e>amp"e, meta" may +e 'e"ded, mo"ded, $ast, trimmed, s"it or sheared.
These pro$edures often $reate ragged edges or protrusions. The raised parti$"es
and sha%ings that appear 'hen meta" +"an&s are ma$hined are referred to as +urrs,
and the pro$ess +y 'hi$h they are remo%ed is &no'n as de+urring.
9emo%a" of $hip et$ e>tra materia" is de+urring.
!4D0#5: / L!"odineL is a non/anodi$ prote$ti%e $oating. !"odine Ma&a 0ridite,
a&a Chromate Con%ersionN is a mi$ros$opi$ thin fi"m $ommon"y pres$ri+ed on
a"uminum to:
Pro%ide an 5>$e""ent surfa$e prep for paint
!id in Corrosion 9esistan$e
0mpose desired 5"e$tri$a" O9esistan$eO.
ST5PS:/
D5-95!S0#-
8!T5990#S5 2, =, A *1 !S;9. (A=A) !T @B/@@
B
C.
8!T59 90#S5 E, @.
H4T 8!T59 90#S5
H4T !09 D91
;#4!D.
TH5 C!ST0#- !.T59 TH0S H!S ! C4!T0#- PV59 0T 8H0CH
P95V5#TS 0T .94M 4J0D!T04# # 0#C95!SS5S P!0#T !..0#T1.
!.T59 TH0S C!ST0#- 0S 95!D1 .49 M!CH0#-. !#D 0S S5#D T4
M!CH0#5 SH4P.
CORE MA-ING/ TESTING SAND OR CORE&(
Cores are pie$es that are p"a$ed into $asting mou"ds to form interna" $a%ities of
the $asting, or to form e>tra se$tions of the mou"d for $astings that ha%e e>terna"
proje$tions or negati%e draft, 'hi$h, if in$"uded in the pattern, 'ou"d pre%ent the
pattern from +eing remo%ed from the mou"d. Mu"tip"e $ores may +e used in
$omp"e> $astings.
S!#D T5ST0#-:/
C4MP!CT V0*9!T0#- SH!K59P/ This is a ma$hine to &no' the si)e
of sand parti$"es n there e>a$t 6uantity in 2BB gm samp"e.
2BBgram samp"e is ta&en and feed on the top se$tion
this ma$hine has 2B se$tions. !nd at the end of 2B mint run of sha&er the
6uantity in gm is measured in ea$h se$tion or fi"ter
!...S:/ is $a"$u"ated +y doing fo""o'ing $a"$u"ation.
!.S Q (8eight in $ase !H2B R $ase *H=B R $ase CHAB R $ase DHEB R
$ase 5H@B R $ase .H?B R $ase -H2BB R $ase HH2EB R $ase 0H=BB R $ase
GHABB )I 2BB
!fter the sand is $he$& for its parti$"es $omposition it is $on%erted into +ri$&s on
Pie$e Ma&ing Ma$hine at =FB
B
C.
T9!#SV59S ST95#-TH T5ST0#-: / trans%erse "oad $apa$ity is tested then
'hi$h shou"d "ie in range =@B to A@B #I$m
=
.
0. C495 S!#D 0S .4;#D 4K TH5# S5#D T4 SH4P .49 C495
M!K0#-.
0# TH0S S!#D 0S .55D .49M T4P 0# C495 *4J, TH5# *548 P4;9S
0T 0#T4 TH5 D05 80TH 8!T59 # !09 P95SS;95 4. .E@MPa.
!fter =/@ mint of $y$"e $ore is made n then is fi"ed to remo%e +urr, and send to
"o' pressure $asting ma$hine.
