Die Casting Engineering

Die Casting Engineering
A Hydraulic, Thermal, and Mechanical Process
Bill Andresen
Contents
Preface iii
About the Author v
Introduction ix

1. Terms Used in Die Casting 1
2. Product Design . 21
3. The Die Casting Machine . 69
4. Casting Metallurgy 105
5. Metal Handling . 139
6. Concepts of Cavity Fill . 175
7. Metal Feed System . 185
8. Process Control . 209
   vii9. A Thermal Process . 237
9. Designing the Value Stream . 263
10. Die Materials . 289
11. Mechanical Die Design . 305
12. Die Set Up Techniques . 339
13. Die and Plunger Lubrication 353
14. Safety . 365
    References 375
    Index 37
    Index
    APQP, advanced product
    quality planning, 235
    Air in the cavity, 203
    core slides and
    ejector pins, 203
    Allowance for shrinkage, 325
    shrink factor, 326
    Angle pin, 329
    core movement, 329
    Atomized mist, 182
    Base metal, 239
    Basic linear tolerances, 50
    Biscuit thickness
    consistency, 210
    Brinell system, 2
    Cast shape, 180
    Casting cycle, 4
    Casting defects, 54
    Casting quality, 54
    Cavitation, 133
    small pits, 133
    Cavity fill, 6
    Cavity fill time, 177, 202
    fill pattern, 178
    gate area, 202
    gate speed, 202
    Cavity insert size, 318
    Cavity orientation, 318
    Cavity prefill, 180
    Center gating, 327
    Chisel gate, 196
    Cleanliness, 89
    die casting operation, 89
    Cold chamber process, 225
    Cold shut defects, 177
    poor fill, 270
    porosity, defects, 186
    Conductor, 242
    copper, 243
    Constant area sprue, 187
    male post and female
    bushing, 187
    379Constant velocity mode, 212
    Control charts, 266
    Control lines, 266
    lower control limit, 266
    upper control limit, 266
    Core pulls, 309, 329
    Corundum, 157
    dense form of aluminum
    oxide, 157
    Cost justification, 307
    Creep or stress corrosion
    cracking, 47
    Critical design feature, 44
    Critical temperatures, 107
    Crystal or grain, 109
    Cylinder intensifiers, 210
    Degree of complexity, 23
    Dendrite, 113
    Dendrite fingers, 114
    arms, 114
    Design characteristics, 143
    Die and plunger lubricants, 353
    release agents, 353
    Die blow, 26
    degree of difficulty, 26
    Die casting alloys, 239
    Die casting defects, 263
    Die casting engineer, 40
    best casting design, 40
    good die caster, 40
    Die casting machines, 73
    cold-chambered machines, 74
    hot-chambered machines, 74
    Die castings, 105, 108
    aluminum, magnesium, zinc,
    lead or tin, 105
    dense structure, 108
    fine grain size, 108
    superior mechanical
    properties, 108
    Die casting suppliers, 235
    Die checking, 290
    die spray duration, 290
    Die configuration, 309
    Die design, 25
    die halves, 25
    Die height adjustment, 84
    loosening tie bar nuts, 84
    tightening tie bar nuts, 84
    Die layout, 316
    die half, 316
    Die life, 300
    ion nitriding, ball peening,
    rocklinizing, solventing, 300
    Die material costs, 186
    Die materials, 289
    air, oil, or water hardened, 289
    mild steel alloys, 289
    Die pitting, 201
    Die preheating, 343
    Draft allowance, 52
    Draft angles, 327
    Dross, 160
    Economic dimensions, 63
    Ejection systems, 95
    bump bar system, 95
    hydraulic system, 95
    Electrical discharge
    machining, 293
    Electrodeposition, 8
    Electroplating, 3
    Emulsion, 357
    European die caster, 5
    Eutectic, 115
    Eutectic or lowest melting
    point, 239
    Excessive flash, 210
    Expansion, 131
    Failure mechanism, 291
    gross cracking, 291
    heat checking, 291
    Fast shot plunger velocity, 309
    Fill strategy, 318
    First shot success, 32
    Fit tolerances, 218
    380 Index
    5935-4 Andresen Ch00 R3 101504Flow control valve, 87
    velocity of movement, 87
    Fluidity of the casting alloy, 39
    designing wall thickness, 39
    Furnace charts, 300
    Galvanic corrosion, 48
    electromotive scale, 48
    Gate design, 193
    Gate speed, 182
    serious erosion, 182
    turbulence, 182
    Gating and venting, 306
    Geometric tolerances, 24
    Geometrical shape, 55
    boomerang shape, 56
    box shape, 55
    flat plate, 55
    hat shape, 55
    Gravity feed, 186
    Gross distortion, 47
    Hard spots, 269
    Heat checking, 289
    dimensional expansion, 290
    Heat depressions, sinks, 272
    Heat exchanger, 240
    Heat of fusion, 107
    Heat transfer, 155
    radiation, convection,
    conduction, 155
    Heat transfer medium, 241
    oil, 241
    water, 241
    Heavy walls, 60
    thin ribs, 60
    High pressure die castings, 109
    Hot chamber machines, 96
    casting zinc and magnesium, 96
    low temperature alloys,
    lead, 96
    Hot chamber process, 225
    Hydraulic pumps, 87
    high pressure=low volume
    configuration, 87
    low pressure=high volume
    configuration, 87
    Hydrogen in liquid aluminum
    alloys, 157
    density, reduced pressure
    hydrogen probes, 157
    testing, vacuum fusion,
    Hypereutectic aluminium–
    silicon alloy, 122, 390
    Ideal runner system, 192
    IGES (international graphics
    exchange system), 62
    Immersion tube burners, 148
    melting zinc, 148
    Implosion, 134, 200
    die pitting, 134
    Insert, 58
    Interlocking cores, 57
    broken die component, 58
    heroic die maintenance, 57
    Interlocking core arrangement, 58
    Internal defects, 268
    foreign inclusions, 268
    Latent heat of fusion, 115, 137
    Lean technology, 264
    value, value steam,
    flow, pull, perfection, 264
    Leidenfrost phenomenon, 359
    Lettering or any form of artwork, 61
    raised lettering, 61
    a mating component, 61
    Limit switches, 91
    activation and=or
    deactivation of solenoid
    valves, 91, 92
    position of machine
    component, 91
    Index 381
    5935-4 Andresen Ch00 R3 102604Liquid metal containers,
    liquid metal treatments,
    heat sources, thermal
    controls, 141
    Liquid specific heat, 137
    Locking force, 209
    Machine base, 77
    stationary and moving
    parts, 77
    Machine clamping force, 318
    die retainers, 319
    ejector rails, 319
    Machine locking force, 310
    Machining, 292
    drilling, 292
    milling, 292
    Machining stock, 52
    Maintenance and interior
    cleaning, 154
    Maintenance of automated
    equipment, 366
    Manufacture of die castings, 140
    Martinsite, 297
    heat energy, 140
    labor, 140
    metal, 140
    Massive chill plug, 203
    Master shot profile, 236
    Maximum fill time, 227
    net shape of the cavity, 227
    Maximum material condition, 46
    Metal feed system, 187
    Metal fill pattern, 333
    Metal handling, 366
    Melting loss, 133
    Mid area, 194
    Minimum process control, 235
    Motorized die height
    adjustment, 86
    Movement between planes, 112
    twinning mechanism, 112
    Natural air venting, 175
    Near net shape, 42
    North American die casters, 5
    Occupational safety and health
    administration (OSHA), 366
    Operating window (WIN), 229
    dry shot capability, 229
    machine line, 229
    restriction lines, 229
    Overflows, 201
    ejector pin marks, 201
    false ejector, 201
    Pareto chart, 268
    Parting line flash, 60
    flash plane, 60
    hydraulic or mechanical
    trim, 60
    trim cutters, 61
    Parting line geometry, 316, 333
    parting line step, 316
    trim die, 333
    trim operation, 333
    Physical performance, 359
    Platens, 79
    adjustable platen, 79
    ejector platen, 79
    movable platen, 79
    stationary platen, 79
    traveling platen, 79
    Plunger velocity, 213
    Porosity, 276
    PPAP, production parts approval
    process, 30
    PQ Squared concept, 219
    Precision draft tolerance, 53
    Preheating methods, 344
    cold shut, 137
    lamination, 137
    poor fill, 137
    porosity, 137
    propane torch, electric infrared
    heater, hot oil, 344
    Preventive maintenance,
    99, 347
    382 Index
    5935-4 Andresen Ch00 R3 101404Process monitoring, 219, 232
    shot system
    repeatability, 232
    Process variables, 267
    Product design, 54, 64
    Production and assembly, 45
    Quality of die casting production,
    257
    heat, 257
    temperature, 257
    Quenching, 299
    Rapid solidification rate, 107, 108
    Resmelted, 2
    Retainer size, 318
    Reverberatory furnace, 144
    die casting aluminum, 144
    Ribs are structural features, 59
    controlling warpage, 59
    Runners and step, 316
    Runners and gates, 185
    Safeguarding devices, 368
    audible alarm, hard spot,
    infrared sensor, interlock
    switch, light curtain, motion
    detector, physical barrier,
    safety mat, safety mirror,
    ultrasonic sensor, video
    monitor, visual alarm, 368,
    369
    Scale buildup, 256
    Set up techniques, 340
    Shoe horning, 306
    Shot sleeve, 223
    Shot sleeve temperature, 191
    Shrinkage, 130
    Shrinkage porosity, 132, 278
    centerline porosity, 279
    leaker, 279
    rough and irregular inside
    surface, 132
    volumetric shrinkage, 132
    Shut off allowance, 318
    Shut off distance, 318
    Six sigma defect , 265
    Six sigma exercise, 180
    Six sigma opportunity, 265
    Solderage, 274
    Soldering, 49, 302
    Soldering stages, 303
    Solenoid valve, 87
    direction of movement, 87
    Solid specific heat, 137
    Solidification, 2, 317
    Solvent carriers, 356
    Sophisticated process control, 234
    Sources of heat, 141
    natural gas, electricity, 141
    Special gaging, 315
    casting details and tolerances,
    315
    Specific heat, 245
    Specular reflectance, 10
    Spreader pin, 188
    Standard die components, 306
    Sub-assembly supplier, 50
    Submarine cores, 58
    Support pillars, 320
    ejector pins, 320
    inserted cores, 320
    Surface tension, 358
    Swirling effect, 196
    T-slots or tapped holes, 80
    Temperature drop, 135
    Thermal conductivity, 359
    Thermal crowning, 321
    Thermal decomposition, 359
    Thermal extreme, 290
    chemical content, grain
    structure, alignment,
    internal integrity,
    cleanliness, heat
    treatability, 290
    Thermal properties, 358
    Index 383
    5935-4 Andresen Ch00 R3 101404Throughput or yield of salable
    high quality castings, 219
    Tiebars, 81
    Time, temperature,
    transformation curve, 298
    Toggle linkage system, 84
    Tool economy, 66
    Tooling cost, additional, 56
    Tool tolerance, 315
    angularity tolerances, 315
    parting line (die blow), 315
    shrinkage, 315
    Tooling and equipment, 347
    Tooling cost, 63
    critical economic ingredient, 64
    secondary machining, 65
    Trim press, 13
    Variable factors, 235
    dynamic factors, 235
    manual factors, 235
    [Variable factors]
    static factors, 235
    Vena contracta, 189
    air entrapment, 190
    Vent area, 201
    Vent path, 202
    cavity insert and the die
    retainer, 202
    Venting of the die cavity, 201
    Venting, 13
    Wall thickness, 27
    surface area to volume
    ratio, 28
    Water diluent, 356
    Young’s modulus, 125
    Zinc die castings, 134

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