Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

2018 ◽  
Vol 21 (6) ◽  
pp. 1800105 ◽  
Author(s):  
Mikel Merchán ◽  
Pedro Egizabal ◽  
Maider García de Cortázar ◽  
Ane Irazustabarrena ◽  
Haize Galarraga
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Structural Components ◽  
Low Pressure Die Casting ◽  
Die Casting Process ◽  
Pressure Die Casting

Wastage Reduction through Lean Manufacturing in Head Lamp Casing Manufacturing Process

2015 ◽  
Vol 766-767 ◽  
pp. 1196-1200
Author(s):  
P.V. Krishnan ◽  
B. Vijaya Ramnath ◽  
K. Maran ◽  
R. Kesavan
Keyword(s):  
Lean Manufacturing ◽  
Die Casting ◽  
Casting Process ◽  
Quality Cost ◽  
Low Pressure Die Casting ◽  
Product And Process ◽  
Die Casting Process ◽  
Alternate Source ◽  
Pressure Die Casting ◽  
Very High

In Case Industry motorcycles models Head lamp casing is made up of Aluminium and it is manufactured by gravity pressure die casting (GDC) process. The rejections rate and cycle time are very high. These results in frequent line stoppage due to the shortage of Head lamp casing. Hence we have decided to proceed with some other process for the manufacturing of head lamp casing, since the existing GDC process has some limitations it cannot be improved further. To move with other process, we have studied sheet metal, in which our head lamp casing design is so complicated and process would be more tedious. Moreover aesthetics look of the head lamp casing will be affected. So we progressed with other die casting process. We have studied pressure die casting (PDC) process first, but in PDC, head lamp casing cannot be manufactured two halves, due to the size of our head lamp casing. Hence we proceeded with low pressure die casting (LPDC) process, in which sand cores are made and thru which Head lamp casing are manufactured. To move with LPDC process, the present supplier base is not feasible. Hence we decided to move with an alternate source for LPDC process. Three LPDC manufacturing suppliers were shortlisted. Among the three suppliers, based on the quality, cost and delivery time, one supplier is approved. Approved supplier is permitted for die making and manufacturing head lamp casing after the product and process audit. Once die manufacturing is completed, samples were taken and tried out at our end. The new LPDC head lamp casing is found ok and hence rejections at supplier end had minimised and rework at our end had eliminated. These results in eliminating the dispatch constraints and thus our motto of avoiding line stoppage due to the shortage of head lamp casing are eliminated.

Numerical Study on the Low Pressure Die Casting of AZ91D Wheel Hub

2005 ◽  
Vol 488-489 ◽  
pp. 393-396 ◽  
Author(s):  
Ying Hong Peng ◽  
Da Yong Li ◽  
Ying Chun Wang ◽  
Ji Long Yin ◽  
Xiao Qing Zeng
Keyword(s):  
Cooling System ◽  
Numerical Study ◽  
Liquid Fraction ◽  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Cooling Capacity ◽  
Simulation Software ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

Most magnesium alloy components available for automobile are made through die casting. In this paper, PAM-CASTTM, commercial die casting simulation software based on the finite difference method, is employed to simulate the low-pressure die casting process of magnesium wheel hub. The temperature field and velocity field during filling and solidification stages are analyzed; the evolution of temperature distribution and liquid fraction was numerically studied. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes are predicted. The cooling performance of mould during casting is also investigated. Via analyzing the shrinkage defects generated under various cooling conditions, the cooling system set in the side mould is found to be more effective for enhancing the cooling capacity at the rim/spoke junction areas. With this cooling system, the hot spots at the junctions are obviously reduced and product quality is improved.

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