PEMP

PDN 505

Session 14
Design for Die Casting

Lecture delivered by
Prof. M. N. Sudhindra Kumar
Professor MSRSAS-Bangalore
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 1

 PEMP
PDN 505

Session Objectives
At the end of this session the delegate would have understood
DFM for Die Casting Parts
How to design die cast components
Commandments of Die casting design
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 2

 PEMP
PDN 505

Session Topics
1. Dont design castings!
2. Do Practice simultaneous engineering
3. Know Effectiveness of casting design
4. Design for Function & Assembly
5. Rib the part to add strength and stiffness & Reduce
weight
6. Design For Metal-flow
7. Design For Uniform Wall thickness
8. Design with as thin a wall thickness as possible
9. Let walls intersect at right angles
10. Know How to design a Boss?
11. Be generous with drafts
Sudhindra MSRSAS

12. Think Avoidance of side cores

13. Think simplicity (Two-piece die)
M.S Ramaiah School of Advanced Studies - Bangalore 3
 PEMP
PDN 505

Session Topics
14. Think of shop man
15. Dont be too smart with Sliding core
16. Know Limitations of Cast Threads
17. Design Inserts to Cost
18. Limit machining Allowances to a minimum
19. Specify explicitly location of ejector pins
20. Design For Flash and Gate Removal
21. Think of Die-sinking costs
22. Leave the Letters Raised
23. Know the limitations of cored out holes
24. Design for Assembly
25. Know limitations of dimensions & Tolerances
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 4

 PEMP
PDN 505

Introduction:

There is a Japanese methodology called OET(On Error

Training). Once a colleague commits a mistake &
corrects it, he calls all his co-workers & shares his
negative experience.
This session is a compilation of design rules how to
design die cast components & how not to design.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 5

 PEMP
PDN 505

Introduction:
Die cast component design may be thought of as ~ 80%
science & some 20% art(= Design for aesthetic appeal /
Beauty), like in the design of cylinder head fins of a
motorcycle.
We are only covering the science part in this session.
The remaining 20% art-part may sometimes have even
80% impact on the visual appeal to the customer. That is
beyond the scope of this session.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 6

 PEMP
PDN 505

1. Commandment: Dont design castings!

The first Commandment in Design for Castings is-
Dont design castings!( Dont waste your time making detailed
views of the drawings.)
Make sketches & discuss with the founder who is going to make
the casting for you, on matters of
Position of parting plane
Functional features,
Achievable accuracies...
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 7

 PEMP
PDN 505

2. Do Practise simultaneous engineering

Practicesimultaneous engineering-
Discussion of the details of the casting by part-
designer with the die-maker is required for
maximum effectiveness of the design of the
casting.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 8

 PEMP
PDN 505

3. Know Effectiveness of casting design:

Easy to cast without filling problems
Easy to machine without the disadvantages of
either too less or too much material to remove by
machining
The most economical in cost by reducing
Cost of the die
Cost of component
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 9

 PEMP
PDN 505
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 10

 PEMP
PDN 505

QUALITY PARADOX
100% For a PDC Die 100%

Flexibility & Knowledge /

Opportunity Expertise of our
to improve own casting !
design Cost of Change !
quality of a
new Casting
Sudhindra MSRSAS

0% 0%
Concept Detailed Time
FMEA Die Mfg. Trial Production
Design Design
M.S Ramaiah School of Advanced Studies - Bangalore 11
 PEMP
PDN 505

4.Design for Function & Assembly

Part designer should

Study overall function of the product
Consider the possibility that several functions
can be incorporated into one casting with
integral features
Design for attachment and assembly
Typified by the chassis for Xerox high
speed electronic printer
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 12

 PEMP
PDN 505

Example of multi-functional casting design:

One-piece chassis for a high-speed electronic printer replaced 82

separate components and fasteners in the forerunner assembly.
Drilling and tapping have been eliminated by incorporating cored
holes, which receive thread-forming screws for fastening. (Courtesy
Sudhindra MSRSAS

Diablo Systems, a Xerox company.)

M.S Ramaiah School of Advanced Studies - Bangalore 13

 PEMP
PDN 505

5. Rib the part to add strength and stiffness &

Reduce weight:

Ribs are mainly incorporated into a die

casting to reinforce it structurally, with a
minimum increase in weight, replacing
heavy sections that would be otherwise
necessary.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 14

 PEMP
PDN 505

Think Ribs:

Ribs are
fairly easy
to
incorporate
into an
existing
hardened
die
Sudhindra MSRSAS

Ribbing of various forms used to stiffen

the wall of a die casting.

M.S Ramaiah School of Advanced Studies - Bangalore 15

 PEMP
PDN 505

Examples of strong light weight components

Aluminum die castings for two-wheeler engines show how good

design can provide ribs where needed for strength and cored holes
for fastening while maintaining fairly constant wall thickness.
Sudhindra MSRSAS

(Courtesy Aluminum lndustrie Vaasen.)

M.S Ramaiah School of Advanced Studies - Bangalore 16

 PEMP
PDN 505

Examples of large light weight components

These die-cast aluminum components for a weight scale

Sudhindra MSRSAS

demonstrate intelligent use of ribbing to promote strength and

stiffness. (Courtesy Aluminum Industrie Vaasen.)
M.S Ramaiah School of Advanced Studies - Bangalore 17
 PEMP
PDN 505

Where & How to Design Ribs?

Box shaped components are strengthened by incorporating internal

Sudhindra MSRSAS

ribs that run the full depth of the part.Corners are reinforced by
radiusing to avoid corner fractures in the casting
M.S Ramaiah School of Advanced Studies - Bangalore 18
 PEMP
PDN 505

Where & How to Design Ribs?

Where there would normally be a heavy section

adjacent to a cored area, introduce further coring to
Sudhindra MSRSAS

create ribs, thereby removing mass & obtaining uniform

wall thickness
M.S Ramaiah School of Advanced Studies - Bangalore 19
 PEMP
PDN 505

Poor Design Of Rib

Acute-angle intersections cause the die

to overheat in the area between the ribs.
Multiple intersections of radial ribs
should be avoided; otherwise, the
Sudhindra MSRSAS

intersection will contain porosity.

M.S Ramaiah School of Advanced Studies - Bangalore 20
 PEMP
PDN 505

Typical case of how ribs

should not be designed
Sudhindra MSRSAS

Number of ribs intersecting = 6!

M.S Ramaiah School of Advanced Studies - Bangalore 21
 PEMP
PDN 505

Slightly improved design of ribs:

Number of intersections = 4
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 22

 PEMP
PDN 505

Optimum Rib design:

Much improved rib design(Only 3 ribs

intersect at each point)
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 23

 PEMP
PDN 505

Procedure for design of Reinforcing Ribs

Designer may under-design initially,

test sample castings, then add strength if necessary
by removal of die steel until the
optimum combination of mechanical properties
and casting-material conservation is
reached.
(Preferable to over-designing and having to
lighten the die casting later by welding the die,
Sudhindra MSRSAS

which is a costly, life-limiting procedure.)(E.g..)

M.S Ramaiah School of Advanced Studies - Bangalore 24
 PEMP
PDN 505

6.Design For Metal-flow:

Avoid
Abrupt section changes
Sharp corners
Walls at an acute angle to one another
(Disturb the continuity of metal flow and
promote porosity and surface
irregularities)

Blend differing sections into one another with

Sudhindra MSRSAS

radii as generous as possible.

M.S Ramaiah School of Advanced Studies - Bangalore 25
 PEMP
PDN 505

Design For Metal-flow:

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 26

 PEMP
PDN 505

Why More Radii?

Radii
Sharp external corners are undesirable because
they become a localized point of heat and stress
buildup in the die steel that can cause die cracking
and early failure.

Therefore, radii and fillets should be as generous

as possible, preferably at least 1.5 times wall
Sudhindra MSRSAS

thickness for both inside and outside radii.

M.S Ramaiah School of Advanced Studies - Bangalore 27

 PEMP
PDN 505

Sharp corners cause

uneven cooling, while
rounded corners
permit uniform
cooling with much
less stress; Rounded
corners that maintain
uniform wall
thickness provide the
T best results
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 28

 PEMP
PDN 505

Why to avoid sharp corners?

Sudhindra MSRSAS

Sharp edges on cores are difficult to maintain because they are points of heat
concentration,
with resulting premature erosion of the die material.
M.S Ramaiah School of Advanced Studies - Bangalore 29
 PEMP
PDN 505

7.Design For Uniform Wall thickness

The easiest die casting to make and the soundest

in terms of minimum porosity is one that has
uniform wall thickness.

Sharp changes in sectional area or heavy sections

over 6 mm thick should be avoided if possible.

When a heavy section seems to be indicated, its

Sudhindra MSRSAS

underside should be cored out.

M.S Ramaiah School of Advanced Studies - Bangalore 30
 PEMP
PDN 505

Importance of Uniformity of wall thickness

Less Problems
Sudhindra MSRSAS

More Problems

M.S Ramaiah School of Advanced Studies - Bangalore 31

 PEMP
PDN 505

8. Design with as thin a wall thickness as possible:

Sudhindra MSRSAS

*Fine-grained dense structure, devoid of porosity, thus making the skin the strongest
part of wall thickness (?)
M.S Ramaiah School of Advanced Studies - Bangalore 32
 PEMP
PDN 505

Max Strength/Weight is achieved with 0.8 - 1.3 W.T

Strength
Weight
Ratio
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 33

 PEMP
PDN 505

9.Let walls intersect at right angles:

Sudhindra MSRSAS

Intersection of two walls should be at right angles to

avoid sharp corner hot spots
Fig.20 M.S Ramaiah School of Advanced Studies - Bangalore 34
 PEMP
PDN 505

10.Know How to design a Boss?

Sudhindra MSRSAS

To avoid surface shrinks, relocate the boss and connect it to the wall with a short rib.
The ribs should be no wider than the thickness of the casting wall

M.S Ramaiah School of Advanced Studies - Bangalore 35

 PEMP
PDN 505

11.Be generous with drafts:

When the draft angle is abnormally small, even the slightest depression in the drafted
Sudhindra MSRSAS

surface of the die will prevent ejection causing drag marks in the surface of the casting

M.S Ramaiah School of Advanced Studies - Bangalore 36

 PEMP
PDN 505

12. Think Avoidance of side cores:

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 37

 PEMP
PDN 505

12. Think Avoidance of side cores:

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 38

 PEMP
PDN 505

13.Think simplicity (Two-piece die)

Sudhindra MSRSAS

If possible, the part should be designed so that it can be made in a simple two-piece die.

M.S Ramaiah School of Advanced Studies - Bangalore 39

 PEMP
PDN 505

14.Think of shopman :

Through-wall cored holes for tapping should be countersunk on both sides to avoid
deburring; Holes for tapping should be cored rather than drilled. A drilling operation is
Sudhindra MSRSAS

eliminated, and the tap will cut into dense material for a higher-quality thread.

M.S Ramaiah School of Advanced Studies - Bangalore 40

 PEMP
PDN 505

15.Dont be too smart with Sliding core

Should never be designed to intersect the opposite die half, since imperfect die closure
Sudhindra MSRSAS

(possibly the result of flash at the parting plane not being fully removed) would result
in a damaged die
M.S Ramaiah School of Advanced Studies - Bangalore 41
 PEMP
PDN 505

16.Know Limitations of Cast Threads:

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 42

 PEMP
PDN 505

16.Know Limitations of Cast Threads:

It is possible to die-cast internal threads in
zinc parts only by using techniques that
involve either unscrewing the casting from
a threaded core or rotating the core out of
the casting during ejection.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 43

 PEMP
PDN 505

Design of bush type inserts:(To resist both

axial and rotational forces).

Insert with knurled circumference (Positive

location within the die must be provided to
Sudhindra MSRSAS

prevent insert movement during the casting

cycle)
M.S Ramaiah School of Advanced Studies - Bangalore 44
 PEMP
PDN 505

Design of bolt type inserts:

Insert with recess & longitudinal grooves

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 45

 PEMP
PDN 505

Design of bolt type inserts:

Insert Machined & U/C square

(insert's threads must be kept away
Sudhindra MSRSAS

from the casting face)

M.S Ramaiah School of Advanced Studies - Bangalore 46
 PEMP
PDN 505

Design of bush type inserts:

Insert with locally machined flat

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 47

 PEMP
PDN 505

Design of bush type inserts:

Insert with drilled anchor holes

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 48

 PEMP
PDN 505

17. Design Inserts to Cost

Sudhindra MSRSAS

Decision based on Cost comparison for inserts

M.S Ramaiah School of Advanced Studies - Bangalore 49
 PEMP
PDN 505

18.Limit machining Allowances to a minimum:

Sudhindra MSRSAS

Deeper cuts could open up unsightly subsurface porosity and

possibly affect function
M.S Ramaiah School of Advanced Studies - Bangalore 50
 PEMP
PDN 505

19. Specify explicitly location of ejector pins:

If an area to be machined covers ejector-pin

locations, their impressions should be
0 to 0.4 mm depressed-so that they are
removed in machining.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 51

 PEMP
PDN 505

20.Design For Flash and Gate Removal

With complex castings having massive core
slides, the cost of complete removal by a
combination of die trimming and hand operations
can be as much as, or even considerably more
than, the cost of the raw casting !
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 52

 PEMP
PDN 505

20.Flash and Gate Removal:

Sudhindra MSRSAS

Avoid an angled junction of an external wall with the parting line.It is preferable to add a
minimum-draft shoulder at the parting line, so that most of the gate material will come
away in trimming.

M.S Ramaiah School of Advanced Studies - Bangalore 53

 PEMP
PDN 505

20.Simplify Flash and Gate Removal

Sudhindra MSRSAS

Trimming tool to match intricate geometry would be expensive and hard to maintain.
Advisable to add a shoulder between wall detail and parting line to allow for use of a single
trimming die or a lathe-turning operation to remove gates and flash.
M.S Ramaiah School of Advanced Studies - Bangalore 54
 PEMP
PDN 505

21.Think of Die-sinking costs:(?)

Sudhindra MSRSAS

If the casting is designed with convex features in outside walls,it is a straightforward job
to mill the corresponding concavities into the steel.
M.S Ramaiah School of Advanced Studies - Bangalore 55
 PEMP
PDN 505

22. Leave the Letters Raised :

There are two alternatives.
The easy way is to specify that the
characters be raised in the casting.
This can be accomplished by relatively
inexpensive engraving of the die.

If the characters are to be depressed into the

casting, however, all the background steel on that
Sudhindra MSRSAS

face of the die must be painstakingly removed

around the characters.
M.S Ramaiah School of Advanced Studies - Bangalore 56
 PEMP
PDN 505

Design for Die Casting

On Lettering
If the designer wants the economy of raised
characters but does not wish them to
project above the surrounding surface, a raised
pad can be incorporated into the die to
form a depressed area in the casting. Then when
the pad is engraved, the lettering will
come out flush.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 57

 PEMP
PDN 505

23.Know the limitations of cored out holes

The die-casting process can accommodate the
coring in of holes into the body of the
casting at right angles to the parting line.

However, there are core-length limits, depending

on diameter, that should not be exceeded.(Ref.4
page 5.68)
Sudhindra MSRSAS

Long, slender cores may lead to core breakage

M.S Ramaiah School of Advanced Studies - Bangalore 58

 PEMP
PDN 505

24.Design for Assembly:

Sudhindra MSRSAS

Zinc only!
M.S Ramaiah School of Advanced Studies - Bangalore 59
Fig.39
 PEMP
PDN 505
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 60

 PEMP
PDN 505

25.Know limitations of dimensions & Tolerances

The as cast dimensional variations of a die casting

depend on part size.
This dependency is largely due to thermal expansion and
contraction of both the die and the casting. The die
expands at operating temperatures, and the casting
shrinks after it leaves the die.
Variations in die operating temperatures and the
temperature of the molten metal entering the die add to
Sudhindra MSRSAS

the need for a design tolerance on die-casting dimensions.

M.S Ramaiah School of Advanced Studies - Bangalore 61

 PEMP
PDN 505

25.Know limitations of dimensions & Tolerances

Tolerances across the parting line and between core

slides and main die blocks must be greater because of
the clearances that are incorporated into these features
in the die to enable them to function at elevated
temperatures.
Recommended tolerances also allow for gradual wear
in die components over the life of tooling. This is a
significant factor.
Another is warpage.
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 62

 PEMP
PDN 505

Some case-studies of Problems encountered

during die casting of engineering components
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 63

 PEMP
PDN 505

Outside view of Motor Body Housing Casting

~ 180 dia; ~100mm deep; 800gm

Support
pin
locations

10
Sudhindra MSRSAS

Problem: Non-filling of window portions

M.S Ramaiah School of Advanced Studies - Bangalore 64
 PEMP
PDN 505

Inside view of Motor Body Housing Casting

Nominal Wall
thickness ~
2 mm

CI Insert
for bearing
Sudhindra MSRSAS

Problem: Non-filling of window portions

M.S Ramaiah School of Advanced Studies - Bangalore 65

 PEMP
PDN 505

Motor Body Housing Casting

Original
runner
location near
heavy sections
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 66

 PEMP
PDN 505

Motor Body Housing Casting

Fully filled
windows
after the
addition of
Sudhindra MSRSAS

extra runner
M.S Ramaiah School of Advanced Studies - Bangalore 67
 PEMP
PDN 505

Housing
Housing ForforHand-grinder
hand-grinder
Sudhindra MSRSAS

Typically asymmetric flow of metal required

M.S Ramaiah School of Advanced Studies - Bangalore 68
 PEMP
PDN 505

Housing for Hand-grinder

Sudhindra MSRSAS

Problem:Non filling of semi cylindrical portion : part sticking

to cavity
M.S Ramaiah School of Advanced Studies - Bangalore 69
 PEMP
PDN 505

Housing For Hand-grinder

Subrunner

Runner
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 70

 PEMP
PDN 505

Design For Die-casting

How did they solve the problem of

Part sticking to the cavity?
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 71

 PEMP
PDN 505

Motor Housing Non-drive End (Outside view)

Sudhindra MSRSAS

Dia 180mm; 100mm high;750gm

M.S Ramaiah School of Advanced Studies - Bangalore 72
 PEMP
PDN 505

Motor Housing Non-drive End (Inside view)

Sudhindra MSRSAS

2.5mm Wall thickness

M.S Ramaiah School of Advanced Studies - Bangalore 73
 PEMP
PDN 505

Motor Housing Non-drive End

Cracks
near the
opening
Sudhindra MSRSAS

Problem: Fin area not being filled at all

M.S Ramaiah School of Advanced Studies - Bangalore 74
 PEMP
PDN 505

Motor Housing Non-drive End

Cracks
below
opening
Location of
runners near
heavy sections
Sudhindra MSRSAS

Problem: Fins not at all filling

M.S Ramaiah School of Advanced Studies - Bangalore 75
 PEMP
PDN 505

Motor Housing Non-drive End

Extra sub-
runner just
below
rectangular
Sudhindra MSRSAS

opening
added
M.S Ramaiah School of Advanced Studies - Bangalore 76
 PEMP
PDN 505

Fan Casting : Dia ~ 150mm; ~75mm long; gm

16
ejection
pins

170 dia; 30 height; 500gm

Sudhindra MSRSAS

Problem: Fins Breaking; Ejection sticky

M.S Ramaiah School of Advanced Studies - Bangalore 77
 PEMP
PDN 505

Fan Casting
Sudhindra MSRSAS

Problem: Fins breaking;ejection sticky

M.S Ramaiah School of Advanced Studies - Bangalore 78
 PEMP
PDN 505

Fan Casting
Sudhindra MSRSAS

Draft angle of blades increased from 2 deg to 5 deg

Extra ejection pins 6 nos added
M.S Ramaiah School of Advanced Studies - Bangalore 79
 PEMP
PDN 505

Family die for Flange & Bearing Cover

5mm
50dia
thick;
8gm

40dia
Sudhindra MSRSAS

20mm thick; 30 gm

M.S Ramaiah School of Advanced Studies - Bangalore 80

 PEMP
PDN 505

Family die for Flange & Bearing Cover

Problem:
Only one set of
good parts obtained out of
each shot
Severe Blow-holes

Analysis: Severe unbalanced

Mass-flow; C.f. : 46gm Vs
68gm
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 81

 PEMP
PDN 505

Family die for Flange & Bearing Cover

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 82

 PEMP
PDN 505

Solution: Progressively reducing runner

width Increase radii for improved flow;
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 83

 PEMP
PDN 505

Design For Die-casting

Lesson learnt:
For optimum results, the degree of imbalance
between the two sides of a family die should
not exceed + / - 10%
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 84

 PEMP
PDN 505

Gear Cover Casting

Sudhindra MSRSAS

140mm dia; 60mm height; 300gm

M.S Ramaiah School of Advanced Studies - Bangalore 85
 PEMP
PDN 505

Gear Cover Casting

Sudhindra MSRSAS

Problem: Non-filled area

M.S Ramaiah School of Advanced Studies - Bangalore 86
 PEMP
PDN 505

Gear Cover Casting

Sub-
runner
added
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 87

 PEMP
PDN 505

Base Casting for Electric Cutter

~300mm X ~ 150mm; 400gm -- Wall thickness 3mm
Sudhindra MSRSAS

Not Filling
M.S Ramaiah School of Advanced Studies - Bangalore 88
 PEMP
PDN 505

Base Casting for Electric Cutter

Initial Gate Position

Sudhindra MSRSAS

Not Filling
M.S Ramaiah School of Advanced Studies - Bangalore 89
 PEMP
PDN 505

Base Casting for Electric Cutter

Fully filled with redefined gatings

Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 90

 PEMP
PDN 505

Cover for Cutter

Non- Filling
Sudhindra MSRSAS

Dia 240mm;120 mm; 2mm nominal thickness

M.S Ramaiah School of Advanced Studies - Bangalore 91
 PEMP
PDN 505

Cover for Cutter

Sudhindra MSRSAS

Wafer-thin wall
M.S Ramaiah School of Advanced Studies - Bangalore 92
 PEMP
PDN 505

Cover for Cutter

Solution:
Maintain uniform wall thickness
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 93

 PEMP
PDN 505

Conclusion:

20 %
80 %

80 %

20 %

Cause Effect
Sudhindra MSRSAS

Pareto Principle
M.S Ramaiah School of Advanced Studies - Bangalore
Fig. 67 94
 PEMP
PDN 505

Design For Die-casting

Have always the simple mind of a student,

because on the simplest of foundations are built
the most wonderful works of nature.
Dr.W.A.J.Chapman
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 95

 PEMP
PDN 505

Design for Die Casting

References:
1.Die casting book by Dr.Arthur Street
2.Metals Hand book Volumes 5A,5B,15 SME
3.Principles of Metal Casting By Richard W.Heine
4.Design for Manufacturability By James Bralla
Sudhindra MSRSAS

M.S Ramaiah School of Advanced Studies - Bangalore 96

 PEMP
PDN 505

Summary
Die castings are extensively used for manufacture of intricate
engineering components
Die castings are made in alloys of aluminum , magnesium ,
or zinc, and are used where good mechanical properties and
absence of creep is required
Typical applications are housings for automotive
assemblies and electrical motors/ pumps, and structural parts
for electronic equipment
Design of parts for die casting is critical for obtaining good
castings- It involves providing proper gating systems and
design for uniform metal flow, uniform wall thickness,
Sudhindra MSRSAS

bosses, avoidance of side cores, provision for inserts,

providing generous drafts, and keeping minimum machining
allowance
M.S Ramaiah School of Advanced Studies - Bangalore 97