2023 BEST E-Book on #IndustrialEngineering.
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING.PRODUCT INDUSTRIAL ENGINEERING - FACILITIES INDUSTRIAL ENGINEERING - PROCESS INDUSTRIAL ENGINEERING. Free Download.
https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0
Engineering in Industrial Engineering - Machine work study or machine effort improvement, value engineering and design for manufacturing and assembly are major engineering based IE methods. All are available as existing methods.
Product Design for Manufacture and Assembly, Third Edition
Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight
CRC Press, 08-Dec-2010 - Technology & Engineering - 712 pages
https://books.google.co.in/books/about/Product_Design_for_Manufacture_and_Assem.html?id=W2FDCcVPBcAC
Note: It is important to read the books by Boothroyd to understand the full method of DFMA. The DFMA method is to be combined with Value Analysis and Engineering to do product industrial engineering. In the note only attempt is made to make readers aware of issues raised and solutions proposed by DFMA method.
DESIGN PRINCIPLES
Generally accepted guidelines for die casting design.
1. Die castings should be thin-walled structures. To ensure smooth metal flow during filling and minimize distortion from cooling and shrinkage, the wall should be uniform. Zinc die castings should typically have wall thicknesses between 1 and 1.5mm. Similar size castings of aluminum or magnesium should be 30 to 50% thicker than zinc, and copper die castings are usually 2 to 3 mm thick. These thickness ranges result in a fine-grained structure with a minimum amount of porosity and good mechanical properties.
Thicker sections in a casting will have an outer skin of fine metal, with thicknesses about half of the preceding values, with a center section that has a coarser grain structure, some amount of porosity, and poorer mechanical properties. The designer should, therefore, be aware that mechanical strength does not increase in proportion to wall thickness. However, large die castings are often designed with walls as thick as 5mm and sections up to 10mm thick. The cooling time for die castings is proportional to thickness. A 5 mm thick die casting may take only about 4 s. Perhaps of greater significance, a 2 mm thick die casting, which may have the same stiffness as the 5 mm injection-molded part, would only take 2 s to cool. This comparison suggests an economic advantage for die casting where good mechanical properties or heavy walls are required.
2. Features projecting from the main wall of a die casting should not add significantly to the bulk of the wall at the connection point. This would produce delayed cooling of the localized thickened section of the main wall, resulting in contraction of the surface (sink marks) or internal cavitation. A general rule is that the thickness of projections, where they meet the main wall, should not exceed 80% of the main wall thickness.
3. Features projecting from the side walls of castings should not, if possible, lie behind one another when viewed in the direction of the die opening. In this way, die locking depressions between the features will be avoided which would otherwise require side-pulls in the die. Projections that are isolated when viewed in the direction of the die opening can often be produced by making a step in the parting line to pass over the center of the projection.
4. Internal wall depressions or internal undercuts should be avoided in casting design, since moving internal core mechanisms are virtually impossible to operate with die casting. Such features must invariably be produced by subsequent machining operations at significant extra cost. Notwithstanding the preceding guidelines, the power of die casting lies in its ability to produce complex parts with a multitude of features to tight tolerances and with good surface finish. Thus, having made the decision to design for die casting, the most important rule is to get as much from the process as is economically possible. In this way, the structure of the assembly will be simplified with all the resulting cost and quality benefits. The main purpose of the procedures established on this topic by the authors is to help the designer to identify economic applications of the die casting process and to quantify, if necessary, the cost of alternative designs.
Design for Die Casting: What features can and should be die cast?
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https://www.youtube.com/watch?v=GpHh-zXOKwg
Die Casting Process: What is the die casting process? https://www.youtube.com/watch?v=bH1WlgGvOcE
High-Pressure Die-Casting at GF Casting Solutions, 26 Oct 2021
https://www.youtube.com/watch?v=EAbH168XGkM
High Pressure Die Casting Process Video - 27 Feb 2021
https://www.youtube.com/watch?v=pvABXC8zRsA
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Design Rules - Zinc Die Casting
https://diecasting.zinc.org/properties/en/design/eng_prop_d_design-rules/
Book - Product Design for Die Casting - Detailed Description of Die Casting Process and Design
https://cwmdiecast.com/wp-content/uploads/2020/06/Die-Casting-Prod-Design-NADCA-min.pdf
What Common Improvements Can DFM Make To Die Cast Parts?
https://www.sofeast.com/knowledgebase/dfm-improvements-die-cast-parts/
Design for Manufacturability (DFM) Tips for Die Cast Parts
https://nacastingcorp.com/die-casting-design-tips/
Applications
Die Casting Study - Housing of a Fan
2003
https://www.sfsa.org/tutorials/nadca2/thermofan.pdf
Design of Three Cavity Diecasting Die for Rotors - IJERT - 2017
https://www.ijert.org/research/design-of-three-cavity-diecasting-die-for-rotors-IJERTV6IS020017.pdf
Die Casting Die Design and Process Optimization of Aluminum Alloy Gearbox Shell
Mingyu Huang, Qian Zhou, Junyou Wang, and Shihua Li
Materials (Basel). 2021 Jul; 14(14): 3999.
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8303643/
REFERENCES
1. Metals Handbook, ASM, Metals Park, OH, 1986.
2. Introduction to Die Casting, American Die Casting Institute, Des Plaines, IL, 1985.
3. Reinbacker, W.R., A Computer Approach to Mold Quotations, PACTEC y 5th Pacific Technical Conference, Los Angeles, February 1980.
4. Herman, E.A., Die Casting Dies: Designing, Society of Die Casting Engineers, River Grove, IL, 1985.
5. Slum, C., Early Cost Estimation of Die Cast Components, M.S. Thesis, University of Rhode Island, Kingston, 1989.
6. Ostwald, PR, American Machinist Cost Estimator, American Machinist, New York, 1985.
7. Pokorny, H.H., and Thukkaram, P., Gating Die Casting Dies, Society of Die Casting Engineers, River Grove, IL, 1981.
8. Geiger, G.H., and Poirier, D.R., Transport Phenomena in Metallurgy, Addison-Wesley, Reading, MA, 1973.
9. Reynolds, C.C., Solidification in Die and Permanent Mold Castings, Ph.D. Dissertation, Massachusetts Institute of Technology, Cambridge, 1963.
10. Sekhar, J.A., Abbaschian, G.J., and Mehrahian, R., Effect of Pressure on Metal-Die Heat Transfer Coefficient During Solidification, Mater. Sci. Eng., Vol. 40, p. 105, 1979.
11. Dewhurst, P., and Slum, C., Supporting Analyses for the Economic Assessment of Die Casting in Product Design, Annals CIRP, Vol. 38. p. 161, 1989.
Thank you for your blog Zinc High Pressure Die Casting Manufacturers
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