Design and Development of Automation System for Opening and Closing of Mould and Core in Gravity Die Casting Machine

Abstract

Gravity Die Casting (GDC) process is capable of making complicated high integrity components, such as wheels, cylinder heads, engine blocks, brake callipers etc. at lower cost than most other casting processes. Cycle times for Gravity Die Casting are shorter than for the sand casting process leading to larger quantities of casting produced per unit time. Surface nish and internal qualities are also better using the GDC process. Improvement to both product quality and process productivity can be bought about improve design. As part of this project a hydraulic system is designed for controlling the opening and closing movements of casting dies and release and tting of core/punch to the die, easy removal of punches from die for cleaning purpose. Guiding system has been designed for smooth movement of dies and punches. Designed system would reduce the dependence on skill of labour, labour cost and heat loss. The proposed system would improve the production rate. CAD packages are used for the designing of the proposed design and CAE tools ANSYS is used for improved quality and enhance productivity of the enterprise by way of faster development of new product. Di er- ent components of GDC machine have been designed analytically and analysed using FEA software ANSYS. Static analysis results for total deformation and equivalent (von-mises) stresses are compared with standard values. Due to high temperature of die, machine components near die are required to be thermally analysed, thermal and structural couple analysis results for directional heat Flux and total deformation are compared with standard values.