This introduction paper is based on the paper "Permanent Mold Casting" Excellent Casting Method for Manufacture of Automotive Components" published by "International Journal on Recent and Innovation Trends in Computing and Communication".
1. Overview:
- Title: “Permanent Mold Casting" Excellent Casting Method for Manufacture of Automotive Components
- Author: Ajay Bhardwaj, Mahesh V. Rawlani, C.K Mukherjee
- Year of publication: 2014
- Journal/academic society of publication: International Journal on Recent and Innovation Trends in Computing and Communication
- Keywords: Mold, Mold material, Non ferrous metals, Risers
2. Abstract:
In this paper the study has been done why permanent mold casting method is excellent for manufacture of automotive components. In permanent mold casting process no external pressure is applied but hydrostatic pressure created by the risers is mainly responsible for casting of metal in the mold. As no external pressure is applied hence this process is also called Gravity die casting. In this process, solidification occurs much more rapidly than in sand casting, the main advantage is a permanent mold that can be used repeatedly for multiple metal castings. The mold also called a die is commonly made of steel or iron, but other metals or ceramics can be used. Permanent mold casting is typically used for high-volume production of small, simple metal parts with uniform wall thickness. Non-ferrous metals are typically used in this process, such as aluminum alloys, magnesium alloys, and copper alloys. However, irons and steels can also be cast using graphite molds. Common permanent mold parts include gears and gear housings, pipe fittings, and other automotive and aircraft components such as pistons, impellers, and wheels.
3. Introduction:
[1]To manufacture automotive component using permanent mold manufacturing process the first step is to create the mold. The sections of the mold are most likely machined from two separate metal blocks. These parts are manufactured precisely. They are created so that they fit together and may be opened and closed easily and accurately. The gating system as well as the part geometry is machined into the casting mold. A significant amount of resources need to be utilized in the production of the mold, making setup more expensive for permanent mold manufacturing runs. However, once created, a permanent mold may be used tens of thousands of times before its mold life is up. Due to the continuous repetition of high forces and temperatures, all molds will eventually decay to the point where they can no longer effectively manufacture quality metal castings. The number of castings produced by that particular mold before it had to be replaced is termed mold life. Many factors affect mold life such as the molds operating temperature, mold material and casting metal. Before pouring the metal casting, the internal surfaces of the permanent mold are sprayed with refractory materials. This coating serves as a thermal gradient, helping to control the heat flow and acting as a lubricant for easier removal of the cast part. In addition, applying the refractory coat as a regular part of the manufacturing process will increase the mold life of the valuable mold. The two parts of the mold must be closed and held together with force, using some sort of mechanical means. Most likely, the mold will be heated prior to the pouring of the metal casting. A possible temperature that a permanent metal casting mold may be heated to before pouring could be around 350F (175C). The heating of the mold will facilitate the smoother flow of the liquid metal through the mold's gating system and casting cavity. Pouring in a heated mold will also reduce the thermal shock encountered by the mold due to the high temperature gradient between the molten metal and the mold. This will act to increase mold life. Once securely closed and heated, the permanent mold is ready for the pouring of the cast part. After pouring, the metal casting solidifies within the mold. In manufacturing practice, the metal cast part is usually removed before much cooling occurs, to prevent the solid metal casting from contracting too much in the mold. This is done to prevent cracking the casting, since the permanent mold does not collapse. The removal of the part is accomplished by way of ejector pins built into the mold.
4. Summary of the study:
Background of the research topic:
The automotive industry requires efficient manufacturing processes for producing high-quality components. Permanent mold casting is presented as a viable method for manufacturing automotive components due to its capacity for producing parts with good mechanical properties and dimensional accuracy. The paper investigates the reasons behind the suitability of permanent mold casting for this application.
Status of previous research:
The paper does not explicitly detail the status of previous research, but it implies that permanent mold casting is an established manufacturing process. The introduction describes the steps involved in the process, indicating a level of existing knowledge and practical application.
Purpose of the study:
The primary purpose of this study is to demonstrate and explain why permanent mold casting is an "excellent casting method" for the manufacture of automotive components. The paper aims to highlight the advantages and key considerations of this process in the context of automotive part production.
Core study:
The core study revolves around elucidating the advantages of permanent mold casting, including:
- Elimination of external pressure, relying on hydrostatic pressure from risers (Gravity die casting).
- Rapid solidification compared to sand casting.
- Reusability of the permanent mold.
- Suitability for high-volume production of simple parts with uniform wall thickness.
- Typical use with non-ferrous metals (aluminum, magnesium, copper alloys) and potential for irons and steels with graphite molds.
- Application for various automotive components like gears, housings, pipe fittings, pistons, impellers, and wheels.
- Factors affecting mold life and process parameters.
- Mold design considerations (venting, gating, risering, chills) and material properties.
5. Research Methodology
Research Design:
This paper appears to be a descriptive review, summarizing the principles, advantages, and considerations of permanent mold casting based on existing knowledge and potentially industrial practices. It is not an experimental study but rather an overview of the technology.
Data Collection and Analysis Methods:
The paper compiles information from existing literature and potentially industrial experience related to permanent mold casting. It does not involve primary data collection or statistical analysis but rather presents a synthesis of information to support the claim of permanent mold casting being an excellent method.
Research Topics and Scope:
The scope of the paper is focused on permanent mold casting as a manufacturing method, specifically for automotive components. It covers aspects from mold creation and material selection to process advantages and design considerations relevant to achieving high-quality castings for automotive applications.
6. Key Results:
Key Results:
The paper highlights several key advantages and characteristics of permanent mold casting:
- Material Suitability: Generally suited for materials with lower melting temperatures like zinc, copper, magnesium, and aluminum alloys. Cast iron and steels are also possible with specific mold materials.
- Mold Cooling: Molds can be cooled using water or heat fins to manage heat dissipation.
- Part Geometry: Part geometry is limited due to the need to open and close the mold, but semi-permanent methods can allow for more complex internal geometries.
- Rapid Solidification: Leads to a smaller grain structure and superior mechanical properties.
- Uniform Properties: Results in more uniform material properties throughout the cast part.
- Dimensional Accuracy and Surface Finish: Provides closer dimensional accuracy and excellent surface finish compared to expendable mold processes.
- Lower Rejection Rate: In industrial settings, permanent mold casting results in a lower percentage of rejects.
- Automation and Economy: Suitable for high volume production and can be highly automated and economical at high production rates.
- Soundness and Strength: Castings are generally sounder, stronger, and less porous than sand castings.
- Finer Microstructure: Produces castings with finer dendritic arm spacing (DAS) and grain structure, leading to better strength.
- Design Flexibility: Allows for thinner sections and lighter weight designs.
- Reliability: Offers a higher degree of reliability for pressure applications.
- Material Efficiency: Lightweight materials are suitable for automotive components to reduce inertia.
Figure Name List:
- No figures are present in the provided paper.
7. Conclusion:
The castings produce by Permanent mold method are generally sounder than sand castings and are generally stronger than sand or die-castings, and less porous.
Castings produced in the permanent mold process have finer dendritic arm spacing (DAS) and grain structure. The finer structure displays better strength properties than those cast in similar alloys in sand castings. Permanent mold castings have fewer inclusion defects than sand castings. The casting designer can use thinner sections and lighter weight for designs. The castings produced by this method have a higher degree of reliability with regard to pressure applications of fluids and gases. The material for automotive components should be lightweight for inertia force reduction, increased speed, and cost effective method of manufacturing. The connecting rod must be able to withstand tremendous loads and transmit a great deal of power. Reducing the weight of the rods reduces the mass of the rotating and reciprocating parts and allows the engine to revolve faster and revolve higher.
8. References:
- [1] thelibraryofmanufacturing.com/basic_permanent_mold_casting.html
- [2] www.cmhmfg.com/pdf/Permanent_Mold.pdf
- [3] Production Technology by R. K Jain
- [4] en.wikipedia.org/wiki/Riser_ (casting)
9. Copyright:
- This material is a paper by "Ajay Bhardwaj, Mahesh V. Rawlani, C.K Mukherjee". Based on "Permanent Mold Casting" Excellent Casting Method for Manufacture of Automotive Components".
- Source of the paper: http://www.ijritcc.org
This material is summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
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