PRODUCTION OF GEARS BY DIE CASTING

BATCH-2

DIE CASTING
In Die casting the molten metal is forced to flow into a permanent metallic mold under moderate to high pressures, and held under pressure during solidification. This high pressure forces the metal into intricate details, produces smooth surface and excellent dimensional accuracy. High pressure causes turbulence and air entrapment. In order to minimize this larger in-gates are used and in the beginning, pressure is kept low and is increased gradually. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.

 Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminum, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Hot chamber casting

Cold chamber casting

GEARS MADE BY DIE CASTING

Large quantities of small, low-cost gears are made by the cold chamber die casting process. Die cast gears are usually under 150 mm (6 in.) in diameter and from 10 to 48 diametral pitch(DP). Complicated gear shapes which would be quite costly to machine can be made quickly and at low cost by the die casting process. The main disadvantage of the process is that the lowmelting point metals suitable for die casting aluminum, zinc, and copperdo not have high enough hardness for high load-carrying capacity.

 Many different types of gears can be die cast, such as spur, helical worm, clusters, and bevel gears. Applications for these types of gears include toys, washing machines, small appliances, hand tools, cameras, business machines, and similar equipment.

OPERATION CYCLE
In a cold chamber process, the molten metal is poured into the cold chamber in each cycle. The operating cycle is (i) Die is closed and molten metal is ladled into the cold chamber cylinder (ii) Plunger pushes molten metal into die cavity; the metal is held under high pressure until it solidifies (iii) Die opens and plunger follows to push the solidified slug from the cylinder, if there are cores, they are retracted away (iv) Ejector pins push casting off ejector die and plunger returns to original position. This process is particularly useful for high melting point metals such as Aluminum, and Copper (and its alloys).

ADVANTAGES
Excellent surface finish Excellent dimensional accuracy High production rate Complex shapes can be cast Little or no finishing cost

DISADVANTAGES
Limitation on part size High cost of die Generally limited to casting of non ferrous metals

ALUMINIUM BRONZE CASTING

STRENGTH
Zinc diecastings ambient temperature Yield Strengths are far more superior than those of Aluminium and Magnesium. Zinc diecastings Ultimate Tensile Strengths (UTS) can outperform Aluminium and Magnesium. The strength of zinc diecastings in shear, torsion, under bending and in compression is far superior to aluminium, magnesium and plastics

TOUGHNESS
At normal ambient temperatures, zinc diecastings have a much greater impact resistance than Aluminium and Magnesium, and ABS plastics. At minus 30C zinc alloys still remain far better. Even at minus 40C zinc at least matches the impact resistance of diecast aluminium. Zinc alloys are significantly harder than aluminium and magnesium. Alloying additions such as copper, contribute considerably to the good wear resistance exhibited by zinc alloys

 Fatigue is one of the most frequent failure mechanisms in components. Zinc, like other diecast metals, is between 7 to 10 times more resistant to fatigue than ABS. The Fracture Toughness of diecast zinc and other metals is around 10 to 30 times greater than that of engineering plastics.

CONSISTANCY
Pressure diecastings are 5 to 10 times more accurate than products made by other processes such as pressing, gravity casting or powder forming. Within pressure diecasting, zinc alloy castings are 2 to 4 times more accurate than those made from magnesium and aluminium alloys. High solidification shrinkage and water absorption make close tolerances in plastics difficult to achieve. The exceptional accuracy, predictability and repeatability obtained from the zinc die casting process. Surface quality consistency is excellent due to the extremely low rate of tool surface degradation.

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