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Q. Explain the die procedure of a blanking die with suitable example?

Q. how are dissolved gases removed from molten metal?

Q. What is Spring back effect in sheet metal work method to a

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Q.Explain this quiz casting process?

Squeeze casting is a method combining casting and forging technologies.

In contrast to other casting techniques (sand casting, die casting), in which a molten metal is poured (injected) into the mold cavity
after the two parts ofthe mold are assembled, squeeze casting mold is closed after a portion of molten metal has been poured into the
preheated bottom die.
The upper die lowers towards the bottom die causing the melt to fill the mold cavity.

The squeezing pressure is applied until full solidification of the casting.

A scheme of the process is shown in the picture:

Squeeze castings are characterized by:

 low shrinkage and gas porosity;
 enhanced mechanical properties because of fine grain structure caused by rapid solidification ;
 good surface quality.
Squeeze casting is commonly used for processing aluminum and magnesium alloys.
This process is also used for fabrication of reinforced metal matrix composites where molten aluminum infiltrates a fiber reinforcing
structure.

Q. Explain the function of single action and double action draw die?

Any type of die that performs a drawing operation is referred to as a drawing die, regardless of its construction. Fig. 25 shows a
drawing punch and die in its simplest form, producing only shallow cups, as in Fig. 26, from blanks made from another die. The chief
difference between this punch and die and the plain blanking type is that the punch, instead of fitting the die, is made smaller than the
die by an amount equal to twice the thickness of the stock to be drawn. Also the sharp corners of the die are removed to allow the
stock to slide freely from the flat state to cup shape, and to prevent scratching the blank.
Fig. 27 shows types of cups that are formed by the drawing die in Fig. 28. When using this design of die, however, the blanks must be
punched out with another die. This die should not be designed for use except when a small quantity of cups are required.
For producing the blanks seen in Fig. 29, the type of drawing die shown in its simplest form in Fig. 30 is employed. This die also
requires blanks previously punched from sheet stock. As is the case with all the foregoing drawing dies, this type should not be
designed where rapid production or quality is required.
Fig. 25. Simple Form of Drawing Punch and Die.

Fig. 26. Typical Cups Formed by Drawing Die.

Q. Explain product design for die casting?

Die Casting Product Design

Draft Angle
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the outer and inner walls of the part as well as the openings created using sliding cores. This enables the castings to be easily ejected
from the die casting die.

Uniform wall thickness

Consistency of the wall thickness is the key for creating high quality die cast parts. Any unnecessary changes in thickness or abrupt
changes in the geometry of the component will cause disruption to the flow of metal entering the cavity.

Parting Line:
Die cast component will always have a parting line. This is where the two halves of the dies meet on the part. This is generally noted
on the part drawing as Parting Line or P/L.

Fillets:
Die Cast parts are rarely flat, therefore it is important to add curved surfaces where two surfaces or intersections meet to avoid
creating sharp corner or edges.

Bosses:
Bosses are often added on die cast parts as mounting points with other components. This problem can be minimized by adding
adequate fillet and draft angle to ensure that the molten metal can flow into these areas and will also help the ejection of the die cast
component.

Openings:
Die casting parts are often design as housings or enclosures for electronics and telecommunication applications. These product will
often feature keypads and displays which will require the die cast parts to have small openings for keys and connectors as well as
bigger openings for features like LCD or LED displays.

Lettering:
Often times, lettering such as logos, trademarks, identification numbers will be added to the part.

Q. Explain how clearance are located in blanking and piercing operation?

Q. Difference between compound and progressive die?

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 Progressive die is a kind of multitasking sequence die, which has multiple process such as cutting, bending forming and
stretch, Progressive die has the very high productivity;
2. Safety for operation;
3. Automation;
4. High speed stamping manufacture;
5. Save facilities such as punch press, factory area, transportation and warehouse;
6. Super precision metal part is not adapted for progres operation

Q. Explain the design consideration data in important in expendable mould design?

Expendable mold process cool much slower than die casting

Important design considerations are:

1.
 Mold Layout
must be placed logically and compactly with gates
2.
 Riser Design
consideration in size and placement of risers
3.
 Machining Allowance
require for additional finishing operations

Q. What are the form of raw materials used for processing plastic into product?

Plastic materials have been created using many different kinds of matter over the years. Originally, resins were made from
vegetable matter including cellulose from cotton, furfural from oat hulls, oil from seeds and various starch derivatives. Bakelite
(phenol formaldehyde resin), one of the first plastics made from synthetic components

Polymer Synthesis
Plastics are organic materials that contain such elements as carbon (C), hydrogen (H), nitrogen (N) chlorine (Cl) and sulfur (S). They
are made from raw materials such as oil, natural gas and coal.

Q. Explain the die design procedure for a drawing die?

Design considerations for draw dies
Before beginning the designs make sure that method plan (deciding all the operation that has to be performed in order get
finished component) is kept ready in all aspects.

1. Decide the blank holder shape

2. Decide for the beads at appropriate places for deeper draws

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3. For shallow draws provide some locations for trim dies in non working area

4. Calculate the draw force required

5. Calculate the cushion force required for blank holder as it plays an important role in flow of material

6. Select the suitable press required either mechanical or hydraulic as specified by the customer

7. Select the cushion area in such a way that it balances the blank holder

8. Select for clamping slots required from the press layout

9. Material for draw punch & die is HcHcr hardened to 56-58 HRC.

10. Provide wear plates for draw punch & blank holder sliding at appropriate position so that it balances

11. Provide guide pillars on blank holder & guide bush on draw die. So that there will be initial alignment between
the draw die & blank holder.

12. Provide heel guides with wear plates on draw die only if customer insists or other wise it is not necessary

13. Decide for blank holder travel (blank holder surface should be always above the punch surface by 5-10 mm)

14. Provide shoulder bolt at appropriate position & to be fastened to bottom punch/base plate so that in controls
the travel of blank holder.
Cost benefit analysis: What is it?

A cost benefit analysis (also known as a benefit cost analysis) is a process by which organizations can analyze decisions, systems or
projects, or determine a value for intangibles. The model is built by identifying the benefits of an action as well as the associated costs,
and subtracting the costs from benefits. When completed, a cost benefit analysis will yield concrete results that can be used to develop
reasonable conclusions around the feasibility and/or advisability of a decision or situation.

As mentioned previously, cost benefit analysis is the foundation of the decision-making process across a wide variety of disciplines. In
business, government, finance, and even the nonprofit world, cost benefit analysis offers unique and valuable insight when:

 Developing benchmarks for comparing projects

 Deciding whether to pursue a proposed project
 Evaluating new hires
 Weighing investment opportunities
 Measuring social benefits
 Appraising the desirability of suggested policies
 Assessing change initiatives
 Quantifying effects on stakeholders and participants

Now that your framework is in place, it’s time to sort your costs and benefits into buckets by type. The primary categories that costs
and benefits fall into are direct/indirect, tangible/intangible, and real:
Direct costs are often associated with production of a cost object (product, service, customer, project, or activity)

 Indirect costs are usually fixed in nature, and may come from overhead of a department or cost center
 Tangible costs are easy to measure and quantify, and are usually related to an identifiable source or asset, like payroll, rent,
and purchasing tools
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 Intangible costs are difficult to identify and measure, like shifts in customer satisfaction, and productivity levels
 Real costs are expenses associated with producing an offering, such as labor costs and raw materials

Q. State the importance of centre of pressure in press operation?

Q. State the parameters that are considered for designing strip layout?

STRIP LAYOUT
A strip layout represents the sequence of the logical, workable operations, which is to say a sequence of ideas.
If this sequence of operations has error, the error will be surely emerge in a try out press.
Factors to be considered while designing the layout are.
Shape of the blank.
Production requirement.
Grain direction.
Burr side.
Stock material.

Shape of the blank:

The contour of the blank, decides the position of the strip.
Some of the blanks are laid at an angle.

Production Requirement:
If production requirement is less, then material conservation is necessary.
This must not increase the tool cost.
Gang die may be suitable for the mass production.

Grain Direction:
The grains are found in the sheets when they are rolled.
Bending the strip along the grain direction results in crack and fracture.

Burr Side:
It is a decisive factor in laying the strip.
In blanking, burr is found on the punch side.
In piercing ,burr is found on the die side.

Stock Material:
Every means is to be seen to conserve the stock material.
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A double pass layout would justify the cost of stock material conserved.

Q. explain the hot chamber die casting process and cold chamber die casting process?

Hot Chamber Die Casting

Hot chamber die casting is a type of die casting that uses alloys with low melting temperatures (i.e. Zinc, some Magnesium
alloys). Using alloys with high melting temperatures would result in
damage to the gooseneck, nozzle and other components.
In a hot chamber die casting machine, the fixed die half is called a cover die, which is mounted to a stationary platen (large plate to
which each die half is mounted) and aligns with the nozzle of the gooseneck. The movable die half is the ejector die and is mounted
to a movable platen, which slides along tie bars.

The metal is contained in an open holding pot, which is placed in the furnace and melted to the needed temperature. When the plunger
is in the “up” position, the molten metal flows into the shot chamber. As the plunger moves down, it forces the molten metal through
a gooseneck and into the die at injection pressures ranging from 1,000 – 5,000 psi.

The machine pushes the moving platen towards the cover die and holds it closed with great pressure until the molten metal is
injected. The plunger remains in the “down” position to hold the pressure while the casting “cools off.” After solidification, the
plunger is retracted and the cast part is either ejected, manually removed from the machine or pushed off the cover die. This ejection
system, which includes an ejector die and ejector pins, allows the casting to be pushed out while releasing the die halves.

Q. Discuss the importance of clearance in sheet metal cutting operation?

Q. What are the product design consideration of a plastic parts?

Design of plastic components
Mold Wall Thickness
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Non-uniform wall sections can contribute to warpage and stresses in molded parts. Sections which are too thin have a higher chance of
breakage in handling, may restrict the flow of material and may trap air causing a defective part. Too heavy a wall thickness, on the
other hand, will slow the curing cycle and add to material cost and increase cycle time.

Generally, thinner walls are more feasible with small parts rather than with large ones.

Draft angles
Draft angle design is an important factor when designing plastic parts. Because of shrinkage of plastic material, injection molded parts
have a tendency to shrink onto a core. This creates higher contact pressure on the core surface and increases friction between the core
and the part, thus making ejection of the part from the mold difficult. Hence, draft angles should be designed properly to assist in part
ejection.

Radius at corner
Generously rounded corners provide a number of advantages. There is less stress concentration on the part and on the tool. Because of
sharp corners, material flow is not smooth and tends to be difficult to fill, reduces tooling strength and causes stress concentration.
Parts with radii and fillets are more economical and easier to produce, reduce chipping, simplify mold construction and add strength to
molded part with good appearance.

Hole depth to diameter ratio

Core pins are used to produce holes in plastic parts. Through holes are easier to produce than blind holes which don't go through the
entire part.

Q. What are the most common metal process using die casting which type casting machine usually have a higher production
rate and what is flash in die casting?

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

Flash — A thin web or fin of metal on a casting which occurs at die partings, vents and around moveable cores. This excess metal is
due to working and operating clearances in a die.

Q. What’s are different properties of aluminium that makes it suitable for it used in die casting?

Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical
properties; high thermal and electrical conductivity; retains strength at high temperatures

Q. Define the following press operations blanking and piercing drawing sharing bending?

Sheet Metal Operations-Cutting Operations:

2.Blanking Operation: When the force is applied by using the punch on to the sheet, the cutting or shearing action will be taking
place in the sheet producing a piece/blank. Sheet Metal Operations-Blanking OperationIn punch and die working, if the Piece/blank
produced in the sheet is useful, it is called a Blanking operation. In blanking Operation, the die size is made equal to blank size and
clearance is provided only on the Punch and also in blanking, the shear is provided only on the die.

3.Deep Drawing Operation: It is a Sheet Metal forming process in which a sheet metal blank is radially drawn into a forming die by
the mechanical action of a punch. Deep drawing is mainly used for producing Cup-shaped components. Ex: Most of the utensils used
in the kitchen are produced by using Deep Drawing Operation only.
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Deep Drawing Operation-Sheet Metal OperationsIn Deep drawing operation, when the force is applied by using the punch, the sheet is
simply pulled into the die without any shearing action and taking the shape and size same as that of the die.

Applications: Cookware, Aluminum cans, and kitchen sinks.

4.Bending Operation: It is used for bending the sheet into the required angle.

 Straining sheet metal around a straight axis to take a permanent bend is called Bending Process.
 Metal on the inside of a neutral plane is compressed, while metal on the outside of a neutral plane is stretched.

Bending -Sheet Metal Operations

Types of bending operations:

1. V bending
2. U bending
3. Edge Bending

Applications of Bending Operation:

 Drawing board clip, tube light frame, air conditioning duct, etc.
 Automotive industries.
 Delivery of fluids, either gaseous or liquid, in a process plants in Containers.

Shearing, also known as die cutting,[1] is a process which cuts stock without the formation of chips or the use of burning or melting.
Strictly speaking, if the cutting blades are straight the process is called shearing; if the cutting blades are curved then they are
shearing-type operations.[2] The most commonly sheared materials are in the form of sheet metal or plates, however rods can also be
sheared. Shearing-type operations include: blanking, piercing, roll slitting, and trimming. It is used in metalworking and also with
paper and plastics.

Q. Difference between expandable and permanent mould?

Expendable molds can be used once and they must be recreated. Permanent molds can be used multiple times. Expendable molds
typically cost less, but permanent molds yield castings with better dimensional accuracy. Permanent metal molds are better heat
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conductors than expendable nonmetallic molds so the solidifying casting is subject to a higher rate of cooling, which in turn affects the
microstructure and grain size within the casting.

Q. What are the factor to be considered while selecting a press?

Q. how will you stimulate the bending force in a press working operation and what do you mean by bending allowance?

The Bend Allowance

The bend allowance defines the material you will need to add to the actual leg lengths of the part in order to get the flat pattern cut to
a correct size.

The legs of the part are the sides outside of the bend which you can see on the image below.

To calculate this bend allowance, following formula can be used:

This formula takes into account the different geometries of the

part you are forming and its properties.
The most important aspects of this calculation are the material thickness (MT), the bend angle (B), the inside bend radius (IR) and the

K- factor of the material you are bending.

Q. Discuss in detail about the various elements of three plate cold runner injection mould with neat sketch.

Three-plate systems allow the part to be ejected from the runner without an ejection system, but are a little more complicated than
a two-plate system, which does require an ejection system to remove the part and the runner from the mold. Two-plate systems can
handle most molds, however a three-plate system is friendlier when it comes to complex designs.

Pros and Cons of Cold Runner System

Pros
 Inexpensive
 Few restrictions on types of polymers
 Easy to maintain
 Easy to change colors
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Cons
 Runners have to be removed
 Takes4 longer than a hot-runner system

Q. What is meant by Sant height of a press?

SHUT HEIGHT – DIE HEIGHT

The shut height of an upright press is the distance from the top of the bed to the bottom of the slide with stroke down and adjustment
up. The shut height must always be defined either from the top of the bed or from the top of the bolster. The shut height of a horizontal
or inverted press, or of a press with adjustable bed, can be defined in a similar manner. Generally the shut height is equal to the
maximum die-height of the die that can be accommodated, taking the bolster into consideration. Die Height is measured the same but
to the top of the bolster.

Q. What is meant by die clearance how is die clearance expressed and what is the result excessive die clearance and insufficient die
clearance?

Die clearance is equal to the space between punch and pie when the punch enters the die opening.

Q. discuss how will you control warpage in plastic injection mould?

Warping

Description: Warping (or warpage) is the deformation that occurs when there is uneven shrinkage in the different parts of the molded
component. The result is a twisted, uneven, or bent shape where one was not intended.
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Causes: Warping is usually caused by non-uniform cooling of the mold material. Different cooling rates in different parts of the mold
cause the plastic to cool differently and thus create internal stresses. These stresses, when released, lead to warping.

Remedies:

1. Ensure that the cooling time is sufficiently long and that it is slow enough to avoid the development of residual stresses being
locked into the part.

2. Design the mold with uniform wall thickness and so that the plastic flows in a single direction.

3. Select plastic materials that are less likely to shrink and deform. Semi-crystalline materials are generally more prone to
warping.

Q. define the following sheet metal operations like plain blanking lancing piercing notching and shaving?

Q. State the advantage and limitation of die casting process?

A D V A N T A G E S O F D I E C A S T I N G :
Easy for mass production – Since die casting is made from die casting mold, they can be obtained within specified tolerance and
shapes. Little or no machining is required and thousands of identical castings can be produced before additional tooling is required. So
it’s quiet easy to put on mass production.
Dimensional accuracy and stability – Die casting produces parts that are durable and dimensionally stable, while maintaining close
tolerances. They are also heat resistant.
Strength and weight – Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are
stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded
or fastened together, the strength is that of the alloy rather than the joining process.
D I S A D V A N T A G E S O F D I E C A S T I N G :

1) All metals and alloys can not be achieved.

2) The cost of machines, dies and other equipment used is high.

3) It’s not cheap to start with small quantity production.

4) Special precautions are necessary for evacuation of air from die cavity, otherwise cause porosity.

5) It’s impossible to get a die casting prototype when product development process.
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Q. explain the following terms used in casting such as shrinkage allowance draught allowance gate riser parting line?

Various pattern allowances in casting process

1. Shrinkage allowance
2. Draft allowance
3. Finishing or machining allowances
4. Shake allowance
5. Distortion allowance

They are the Pattern allowances in casting process used for making mold.

Shrinkage in casting or shrinkage allowance in casting process:

shrinkage in casting Process one of Pattern allowances

The liquid melon metals are poured into cavity and the mold together after cooling and solidify. In this case the phase change in metal
shorten it`s volume. It is known as shrinkage. Now, the patterns require incorporate suitable allowance for shrinkage. So the patterns
made slightly more than require shape finish.

Draft allowance:

draft on external and internal surface

The leading edge are may be break off or get damaged during the pattern is removed from mold. So that is avoid, the taper is to allow
on the pattern and easily remove from the edge of mold. In this taper having some of angle is called draft angle. The draft angle
depends upon the type of molding, height, and complexity of pattern.

Finishing or machining allowance: The produce the part by using sand casting method. The surface finish of the part will be poor.
So this avoid, the casting of product is machined together in surface like turning or grinding to improve the surface finish during the
machining process, some sufficient amount of metal removed from the mold part. To compensate this, the machining or finishing
allowances are given in the casting. This allowance is added together in basic size of the pattern.

The amount of allowance added to pattern based on,

 Type of machining process

 Material used
 Requirement of accuracy
 Molding method

It ranges from lower than 2 mm to 15 mm based on size and material of the part. For too large machining allowance to increase cost
of molten metal and more removal of metal from mold part by machining.
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Shake or rapping allowance:

The pattern are removed from the mold cavity, sometime the pattern are rapped in easily remove from cavity. In this case the final
mold cavity is enlarged. So to compensate for enlargement, the pattern dimension to be reduced. It is called shake or rapping
allowance.

Distortion or camber allowance:

Distortion or camber allowance

When the mold is cooling process, the stress is developed in solid metal because of the uneven metal thickness or more cooling to
allow in the casting. These stresses may be inducing distortion or bending in the casting. This can be avoided by initially distorting the
pattern in opposite direction.

Decision criteria for parting line selection

In the previous section, factors affecting parting line determination have been discussed.

However, some of these factors are conflicting which necessitates selection of an optimal

parting line. This section gives the out line for selection of parting line. These steps are

explained as under.

i. The part is examined carefully and different features of the part are identified.

ii. Candidate parting directions are identified which are generally along three principal axes

of the part.

iii. Optimal parting direction is selected by following the criteria of minimum number of

undercuts.

iv. Possible parting lines for chosen parting direction are identified.
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v. Candidate parting lines are evaluated using decision criteria to find optimal parting line.

A riser, also known as a feeder is a reservoir built into a metal casting mold to prevent cavities due to shrinkage. Most metals are
less dense as a liquid than as a solid so castings shrink upon cooling, which can leave a void at the last point to solidify. Risers prevent
this by providing molten metal to the casting as it solidifies, so that the cavity forms in the riser and not the casting.
If the riser is located on the casting then it is known as a top riser, but if it is located next to the casting it is known as a side riser.
Injection machine
The injection machine is a machine that melt plasticize the molding material inside the heating
cylinder and inject this into the mold tool to create the molded product by solidifying inside it. The
injection machine is constructed of a mold clamping device that opens and closes the mold tool, and
device that plasticize and inject the molding material. There are several types in the injection
machine, and the difference is made by how these two devices are arranged.

（1） Horizontal injection machine ： Both mold clamping device and injection device compounded

horizontally

（2） Vertical injection machine ： Both mold clamping device and injection device compounded vertically

（3） Two-color injection machine

（4） Rotary injection machine

（5） Low foam injection machine

（6） Multi material injection machine

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（7） Sandwich injection machine

Q. What are patterns?

Types of patterns:
The following factors affect the choice of a pattern.
(i) Number of Castings to be produced.
(ii) Size and complexity of the shape and size of casting
(iii) Type of molding and castings method to be used.
(iv) Machining operation
(v) Characteristics of castings

Different types of patterns:

The common types of patterns are:

1) Single piece pattern

2) Split piece pattern
3) Loose piece pattern
4) Gated pattern
5) Match pattern
6) Sweep pattern
7) Cope and drag pattern
8) Skeleton pattern
9) Shell pattern
10) Follow board pattern
Q. Precautions necessary while die casting the aluminium parts?
Failure to use proper procedures in melting and casting aluminum can be dangerous. Molten Aluminum is typically handled at 1300-
1450 degrees Fahrenheit to avoid premature solidification. Contact with molten aluminum can cause severe burns and create a serious
fire hazard. Mixing water or other contaminants with molten aluminum can cause explosions. Explosions can also occur in the aluminum
scrap re-melting process due to moisture and contamination in scrap.

TheseThese explosions range widely in violence and can result in injury or death as well as destruction of equipment and plant
facilities. Where there is possibility of splash or other direct exposure, personnel working with molten aluminum must wear eye and
face protection as well as protective clothing.

Q. What are the die design principle?

The main components for die tool sets are:

 Die block – This is the main part that all the other parts are attached to.
 Punch plate – This part holds and supports the different punches in place.
 Blank punch – This part along with the blank die produces the blanked part.
 Pierce punch – This part along with the pierce die removes parts from the blanked finished part.
 Stripper plate – This is used to hold the material down on the blank/pierce die and strip the material off the punches.
 Pilot – This will help to place the sheet accurately for the next stage of operation.
 Guide, back gauge, or finger stop – These parts are all used to make sure that the material being worked on always goes in the same
position, within the die, as the last one.
 Setting (stop) block – This part is used to control the depth that the punch goes into the die.
 Blanking dies – See blanking punch
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 Pierce die – See pierce punch.

 Shank – used to hold in the presses. it should be aligned and situated at the center of gravity of the plate

Q. Method of reducing cutting force with suitable sketches of punch design?

Q. Define press tonnage?

Q. Types of material used in die for die casting?

Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based
alloys.
Q. Types of press used in sheet metal work?
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Q. Why casting preferred over other method of manufacturing?

Advantages and Disadvantages:
Advantages:
Casting has following advantages over other manufacturing process.

 It can create any complex structure economically.

 The size of object doesn’t matter for casting.
 The casting objects have high compressive strength.
 All structure made by casting has wide range of properties.
 This can create an accurate object.
 All material can be cast.
 It creates isotropic structure.
 It is cheapest among all manufacturing processes.
 Composite component can be easily made by casting.
Disadvantages:
Along these advantages, casting has following disadvantages.

 It gives poor surface finish and mostly requires surface finish operation.
 Casting defects involves in this process.
 It gives low fatigue strength compare to forging.
 It is not economical for mass production.

Q. Die casting advantages ?

ADVANTAGES OF DIE CASTING

Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing
technique. Parts have long service life and may be designed to complement the visual appeal of the surrounding part. Designers can
gain a number of advantages and benefits by specifying die cast parts.
High-speed production – Die casting provides complex shapes within closer tolerances than many other mass production processes.
Little or no machining is required and thousands of identical castings can be produced before additional tooling is required.
Dimensional accuracy and stability – Die casting produces parts that are durable and dimensionally stable, while maintaining close
tolerances. They are also heat resistant.
Strength and weight – Die cast parts are stronger than plastic injection moldings having the same dimensions. Thin wall castings are
stronger and lighter than those possible with other casting methods. Plus, because die castings do not consist of separate parts welded
or fastened together, the strength is that of the alloy rather than the joining process.
Multiple finishing techniques – Die cast parts can be produced with smooth or textured surfaces, and they are easily plated or
finished with a minimum of surface preparation.
Simplified Assembly – Die castings provide integral fastening elements, such as bosses and studs. Holes can be cored and made to
tap drill sizes, or external threads can be cast.
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Q. Advantage and limitation of sand casting?

Q. Explain feed ejection and cooling system?

1.1 COOLING CHANNEL:

Mould cooling process accounting for more than two-third of the

total cycle time in the production of Die Casting die parts. An

efficient cooling channel design reduces the cooling time and

increases overall productivity of the moulding process.

Moreover, uniform cooling improves part quality by reducing

residual stresses and maintaining dimensional accuracy and

stability.

TYPES OF COOLING CHANNEL

I. Conventional cooling channel.

II. Conformal Cooling Channel.

i. CONVENTIONAL COOLING CHANNEL:

There are two types:

Parallel cooling channels.

Serial cooling channels.

1. Cooling
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- The molten metal that is injected into the die will begin to cool and solidify once it enters the die cavity. When the entire cavity
is filled and the molten metal solidifies, the final shape of the casting is formed. The die can not be opened until the cooling time
has elapsed and the casting is solidified. The cooling time can be estimated from several thermodynamic properties of the metal,
the maximum wall thickness of the casting, and the complexity of the die. A greater wall thickness will require a longer cooling
time. The geometric complexity of the die also requires a longer cooling time because the additional resistance to the flow of heat.

2. Ejection
- After the predetermined cooling time has passed, the die halves can be opened and an ejection mechanism can push the casting
out of the die cavity. The time to open the die can be estimated from the dry cycle time of the machine and the ejection time is
determined by the size of the casting's envelope and should include time for the casting to fall free of the die. The ejection
mechanism must apply some force to eject the part because during cooling the part shrinks and adheres to the die. Once the casting
is ejected, the die can be clamped shut for the next injection.

Materials Properties

 Low density
 Good corrosion resistance
Aluminum alloys  High thermal and electrical conductivity
 High dimensional stability
 Relatively easy to cast
 Requires use of a cold chamber machine

 High strength and toughness

 High corrosion and wear resistance
Copper alloys  High dimensional stability
 Highest cost
 Low die life due to high melting temperature
 Requires use of a cold chamber machine

 Very low density

Magnesium alloys  High strength-to-weight ratio
 Excellent machinability after casting
 Use of both hot and cold chamber machines

 High density
 High ductility
 Good impact strength
 Excellent surface smoothness allowing for painting or plating
Zinc alloys  Requires such coating due to susceptibility to corrosion
 Easiest to cast
 Can form very thin walls
 Long die life due to low melting point
 Use of a hot chamber machine

Injection
- The molten metal, which is maintained at a set temperature in the furnace, is next transferred into a chamber where it can be injected
into the die. The method of transferring the molten metal is dependent upon the type of die casting machine, whether a hot chamber or
cold chamber machine is being used. The difference in this equipment will be detailed in the next section. Once transferred, the molten
metal is injected at high pressures into the die. Typical injection pressure ranges from 1,000 to 20,000 psi. This pressure holds the
molten metal in the dies during solidification. The amount of metal that is injected into the die is referred to as the shot. The injection
time is the time required for the molten metal to fill all of the channels and cavities in the die. This time is very short, typically less
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than 0.1 seconds, in order to prevent early solidification of any one part of the metal. The proper injection time can be determined by
the thermodynamic properties of the material, as well as the wall thickness of the casting. A greater wall thickness will require a
longer injection time. In the case where a cold chamber die casting machine is being used, the injection time must also include the
time to manually ladle the molten metal into the shot chamber.

Q. Neat sketch of RBI press showing major components explain each components of the press?
OPEN BACK INCLINABLE PRESS (OBI) – the most versatile and most widely used of mechanical presses. It is a single crank
press of either the flywheel or single geared type. It has a gap frame that is arranged so that the press may be inclined. This frame
provides unobstructed access to the die space from three sides of the press and the inclinable allows the press to be arranged so that the
finished parts may be removed from the die by gravity, and directed through an opening in the back of the press. OBI presses are built
in a wide range of sizes with nominal tonnage ratings from 15 to 200 tons, and built to standard specifications. The stroke, shut height
and spm may be varied within limits. The OBI has been put to countless different uses and is an ideal general purpose machine for
work involving blanking, bending, and shallow drawing.

Press types

Open back inclinable (OBI) press

Straight side press

Press brake

Double action press

Triple action press

Knuckle press

Hydraulic press

Base

The all machine tool, base is the one of the parts of a press. It is main supporting

member for workpiece holding dies and different controlling mechanisms of press.

Size of the table limits the size of workpiece that can be processed on a press. In

case of some special presses the base carries mechanism for tilting the frame in
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any desirable inclined position too.

Frame Press and Press Tools

Frame constitute main body of the press located at one edge of its base. It houses

support for ram, driving mechanism and control mechanisms. Some of the press

have column shaped frame.

Ram

This is main operating part of the press which works directly during processing of

a workpiece. Ram reciprocates to and fro within its guideways with prescribed

stroke length and power. The stroke length and power transferred can be adjusted

as per the requirements. Ram at its bottom end carries punch to process the workpiece.

Q. What is meant by stripping? Explain with sketch various types of strippers used in seat metal working ?

Strippers:
After a blank has been cut by the punch on its downward stroke, the scrap strip has the tendency to expand. On the return stroke of the
punch the scrap strip has the tin deny to adhere to the punch and be lifted by it. This action interface with the feeding of the stroke
through the die and some device must be used to strip the scrap material from the punch as it clears up the die block. Such a device is
called “stripper” or stripper plate.
Stripper plate are of two types:
1: fixed or stationary
2: spring loaded or movable
(a): fixed or stationary strippers:
This stripper is attached at a fixed height over the die block. The height should be sufficient to permit the sheet metal to be fed freely
between the upper die surface and the under surface of the stripper plate. The stripper plate thickness is determining by the formula:
Ts =1/8(w/3+16t)
Where w and t are width and thickness of the stock strip. The fixed stripper is also known as ‘channel stripper”
(b): Spring loaded Stripper:
This type is used on large blanking operations and also on very thin and highly ductile materials. As the punch travels downward for
blanking operation the stripping force is determined with the help of following relation. Fs=spt kn
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Where p and t are in mm and s is the stripping constant.

Q. different types of punches used in sheet metal working? Explain them with neat sketches.
Punch is a hard metal rod with a sharp tip at one end and a blunt butt end at the other, which is usually struck by a hammer. Typically,
woodworkers use a ball-peen hammer to strike a punch.
Metal pins and similar connectors are driven in or out of holes using a pin punch.

For removal, first use a starter punch to loosen the pin, then use a pin punch to finish.
center punch is used to mark the center of a point. It is usually used to mark the center of a hole when drilling holes.
A prick punch is similar to a center punch but used for marking out. It has a sharper angled tip to produce a narrower and deeper
indentation.
A transfer punch is a punch (usually in an index set) of a specific outer diameter that is non-tapered and extends the entire length of
the punch (except for the tip). It is used to tightly fit the tolerances of an existing hole and, when struck, precisely transfer the center
of that hole to another surface.
A drift "punch" is misleadingly named; it is not used as a punch in the traditional sense of the term. A drift punch, or drift pin, or
lineup punch, is used as an aid in aligning bolt or rivet holes prior to inserting a fastener.
Spring punches, also called roll pin punches, are used to drive roll pins.

Q. What is the function of pouring basin in metal casting? Discuss its consideration.