Die Cast Engineering

A frequently misunderstood technology, die casting is considered the shortest route between raw material and near net shape. For many decades, high pressure die casting was viewed as an art based upon "seat of the pant" strategies. However, many of these crude reactions actually worked because the fundamental process is quite forgiving of eccentric

A frequently misunderstood technology, die casting is considered the shortest route between raw material and near net shape. For many decades, high pressure die casting was viewed as an art based upon "seat of the pant" strategies. However, many of these crude reactions actually worked because the fundamental process is quite forgiving of eccentricities. Exploring these reactions with scientific logic, Die Casting Engineering presents a broad study of each procedure in the die casting process and clearly outlines its basic science and principles. This guide is written in a reader-friendly and logical format by an experienced authority in quality and productivity enhancement, tooling design, metal feed system analysis, temperature management, and environmental regulation. While its scope is broad and covers the many facets of die casting, the book's main focus is on function, problem identification and solution, and strategic logic. Generously illustrated, it provides a comprehensive explanation of why high pressure die casting is reliable, predictable, and teachable.

For a long time, the die cast industry has used trial and error as a leading development method, resulting in tremendous growth in the utilisation of available CFD (computational fluid dynamics) software. This software allows the development of better products that maximise the advantages the die cast process has to offer. Casting: An Analytical Approach will refresh knowledge of the governing laws of the fluid dynamics that have an effect on die cast die and die cast process design. MATLAB® (MathWorks, Inc.) and Visual Basic® (Microsoft) code are listed in Casting: An Analytical Approach for every stage of product, die and die cast process design; providing better understanding of die and process design and simplifying calculations of the die cast die as well as the die cast process. Gas ventilation system calculations and fundamentals of compressible gas flow are also included. Readers will learn about: the advantages and limitations of the die cast process; the implications that product design has on the quality of the die cast part; how die cast die and process design can affect the physical properties of the casting; the calculations die cast die and process designers have to do; choosing the die cast machine size and the proper gate size; and how to properly design gas ventilation systems, identify an ideal fill time, and calculate fast and slow shot velocity. The use of MATLAB® and Visual Basic® code to illustrate every stage of the design will help readers to gain a better understanding of the importance of collaboration throughout the entire process. Therefore, Casting: An Analytical Approach will be of interest to product designers who design die cast parts, and die cast die and process engineers and designers.

"It's about time that a practicing engineer with casting and academic experience has written a book that provides answers to questions about squeeze casting and semi-solid molding/forming that many engineers and students of casting need answered." —Joseph C. Benedyk, PhD, Consultant and retired technical director, Alcoa High Integrity Die Casting Processes provides a comprehensive look at the concepts behind advanced die casting technologies, including vacuum die casting, squeeze casting, and several variants of semi-solid metalworking. Practical applications for these processes are illustrated in numerous case studies. This single-source reference tool presents the latest material in five sections: Basic concepts of die casting and molten metal flow High integrity die casting processes with case studies Product design considerations Controlling quality and avoiding defects Future advances under development Key coverage includes a survey of liquid metal flow, strategies to overcome the limitations of conventional die casting, and potential defects unique to high integrity die casting processes. Also featured are methods for minimizing porosity, reducing cost by design, practical applied statistical process control techniques, designing for manufacturability, and containment methods for potential processing defects. Several chapters present detailed real-world examples illustrating the broad range of applications possible using high integrity die casting processes. Included with this book is a CD-ROM containing PowerPoint(r) presentations for each chapter. These presentations can be used for training purposes in conjunction with numerous study questions designed to practically apply the content of the book to real-world situations. Selected PowerPoint(r) slides can be used to support engineering proposals, marketing presentations, or customer education seminars. High Integrity Die Casting Processes is a valuable reference for both component producers and component users alike. Process engineers, tool designers, manufacturing engineers, production managers, and machine operators will acquire a better understanding of these advanced die casting processes to optimize manufacturing and improve product quality. Component designers, product engineers, purchasing agents, buyers, supplier quality engineers, and project managers will gain insight into these processes and develop superior products by design.

A frequently misunderstood technology, die casting is considered the shortest route between raw material and near net shape. For many decades, high pressure die casting was viewed as an art based upon "seat of the pant" strategies. However, many of these crude reactions actually worked because the fundamental process is quite forgiving of eccentricities. Exploring these reactions with scientific logic, Die Casting Engineering presents a broad study of each procedure in the die casting process and clearly outlines its basic science and principles. This guide is written in a reader-friendly and logical format by an experienced authority in quality and productivity enhancement, tooling design, metal feed system analysis, temperature management, and environmental regulation. While its scope is broad and covers the many facets of die casting, the book's main focus is on function, problem identification and solution, and strategic logic. Generously illustrated, it provides a comprehensive explanation of why high pressure die casting is reliable, predictable, and teachable.

This practical guide to product and process engineering of various aluminum castings emphasizes process and material characteristics; product-process-alloy integration; manufacturing aspects of aluminum casting; product design features; tooling design, feeding and gating design; product quality needs and specifications; product launches; and successful conversions of aluminum from steel and iron.

This work describes the origin, procedure, and advantages of Die casting. It is a metal casting technique in which one pushes molten metal under high pressure into a mold cavity. Along with presenting the general facts on the subject, the writer goes into detail, explaining the operation of die casting machines, the process of making dies, and some quick tips to help the manufacturers improve efficiency. In addition, the book contains a chapter dedicated to the die casting company E. B. Van Wagner Mfg. Co., illustrating how their operations are carried out. Contents include: Die Casting Making Dies for Die-Casting Machines Van Wagner Mfg. Co.'s Die-Casting Practice