International Journal of Trend in Scientific Research and Development (IJTSRD) Volume 5 Issue 5, July-August 2021 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470 @ IJTSRD | Unique Paper ID – IJTSRD46283 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 2167 Design and Analysis of Pressure Die Casting for Door Handle Lokesh Narayan Dhak 1 , Vaibhav Bankar 2 1Department of Mechanical Engineering, Vidarbha Institute of Technology, Nagpur, Maharashtra, India 2Head of Department of Mechanical Engineering, Vidarbha Institute of Technology, Nagpur, Maharashtra, India ABSTRACT Die casting is a metal casting operation that is specified by forcing molten metal under elevated pressure into a mould cavity. The mould cavity is build using two hardened tool steel dies which have been machined into shape and work closely to an injection mould during the process. While casting, a hot- or cold-chamber machine is used as requirement. While the using of round shaped aluminum door handles it detect that while opening the door whole load is concentrated on two screws which develop in tearing the area where handle is fastened, came in observation that if fastened screw get teared it looks odd . I have redesigned the Door handle maintaining its aesthetic appearance and design to overcome the said identified problem. KEYWORDS: casting, die, cavity etc How to cite this paper: Lokesh Narayan Dhak | Vaibhav Bankar "Design and Analysis of Pressure Die Casting for Door Handle" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456- 6470, Volume-5 | Issue-5, August 2021, pp.2167- 2172, URL: www.ijtsrd.com/papers/ijtsrd46283.pdf Copyright © 2021 by author (s) and International Journal of Trend in Scientific Research and Development Journal. This is an Open Access article distributed under the terms of the Creative Commons Attribution License (CC BY 4.0) (http://creativecommons.org/licenses/by/4.0) I. INTRODUCTION Die casting is a metal casting operation that is specified by forcing molten metal under elevated pressure into a mould cavity. The mould cavity is build using two hardened tool steel dies which have been machined into shape and work closely to an injection mould during the process. While casting, a hot- or cold-chamber machine is used as requirement. The casting appliances and the metal dies shows large capital costs and this tends to curb the process to high-volume production. Die casting is a process for manufacturing and producing metal parts. It is adept by blasting molten metal under high pressure into reusable metal dies The term “die casting” is also used to describe the finished part.The two prime types of die casting activity are hot-chamberand cold- chamber die casting. Two sorts of die casting include: 1. Hot chamber system. 2. Cold chamber system
Low-pressure die casting
Vacuum die casting
Squeeze die casting
Semi-solid die casting II. OBJECTIVES The main objective of the study is to design the pressure die casting tool to produce good quality component economically. Also:-
Change of design to achieve equally distributed load.
Reduction of material.
To maintain aesthetic appearance good..
Make conceptual design of die.
Design calculations. III. MODEL STUDY AND MODELLING OF COMPONENT Model study includes study of model for what to be modified. Examine the criticality of component. Proper design of component. Component is modeled using the software SOLIDWORK. Volume of Component – 1.126 e-005 Cu M Area of Component – 12000 sq. mm. IJTSRD46283 International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID – IJTSRD46283 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 2168 Figure No. 1 3D model of Pressure Die Casting for Door Handle Following Figure shows the Drafting of Pressure Die Casting for Door Handle all Dimensions are in mm. Figure No. 2 Drafting of Pressure Die Casting for Door Handle IV. MACHINE SELECTION Machine selection for creating any casting is be based on clamping force and operating stroke, length of shot stroke, maxi. shot pressure, maxi. die opening and die size, max. & min. die height, clearance between beams, over-all size and price. Clamping force is not necessary the deciding factor in the selection of a die a casting machine. Die dimensions must be considered. The machine having tonnage for casting a part is insufficient platen area or tie-rod spacing for the die, or the opening stroke may not be sufficient for ejection of casting. Another factor is the cost of the equipment, which must be payoff in the cost of operation. The cost of off-line equipment for die casting machine is typically proportionate with the dimensions of the machine. Specification of HMT die casting machines:- Table No. 1 Specification of HMT die casting machines. Production data of HMT die casting machine :- Table No. 2 Production data of HMT die casting machine V. DESIGN CALCULATIONS Volume of Component – 1.126 e-005 Cu M Area of Component – 12000 sq. mm 1. Calculation of opening force: - Opening force (Fo)= Ac x Pc 100 Where: Ac = Area of component X 1.45 sq cm 1.45 = Area of feed system x Area of overflows Pc = Cavity pressure/Technical Part It will considered as 400 bar to 600 bar Ac = 12000 x 1.45 17400 sq. mm 174 sq. cm (Fo)= 174 x 60 100 Fo = 1044 Tons 2. Calculation of Closing Force :- Closing Force = Factor of safety + Opening force Closing Force = 20 x 1044 + 1044 100 = 1252.8 Tons From machine specification, machine will be selected by projected area of component, Our component projected area is 174 sq. cm which is under machine area range. International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID – IJTSRD46283 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 2169 3. Calculation of Gate area:- Where: Qg = Discharge of material through gate Vg= Gate Speed Qg= Volume of component x 1.30 Filling time The filling time is taken as average value Qg= 0.0000126 x 1.30 0.1 Qg= 0.00014638 cu m Qg= 146.38 cu cm/sec Vg= 50 m/sec Vg= 5000 cm/sec Ag= 146.38 5000 = 0.0292 mm = 0.0292 x 100 = 2.92 sq. mm Round of 3 sq. mm 4. Thickness of gate = S/3 Tg = 2/3 Tg =0.667mm Tg = 1 mm Where, S= Area of wall Thickness 5. Width of Gate, Wg = Ag/Tg Where, Ag= Area of gate. Tg= Thickness of gate. Wg = 3/1 = 3 mm 6. Length of Gate Tg = 2 to 3 times of Wg = 2 x 3 Tg= 6mm 7. Area of Runner, Ar = 1.25 x Ag = 1.25 x 3 = 3.75 Ar = 4 mm 8. Runner depth, Tr = Ar/1.6 = 4/1.6 = 1.58mm = 2mm Gate area (Ag)= Qg Vg 9. Width of runner, Wr= Ar/Tr = 4/2 = 2mm 10. Length of Runner, Lr = 2 x Wr = 2 x 2 = 4 mm 11. Ejector pin calculation Ejector area = 4% of component area Ac= 1200 x 4/ 100 Ac= 480sq. mm Consider ejector pin dia as 8mm Area, A (Ejection pin) = r2 = x 42 = 50.26 sq. mm No. of ejection pin = Area (ejection)/ Area (ejection pin) = 480/50.26 = 9.55 = 10 pins 12. Over flow calculation: - Taken as 30% of component volume = 30 x 14.63/100 = 4.389 = 5 cu cm Consider over flow = 3 Volume of single over flow = 5/3 = 1.66 cu cm = 1.66 x 1000 = 1666.66 cu mm By theoretical way Depth = 3 x thickness = 3 x 2 = 6 mm Width = 2 x depth = 2 x 6 = 12 mm Length = 2 x width = 2 x 12 = 24 mm. International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID – IJTSRD46283 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 2170 Cavity Insert Take, where, C1=30 , Distance from center line C2=30 , Distance from center line C3=50 , Distance from center line C4=50 , Distance from center line S = C1+75 = 30+75 = 105 mm W1 = C3+C4+120 = 50+50+120 = 220 mm ST = S+C2+60 = 105+30+60 = 195 mm. Core Insert Take, K1 = 80 , K3 = 100 K2 = 80 , K4 = 100 L = K1+S1+K2 L = 80+95+80 L = 255 mm W = K3+W1+K4 W = 100+220+100 W = 420 mm VI. ANALYSIS The following figure shows various analysis of Door Handle carried out in ANSYS software. Figure No. 3 Force Analysis of Door Handle Figure No. 4 Stress Analysis of Door Handle Figure No. 5 Total Deformation Analysis of Door Handle International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID – IJTSRD46283 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 2171 Figure No. 6 Partial Structure Force Analysis of Door Handle VII. TOOL ASSEMBLY Tool assembly is done in modeling software, includes the fixing of extracted core and cavity inserts into the Die, after assembly 3D models are converted into the 2D drawings for manufacturing process Figure No. 7 3D View Assembly for Pressure Die Casting of Door Handle Figure No. 8 Wireframe View Assembly for Pressure Die Casting of Door Handle Figure No. 9 Ballooning of Pressure Die Casting of Door Handle Figure No. 10 Bill of Material of Assembly of Pressure Die Casting of Door Handle VIII. CONCLUSION In this project, we carried out the Design and Analysis of Pressure Die Casting for Door Handle. The complete pressure die tool is designed for fabricating Door Handle by using solid work. All the results viz. Stress analysis, deformation analysis are analyzed by using ANSYS software. And also we have design the pressure Die casting tool assembly for Door Handle by considering standard design consideration and it has not shown any error in the analysis. International Journal of Trend in Scientific Research and Development @ www.ijtsrd.com eISSN: 2456-6470 @ IJTSRD | Unique Paper ID – IJTSRD46283 | Volume – 5 | Issue – 5 | Jul-Aug 2021 Page 2172 REFRENCES [1] "The Production of Aluminium Die Castings using a Fan Gate" Transactions, Society of Die Casting Engineers, (now NADCA) 1975, Paper G-T75-122 A. J. Davis and P. M. Robinson [2] "The Significance of Metal Pressure in Hot Chamber Die Casting" Parts I,II and III Transactions, Society of Die Casting Engineers, (now NADCA) 1977. A. J. Davis and H. Siauw [3] “Rationale of the SDCE Gating Equation" Proceedings, Australian Die Casting Association, 1989 E. A. Herman [4] “A Fast Die Design Technique" Proceedings, Australian Die Casting Association, 1993 Graham Wilson [5] “The Effect of Operating Conditions & Gate Design on the Fill of 4mm Thick Flat Plate Castings" - Parts 1,2 and 3.Proceedings, Society of Die casting Engineers of Australia (now ADCA), 1980 A Davis, H. Siauw, M. Murray [6] “Zinc Pressure Die Casting - the Metal Flow System" Australian Zinc Development Association M. A. Cope [7] “Venting Design in Die Casting: An Analytical Approach" Transactions, North American Die Casting Association, 1991 Yiftah Karni.