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عدد المساهمات : 18990 التقييم : 35476 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
| موضوع: كتاب Die Casting Engineering السبت 31 ديسمبر 2022, 1:29 am | |
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أخواني في الله أحضرت لكم كتاب Die Casting Engineering A Hydraulic, Thermal, and Mechanical Process Bill Andresen
و المحتوى كما يلي :
Contents Preface iii About the Author v Introduction ix 1. Terms Used in Die Casting 1 2. Product Design . 21 3. The Die Casting Machine . 69 4. Casting Metallurgy 105 5. Metal Handling . 139 6. Concepts of Cavity Fill . 175 7. Metal Feed System . 185 8. Process Control . 209 vii9. A Thermal Process . 237 10. Designing the Value Stream . 263 11. Die Materials . 289 12. Mechanical Die Design . 305 13. Die Set Up Techniques . 339 14. Die and Plunger Lubrication 353 15. Safety . 365 References 375 Index 37 Index APQP, advanced product quality planning, 235 Air in the cavity, 203 core slides and ejector pins, 203 Allowance for shrinkage, 325 shrink factor, 326 Angle pin, 329 core movement, 329 Atomized mist, 182 Base metal, 239 Basic linear tolerances, 50 Biscuit thickness consistency, 210 Brinell system, 2 Cast shape, 180 Casting cycle, 4 Casting defects, 54 Casting quality, 54 Cavitation, 133 small pits, 133 Cavity fill, 6 Cavity fill time, 177, 202 fill pattern, 178 gate area, 202 gate speed, 202 Cavity insert size, 318 Cavity orientation, 318 Cavity prefill, 180 Center gating, 327 Chisel gate, 196 Cleanliness, 89 die casting operation, 89 Cold chamber process, 225 Cold shut defects, 177 poor fill, 270 porosity, defects, 186 Conductor, 242 copper, 243 Constant area sprue, 187 male post and female bushing, 187 379Constant velocity mode, 212 Control charts, 266 Control lines, 266 lower control limit, 266 upper control limit, 266 Core pulls, 309, 329 Corundum, 157 dense form of aluminum oxide, 157 Cost justification, 307 Creep or stress corrosion cracking, 47 Critical design feature, 44 Critical temperatures, 107 Crystal or grain, 109 Cylinder intensifiers, 210 Degree of complexity, 23 Dendrite, 113 Dendrite fingers, 114 arms, 114 Design characteristics, 143 Die and plunger lubricants, 353 release agents, 353 Die blow, 26 degree of difficulty, 26 Die casting alloys, 239 Die casting defects, 263 Die casting engineer, 40 best casting design, 40 good die caster, 40 Die casting machines, 73 cold-chambered machines, 74 hot-chambered machines, 74 Die castings, 105, 108 aluminum, magnesium, zinc, lead or tin, 105 dense structure, 108 fine grain size, 108 superior mechanical properties, 108 Die casting suppliers, 235 Die checking, 290 die spray duration, 290 Die configuration, 309 Die design, 25 die halves, 25 Die height adjustment, 84 loosening tie bar nuts, 84 tightening tie bar nuts, 84 Die layout, 316 die half, 316 Die life, 300 ion nitriding, ball peening, rocklinizing, solventing, 300 Die material costs, 186 Die materials, 289 air, oil, or water hardened, 289 mild steel alloys, 289 Die pitting, 201 Die preheating, 343 Draft allowance, 52 Draft angles, 327 Dross, 160 Economic dimensions, 63 Ejection systems, 95 bump bar system, 95 hydraulic system, 95 Electrical discharge machining, 293 Electrodeposition, 8 Electroplating, 3 Emulsion, 357 European die caster, 5 Eutectic, 115 Eutectic or lowest melting point, 239 Excessive flash, 210 Expansion, 131 Failure mechanism, 291 gross cracking, 291 heat checking, 291 Fast shot plunger velocity, 309 Fill strategy, 318 First shot success, 32 Fit tolerances, 218 380 Index 5935-4 Andresen Ch00 R3 101504Flow control valve, 87 velocity of movement, 87 Fluidity of the casting alloy, 39 designing wall thickness, 39 Furnace charts, 300 Galvanic corrosion, 48 electromotive scale, 48 Gate design, 193 Gate speed, 182 serious erosion, 182 turbulence, 182 Gating and venting, 306 Geometric tolerances, 24 Geometrical shape, 55 boomerang shape, 56 box shape, 55 flat plate, 55 hat shape, 55 Gravity feed, 186 Gross distortion, 47 Hard spots, 269 Heat checking, 289 dimensional expansion, 290 Heat depressions, sinks, 272 Heat exchanger, 240 Heat of fusion, 107 Heat transfer, 155 radiation, convection, conduction, 155 Heat transfer medium, 241 oil, 241 water, 241 Heavy walls, 60 thin ribs, 60 High pressure die castings, 109 Hot chamber machines, 96 casting zinc and magnesium, 96 low temperature alloys, lead, 96 Hot chamber process, 225 Hydraulic pumps, 87 high pressure=low volume configuration, 87 low pressure=high volume configuration, 87 Hydrogen in liquid aluminum alloys, 157 density, reduced pressure hydrogen probes, 157 testing, vacuum fusion, Hypereutectic aluminium– silicon alloy, 122, 390 Ideal runner system, 192 IGES (international graphics exchange system), 62 Immersion tube burners, 148 melting zinc, 148 Implosion, 134, 200 die pitting, 134 Insert, 58 Interlocking cores, 57 broken die component, 58 heroic die maintenance, 57 Interlocking core arrangement, 58 Internal defects, 268 foreign inclusions, 268 Latent heat of fusion, 115, 137 Lean technology, 264 value, value steam, flow, pull, perfection, 264 Leidenfrost phenomenon, 359 Lettering or any form of artwork, 61 raised lettering, 61 a mating component, 61 Limit switches, 91 activation and=or deactivation of solenoid valves, 91, 92 position of machine component, 91 Index 381 5935-4 Andresen Ch00 R3 102604Liquid metal containers, liquid metal treatments, heat sources, thermal controls, 141 Liquid specific heat, 137 Locking force, 209 Machine base, 77 stationary and moving parts, 77 Machine clamping force, 318 die retainers, 319 ejector rails, 319 Machine locking force, 310 Machining, 292 drilling, 292 milling, 292 Machining stock, 52 Maintenance and interior cleaning, 154 Maintenance of automated equipment, 366 Manufacture of die castings, 140 Martinsite, 297 heat energy, 140 labor, 140 metal, 140 Massive chill plug, 203 Master shot profile, 236 Maximum fill time, 227 net shape of the cavity, 227 Maximum material condition, 46 Metal feed system, 187 Metal fill pattern, 333 Metal handling, 366 Melting loss, 133 Mid area, 194 Minimum process control, 235 Motorized die height adjustment, 86 Movement between planes, 112 twinning mechanism, 112 Natural air venting, 175 Near net shape, 42 North American die casters, 5 Occupational safety and health administration (OSHA), 366 Operating window (WIN), 229 dry shot capability, 229 machine line, 229 restriction lines, 229 Overflows, 201 ejector pin marks, 201 false ejector, 201 Pareto chart, 268 Parting line flash, 60 flash plane, 60 hydraulic or mechanical trim, 60 trim cutters, 61 Parting line geometry, 316, 333 parting line step, 316 trim die, 333 trim operation, 333 Physical performance, 359 Platens, 79 adjustable platen, 79 ejector platen, 79 movable platen, 79 stationary platen, 79 traveling platen, 79 Plunger velocity, 213 Porosity, 276 PPAP, production parts approval process, 30 PQ Squared concept, 219 Precision draft tolerance, 53 Preheating methods, 344 cold shut, 137 lamination, 137 poor fill, 137 porosity, 137 propane torch, electric infrared heater, hot oil, 344 Preventive maintenance, 99, 347 382 Index 5935-4 Andresen Ch00 R3 101404Process monitoring, 219, 232 shot system repeatability, 232 Process variables, 267 Product design, 54, 64 Production and assembly, 45 Quality of die casting production, 257 heat, 257 temperature, 257 Quenching, 299 Rapid solidification rate, 107, 108 Resmelted, 2 Retainer size, 318 Reverberatory furnace, 144 die casting aluminum, 144 Ribs are structural features, 59 controlling warpage, 59 Runners and step, 316 Runners and gates, 185 Safeguarding devices, 368 audible alarm, hard spot, infrared sensor, interlock switch, light curtain, motion detector, physical barrier, safety mat, safety mirror, ultrasonic sensor, video monitor, visual alarm, 368, 369 Scale buildup, 256 Set up techniques, 340 Shoe horning, 306 Shot sleeve, 223 Shot sleeve temperature, 191 Shrinkage, 130 Shrinkage porosity, 132, 278 centerline porosity, 279 leaker, 279 rough and irregular inside surface, 132 volumetric shrinkage, 132 Shut off allowance, 318 Shut off distance, 318 Six sigma defect , 265 Six sigma exercise, 180 Six sigma opportunity, 265 Solderage, 274 Soldering, 49, 302 Soldering stages, 303 Solenoid valve, 87 direction of movement, 87 Solid specific heat, 137 Solidification, 2, 317 Solvent carriers, 356 Sophisticated process control, 234 Sources of heat, 141 natural gas, electricity, 141 Special gaging, 315 casting details and tolerances, 315 Specific heat, 245 Specular reflectance, 10 Spreader pin, 188 Standard die components, 306 Sub-assembly supplier, 50 Submarine cores, 58 Support pillars, 320 ejector pins, 320 inserted cores, 320 Surface tension, 358 Swirling effect, 196 T-slots or tapped holes, 80 Temperature drop, 135 Thermal conductivity, 359 Thermal crowning, 321 Thermal decomposition, 359 Thermal extreme, 290 chemical content, grain structure, alignment, internal integrity, cleanliness, heat treatability, 290 Thermal properties, 358 Index 383 5935-4 Andresen Ch00 R3 101404Throughput or yield of salable high quality castings, 219 Tiebars, 81 Time, temperature, transformation curve, 298 Toggle linkage system, 84 Tool economy, 66 Tooling cost, additional, 56 Tool tolerance, 315 angularity tolerances, 315 parting line (die blow), 315 shrinkage, 315 Tooling and equipment, 347 Tooling cost, 63 critical economic ingredient, 64 secondary machining, 65 Trim press, 13 Variable factors, 235 dynamic factors, 235 manual factors, 235 [Variable factors] static factors, 235 Vena contracta, 189 air entrapment, 190 Vent area, 201 Vent path, 202 cavity insert and the die retainer, 202 Venting of the die cavity, 201 Venting, 13 Wall thickness, 27 surface area to volume ratio, 28 Water diluent, 356 Young’s modulus, 125 Zinc die castings, 134
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