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    Design For Manufacturing and Assembly (DFMA)

    Uploaded by

    MK Saravanan
    This document discusses design for manufacturing considerations for die casting processes. It provides formulas to calculate the required clamp force for a die casting machine based on the projected area and pressure of the molten metal. It also discusses how to estimate the plate size needed based on part dimensions and considerations like clearance between cavities. Finally, it shows how to calculate the total cost of the die casting process based on factors like machine operating rate, cost of the die casting die and trim die, and how the number of cavities affects the overall cost. The most economical number of cavities can be determined to minimize the total cost for a given die casting task and machine size.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Design For Manufacturing and Assembly (DFMA)

    Uploaded by

    MK Saravanan
    51 views12 pages
    This document discusses design for manufacturing considerations for die casting processes. It provides formulas to calculate the required clamp force for a die casting machine based on the projected area and pressure of the molten metal. It also discusses how to estimate the plate size needed based on part dimensions and considerations like clearance between cavities. Finally, it shows how to calculate the total cost of the die casting process based on factors like machine operating rate, cost of the die casting die and trim die, and how the number of cavities affects the overall cost. The most economical number of cavities can be determined to minimize the total cost for a given die casting task and machine size.

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    DFMA Lecture 15 Sep 6.pdf

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    This document discusses design for manufacturing considerations for die casting processes. It provides formulas to calculate the required clamp force for a die casting machine based on the projected area and pressure of the molten metal. It also discusses how to estimate the plate size needed based on part dimensions and considerations like clearance between cavities. Finally, it shows how to calculate the total cost of the die casting process based on factors like machine operating rate, cost of the die casting die and trim die, and how the number of cavities affects the overall cost. The most economical number of cavities can be determined to minimize the total cost for a given die casting task and machine size.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    51 views12 pages

    Design For Manufacturing and Assembly (DFMA)

    Uploaded by

    MK Saravanan
    This document discusses design for manufacturing considerations for die casting processes. It provides formulas to calculate the required clamp force for a die casting machine based on the projected area and pressure of the molten metal. It also discusses how to estimate the plate size needed based on part dimensions and considerations like clearance between cavities. Finally, it shows how to calculate the total cost of the die casting process based on factors like machine operating rate, cost of the die casting die and trim die, and how the number of cavities affects the overall cost. The most economical number of cavities can be determined to minimize the total cost for a given die casting task and machine size.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 12

    Design for Manufacturing and Assembly (DFMA)

    Lecture 15 – Design for Casting


    Indian Institute of Information Technology Design and Manufacturing
    Chennai – 600127

    September 6 2019
    Die Casting Machines
    Total cost for die casting process

    Depends on many parameters, formulae available


    - For die casting machine

    the clamp force, F, exerted by the machine on the die must be


    greater than the separating force, f, of the molten metal on the
    die during injection

    For a given die-casting task, the force exerted by the molten metal may be represented as follows:

    The total projection area is given as

    In general,
    In general,

    The cost of material per part

    Dimensional Machine Constraints

    Clamp Stroke D = part depth


    • The clearance between adjacent cavities or between cavities and plate edge should be a minimum of
    7.5 cm with an increase of 0.5 cm for each 100 cm2 of cavity area.

    • Reasonable estimates of the required plate size are given by allowing a 20% increase of part width for
    overflow wells and 12.5 cm of added plate width for the sprue
    The two cavities may be arranged end to end with 9.0 cm
    spacing between them and around the edges, and with a
    20% width increase to allow for the overflow wells. If an
    additional increase of 12.5 cm is then applied to the plate
    width for the biscuit, a final plate size of 67 × 42.5 cm is
    obtained.

    The die separating force using (pressure) data for Thus, the appropriate machine from Table
    Aluminium in Table before is before (for cold die) would thus be the one
    with 6000 kN clamp force, which can
    accommodate plate sizes up to 100 cm × 120
    cm.

    Estimated material cost per part is


    Total cost for die casting process

    The hourly operating rate of a die-casting machine,


    including the operator rate,
    The cost of a multicavity die-casting die, Cdn

    The cost of a multiaperture trim die, Ctn


    Combining all, the Total Cost for all the components is given by

    If full die-casting machine clamp force utilization is assumed, then

    Now,

    Number of cavities that gives the lowest cost for any given die-casting machine size

    Most economical number of die cavities for any


    given diecasting task.
    Example Problem:

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