A Review on Pressure Die Casting Technology and Recent Developments in Die Design

Abstract

A high production rate and cost effective method primarily used in the production of non-ferrous castings is the Pressure Die Casting (PDC) technology. It is widely used in the manufacturing of automobile components of complex geometry and intricate forms and shapes that may be difficult to produce by the other conventional casting processes. This paper gives an insight into the types of pressure die casting techniques. It also describes the recent trends and developments made in the pressure die casting process. Numerical simulation is one of the cost effective methods used in optimization of the casting process. The various simulation methods available for numerical simulation of castings are discussed. The paper also depicts the use of integrated CAD/CAE approach and parametric design approach that makes the design process easier. The importance of residual stresses and their effects on the fatigue life of cast components have also been discussed. The most important tool of the pressure die casting operation is the ‘die’ that consists of the mold cavity where the molten metal is forced under pressure for the required component to be cast. The causes of failures of dies and repair options have also been discussed.