MANUFACTURING PROCESS FOR CYLINDER FIN BODY

FOR 150CC ENGINE

ABSTRACT

The Engine cylinder is one of the major automobile components, which is subjected to
high temperature variations and thermal stresses. In order to cool the cylinder, fins are provided
on the cylinder to increase the rate of heat transfer. By doing thermal analysis on the engine
cylinder fins, it is helpful to know the heat dissipation inside the cylinder.

The principle implemented in this project is to increase the heat dissipation rate by using
the invisible working fluid, nothing but air. We know that, by increasing the surface area we can
increase the heat dissipation rate, so designing such a large complex engine is very difficult. The
main purpose of using these cooling fins is to cool the engine cylinder by any air.

In this project a parametric model of the cylinder fin body is created. For manufacturing
this pressure die casting is used. we are designing mould base for the cold chamber Furness.
Core and cavity are extracted and total mould base is designed for the manufacturing of cylinder
fin body.

CNC Program is to be generated for both core and cavity using roughing and finishing
processes. This is also done in manufacturing module in Pro/Engineer.

Modeling, core-cavity extraction and die design is done by using Pro/engineer software.

Pro/ENGINEER is the standard in 3D product design, featuring industry-leading productivity

tools that promote best practices in design.
 COOLING SYSTEM FOR I.C. ENGINES
Internal combustion engines at best can transform about 25 to 35 percentage of the chemical
energy in the fuel in to mechanical energy. About 35 percentage of the heat generated is lost in to
the surroundings of combustion space, remainder being dissipated through exhaust’ and radiation
from the engine. The temperature of the burning gases in the engine cylinder is about 2000 to
2500° C. The engine components like cylinder head, cylinder wall piston and the valve absorb
this heat. Such high temperatures are objectionable for various reasons state below.

Necessity for Engine Cooling

1) Engine valves warp (twist) due to over heating.

2) Damage to the materials of cylinder body and piston.
3) Lubricating oil decomposes to form gummy and carbon particles.
4) Thermal stresses are set up in the engine parts and causes distortion (twist or change shape)
and cracking of components.
5) Pre – ignition occurs (i.e. ignition occurs before it is required to igniter due to the
overheating of spark plug.
6) Reduces the strength of the materials used for piston and piston rings.
7) Overheating also reduces the efficiency of the engine.
To avoid the above difficulties, some form of cooling is provided to keep the temperature of
engine at the desired level. It should be noted that if the engine becomes every cool the
efficiency reduces, because starting the engine from cold requires more fuel.

Requirements of a good Cooling System

(i) It should remove only about 30% of the heat generated in the combustion chamber. Too much
cooling reduces the thermal efficiency of the engine.
(ii) A good cooling system should remove heat at a faster rate when the engine is hot. During
starting, the cooling should be very slow.
The components in the cylinder must be reasonably hot (250°C).
Over-cooling of the engine results in insufficient vaporization of fuel, loss of power, high fuel
consumption, higher emissions, starting troubles, excessive formation of sludge, lower thermal
efficiency and greater wear and tear of parts.
Methods of cooling
There are two methods of cooling an l.C. engine. They are:
1. Air cooling or Direct cooling.
2. Water cooling or Indirect cooling

AIR COOLING SYSTEM

Air cooling (Direct cooling)

In air cooling, air is circulated around the cylinder block and cylinder head, fins are provided
outside the cylinder and on the cylinder head. Fins increase the surface area exposed to the
atmosphere and the heat radiation from the surface also increases. More air passes over the fins
and comes contact with the cylinder, thus the engine heat is removed efficiently.

The use of fins increases the heat transfer surface by 5 to 10 times its original value (i.e. without
the use of fins). The high velocity of air required for cooling is obtained by the forward motion
of the engine (vehicle) itself. In stationary engine, air circulating fan is provided.

Application
The engine design is much simpler and lighter in weight than water cooling engine. These types
of cooling are used for small industrial engines and small capacity engines such as motor cycle
engine and scooter engine.

Advantages of air cooling

1. The engine design is much simpler.

2. Lighter in weight than water cooled engines since there is no water jacket, radiator, pump
etc. It also minimizes the maintenance and operating cost.
3. There is no danger from freezing water in cold climates.
4. This is very much useful in water scarcity areas and desert.
5. Less space is required.
6. Warming up the engine is faster than water cooled engine.

Disadvantages of air cooling

1. Air cooling is not as effective as water cooling and efficiency of the engine is reduced.
2. Engine parts are not uniformly cooled. The front portion of the engine which faces the air
is cooled more than the rear portion. This results in slight distortion.
3. Not suitable for multi-cylinder engines. This requires a separate fan for circulation.
4. Fans used for a stationary engine consumes 5% of engine power.
5. Such engines are suitable only for low horsepower engines.
Water cooling (Indirect cooling)

In this system, water is circulated around the cylinder and cylinder heat to carry away the heat.
The water passes through a passage called “water jacket” There are two methods of water
cooling;
(i) Natural circulation of water.
(ii) Forced circulation of water.

Cooling by Natural Circulation of Water

The cooling by natural circulation of water is also known thermo-syphon cooling. The principle
that water becomes less dense ‘ heating is the basis of this method of cooling. The radiator is
connection the water jacket at the top and bottom ends. As the water gets heat moves up and
travels through the radiator. There it gets cooled by the radiator fins and travels downwards.
The word radiator is not the correct word. In a radiator the transfer of heat from coolant to the air
is by conduction and forced convention and not radiation.
A drain tap is provided for removing water periodically.

Forced Circulation of Water

Cooling by Forced Circulation of Water

This system has a centrifugal water pump. The water pump gets the power from the rotating
engine crankshaft.

The water pump draws cold water from the radiator. This cold water is forced into the water
jackets of the cylinder. The rate of circulation of water is increased. Thus the engine parts are
cooled efficiently. After circulating, the hot water enters the radiator top. The hot water in the
radiator flows from top to bottom. The heat from the water is cooled by the radiator fins and it
gets circulated again by the water pump. A fan also be provided near the radiator for rapid
transfer of heat from radiator to the outside air.

Since water is circulated by a pump it may become very cold. The water temperature should not
go below 75°C, since this will cause corrosion and acid formation which attack the cylinder
barrel. A temperature controller thermostat valve is provided to control the cooling of water. If
the temperature below 75°C, water is bypassed and when temperature reaches 75°C or above
thermostat valve opens, hot water flows through the radiator and get cooled.

A drain tap is provided at the bottom of the radiator for the removal of water periodically.
Application

This system is used in light and heavy duty vehicles. It is general in automobile engines such as
buses, lorries, cars and trucks.

Advantages of water cooling

1. Cooling is more efficient, thus engine efficiency is more.

2. Uniform cooling is obtained.
3. Water cooled engines can be installed anywhere.
4. Chances of engine overheating are greatly reduced.
5. Engine temperature can be controlled.

Disadvantages of water-cooling

1. More weight, since it uses radiator, pump, fan etc.

2. Requires more maintenance. The engine may have to be stopped even if a small leakage
of water is detected in the radiator.
3. In cold weather, freezing of water causes trouble. An electric heater may be required to
heat the radiator.
4. Water circulating pump consumes more power.
5. Water causes scale formation in the water circulating jacket and corrosion of materials,
hence greater maintenance is required.
 INTRODUCTION TO CAD

Computer-aided design (CAD), also known as computer-aided design and drafting (CADD),
is the use of computer technology for the process of design and design-documentation. Computer
Aided Drafting describes the process of drafting with a computer. CADD software, or
environments, provide the user with input-tools for the purpose of streamlining design processes;
drafting, documentation, and manufacturing processes. CADD output is often in the form of
electronic files for print or machining operations. The development of CADD-based software is
in direct correlation with the processes it seeks to economize; industry-based software
(construction, manufacturing, etc.) typically uses vector-based (linear) environments whereas
graphic-based software utilizes raster-based (pixelated) environments.

CADD environments often involve more than just shapes. As in the manual drafting of technical
and engineering drawings, the output of CAD must convey information, such as materials,
processes, dimensions, and tolerances, according to application-specific conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves,
surfaces, and solids in three-dimensional (3D) objects.

CAD is an important industrial art extensively used in many applications, including automotive,
shipbuilding, and aerospace industries, industrial and architectural design, prosthetics, and many
more. CAD is also widely used to produce computer animation for special effects in movies,
advertising and technical manuals. The modern ubiquity and power of computers means that
even perfume bottles and shampoo dispensers are designed using techniques unheard of by
engineers of the 1960s. Because of its enormous economic importance, CAD has been a major
driving force for research in computational geometry, computer graphics (both hardware and
software), and discrete differential geometry.

The design of geometric models for object shapes, in particular, is often called computer-aided
geometric design (CAGD).

Current computer-aided design software packages range from 2D vector-based drafting systems
to 3D solid and surface modellers. Modern CAD packages can also frequently allow rotations in
three dimensions, allowing viewing of a designed object from any desired angle, even from the
inside looking out. Some CAD software is capable of dynamic mathematic modeling, in which
case it may be marketed as CADD — computer-aided design and drafting.

CAD is used in the design of tools and machinery and in the drafting and design of all types of
buildings, from small residential types (houses) to the largest commercial and industrial
structures (hospitals and factories).
CAD is mainly used for detailed engineering of 3D models and/or 2D drawings of physical
components, but it is also used throughout the engineering process from conceptual design and
layout of products, through strength and dynamic analysis of assemblies to definition of
manufacturing methods of components. It can also be used to design objects.

CAD has become an especially important technology within the scope of computer-aided
technologies, with benefits such as lower product development costs and a greatly shortened
design cycle. CAD enables designers to lay out and develop work on screen, print it out and save
it for future editing, saving time on their drawings.

Types of CAD Software

2D CAD
Two-dimensional, or 2D, CAD is used to create flat drawings of products and structures. Objects
created in 2D CAD are made up of lines, circles, ovals, slots and curves. 2D CAD programs
usually include a library of geometric images; the ability to create Bezier curves, splines and
polylines; the ability to define hatching patterns; and the ability to provide a bill of materials
generation. Among the most popular 2D CAD programs are AutoCAD, CADkey, CADDS 5, and
Medusa.

3D CAD
Three-dimensional (3D) CAD programs come in a wide variety of types, intended for different
applications and levels of detail. Overall, 3D CAD programs create a realistic model of what the
design object will look like, allowing designers to solve potential problems earlier and with
lower production costs. Some 3D CAD programs include Autodesk Inventor, CoCreate Solid
Designer, Pro/Engineer SolidEdge, SolidWorks, Unigraphics NX and VX CAD, CATIA V5.

3D Wireframe and Surface Modeling

CAD programs that feature 3D wireframe and surface modeling create a skeleton-like inner
structure of the object being modeled. A surface is added on later. These types of CAD models
are difficult to translate into other software and are therefore rarely used anymore.

Solid Modeling
Solid modeling in general is useful because the program is often able to calculate the
dimensionsof the object it is creating. Many sub-types of this exist. Constructive Solid Geometry
(CSG) CAD uses the same basic logic as 2D CAD, that is, it uses prepared solid geometric
objects to create an object. However, these types of CAD software often cannot be adjusted once
they are created. Boundary Representation (Brep) solid modeling takes CSG images and links
them together. Hybrid systems mix CSG and Brep to achieve desired designs
 INTRODUCTION TO PRO/ENGINEER

Pro/ENGINEER Wildfire is the standard in 3D product design, featuring industry-leading

productivity tools that promote best practices in design while ensuring compliance with your
industry and company standards. Integrated Pro/ENGINEER CAD/CAM/CAE solutions allow
you to design faster than ever, while maximizing innovation and quality to ultimately create
exceptional products.

Customer requirements may change and time pressures may continue to mount, but your product
design needs remain the same - regardless of your project's scope, you need the powerful, easy-
to-use, affordable solution that Pro/ENGINEER provides.

Pro/ENGINEER Wildfire Benefits:

•Unsurpassed geometry creation capabilities allow superior product differentiation and

manufacturability
•Fully integrated applications allow you to develop everything from concept to manufacturing
within one application
•Automatic propagation of design changes to all downstream deliverables allows you to design
with confidence
•Complete virtual simulation capabilities enable you to improve product performance and exceed
product quality goals
•Automated generation of associative tooling design, assembly instructions, and machine code
allow for maximum production efficiency
Pro ENGINEER can be packaged in different versions to suit your needs, from Pro/ENGINEER
Foundation XE, to Advanced XE Package and Enterprise XE Package, Pro/ENGINEER
Foundation XE Package brings together a broad base of functionality. From robust part
modelling to advanced surfacing, powerful assembly modelling and simulation, your needs will
be met with this scaleable solution. Flex3C and Flex Advantage Build on this base offering
extended functionality of your choosing.

The main modules are

Part Design

Assembly

Drawing

Sheet Metal
Manufacturing

MODEL OF CYLINDER FIN BODY

2D DRAWING
 DIE CASTING
INTRODUCTION

Die casting is a versatile process for producing engineered metal parts by forcing molten metal
under high pressure into reusable steel molds. These molds, called dies, can be designed to
produce complex shapes with a high degree of accuracy and repeatability. Parts can be sharply
defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and
serviceable finishes.

Die castings are among the highest volume, mass-produced items manufactured by the
metalworking industry, and they can be found in thousands of consumer, commercial and
industrial products. Die cast parts are important components of products ranging from
automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector
housing.

Die casting is a method of producing alloy castings by injecting molten metal into metallic mold
under pressure. Die casting process can be classified into
a) Hot Chamber Process
b) Cold Chamber Process

The basic die casting process consists of injecting molten metal under high pressure into a steel

mold called a die. Die casting is an efficient, economical process offering a broader range of

shapes and components than any other manufacturing technique. Parts have a longer service life

when compared to plastic, and may be designed to complement the visual appeal of the

surrounding part. Die casting provides complex shapes within closer tolerances than many other

mass production processes. Little or no machining is required, and thousands of identical

castings can be produced before additional tooling is required. Die casting produces parts that are

durable and dimensionally stable, while maintaining close tolerances. Die cast parts are stronger

than plastic injection moldings having the same dimensions. Thin-wall castings are stronger and

lighter than those possible with other casting methods. Plus, because die castings do not consist

of separate parts welded or fastened together, the strength is that of the alloy rather than the

joining process. Die castings provide integral fastening elements, such as bosses and studs. Holes

can be cored and made to tap drill sizes, or external threads can be cast. Die cast parts can be
produced with smooth or textured surfaces, and they are easily plated or finished with a

minimum of surface preparation.

In this technique, the mould is generally not destroyed at each cast but is permanent,

being made of a metal such as cast iron or steel. There are a number of die casting processes, as

summarized in Figure 2. High pressure die casting is the most widely used, representing about

50% of all light alloy casting production. Low-pressure die casting currently accounts for about

20% of production and its use is increasing. Gravity die casting accounts for the rest, with the

exception of a small but growing contribution from the recently introduced vacuum die-casting

and squeeze casting process.

High Pressure Die Casting :

High Pressure Die Casting (HPDC) is a large volume, high productivity process for the

production of complex, thin walled near net shape castings, with part weights ranging from a few

grams to more than 15 kg. It has traditionally been utilized in the production of housings etc, but

this has changed. Presently, feasible products are automotive front end structures and instrument

panels in magnesium alloys and B-pillars in aluminium alloys. However, for HPDC to be

competitive for extended automotive applications and attractive for new market segments, the

crash worthiness and fatigue properties must be improved and a scientific comprehension of the

process and metal behavior is required. Doehler was the first to patent die casting-related

technology in 1910. The initial machines produced aluminium castings in reusable metal molds,

where a human powered pull bar transmitted the force required to fill the mold. In 1927 the
horizontal cold chamber die casting machine was developed, which represents the basics of

today’s technology.

Gravity Die casting :

A schematic view in Figure 2 shows the main parts constituting a classical mould for

gravity die-casting. Cores (inner parts of the mould) are generally made of bonded sand. Gravity

die-casting is suitable for mass production and for fully mechanized casting.
Low Pressure Die casting:

As schematized in Figure 3, the die is filled from a pressurized crucible below, and

pressures of up to 0.7 bar are usual. Low-pressure die-casting is especially suited to the

production of components that are symmetric about an axis of rotation. Light automotive wheels

are normally manufactured .

Vaccum Die casting:

The principle is the same as low-pressure die-casting. The pressure inside the die is

decreased by a vacuum pump and the difference of pressure forces the liquid metal to enter the

die. This transfer is less turbulent than by other casting techniques so that gas inclusions can be

very limited. As a consequence, this new technique is specially aimed to components, which can

subsequently be heattreated.
Squeeze Casting:

Liquid metal is introduced into an open die, just as in a closed die forging process. The

dies are then closed. During the final stages of closure, the liquid is displaced into the further

parts of the die. No great fluidity requirements are demanded of the liquid, since the

displacements are small. This process can cast thus forging alloys, which generally have poor

fluidities, which normally precludes the casting route.

HIGH PRESSURE DIE CASTING

The four principal metals, with different alloy compositions, that are commonly hot- or cold

chamber die cast are aluminium, zinc, magnesium and copper-base alloys. The injection system

in the hot chamber machines is immersed into the melt and the pressure is therefore limited. The

system also degrades quickly if exposed to aluminium.

In the cold chamber process, the metal reservoir is separated from the injection system. The

metal is filled into the steel shot sleeve, as shown in Figure 1. The shot sleeve is typically 200-

300oC.

The hydraulic energy is provided by a computerized system that permits control of metal,

position, velocity and plunger acceleration to optimize the flow and the pressure during filling

and solidification. The die cavity may be evacuated to reduce air entrapment during die filling,

and high integrity die castings can therefore be produced by utilizing vacuum systems.

Alternatively semi-solid metalworking (SSM) can be used to reduce turbulence. Contrarily, the

quality of conventionally produced die castings has been ensured by the effort and experience

given by the machine operators in the foundry.

A short die filling time and thin walls result in high cooling rates, (typically 1001000 Ks-1). This
promotes a fine grain size which provides decent mechanical properties. However, the properties

can be improved by intimate interrelationship between product and process design through

amended metal handling, accurate process control, and optimized runner and die design.

Principle of Cold Chamber Technologies

Material and properties for Die-Casting

The materials used for die-casting are
1) Aluminum alloys
2) Zinc alloys
3) Magnesium alloys
4) Copper alloys
5) Lead alloys

The desirable properties of die-casting alloys

1) Adaptability to the system
 Should have good fluidity
 Good cast ability
 Less shrinkage
 Range of temperature for solidification
 Low melting point

2) Mechanical properties
  Tensile strength
 Hardness
 Ductility
 Fatigue strength
 Good machinability
 Resistance to corrosion
 Ability to be plated

Shrinkage Table for Die-casting alloys

Casting alloy Shrinkage ( % )
Aluminium 0.5 – 0.7
Magnesium 0.8 – 1.2
Brass 0.7 – 1.2
Led 0.3 – 0.6
Zinc 0.4 – 0.6
Tin 0.2 – 0.5

Die-casting machines
All die-casting machines have one of the two different metal pumping systems;
Hot chamber system
Cold chamber system
If the metal being cast melts at a low temperature and thus does not attack the injection
pump material, the pump can be placed directly into the molten bath (Hot chamber machines).
If the molten metal attacks the pump material at casting temperature, the pump cannot be
placed in the metal bath and a cold chamber machine has to be used.
Hot chamber machines
In this die casting machine, the molten metal is forced under pressure (from 280 - 700
kg/sq.cm) into a permanent mold or die made of steel. The chamber where the high pressure
produced is contained in a molten metal bath. The pressure chamber (shot chamber) is heated to
the melting temperature of the metal to be processed. Generally, a plunger is applied to exert
pressure. Compressed air or some other gas under high pressure is also used.
 The low temperature alloys of zinc, lead, tin do not attack the injection chamber material,
the chamber (pump or shot cylinder) can be placed directly in the molten metal bath. The
machine having this type of arrangement is known as hot chamber machine.
The hot chamber machine, in addition to the pressure chamber (cylinder), gooseneck,
plunger and nozzle are typical of hot chamber injection system. The gooseneck containing the
pressure chamber and plunger is submerged in the molten casting metal and is at a temperature
of the metal bar. This allows the metal to be injected into the cavity in a minimum time and
minimum loss of temperature. The furnace is very much a pat of the machine.
When the plunger is in up position the molten metal flows from the pot into the pressure
cylinder through the inlet port. With the die closed and locked, the shot cylinder is actuated to
move the plunger downward. As the plunger moves down, it seals off the inlet port and the
molten metal is forced through the gooseneck channel and the nozzle into the die casting die.
After the metal solidifies in the die cavity, the power cylinder is actuated in reverse direction
pulling the plunger up. This uncovers the inlet part allowing metal to flow from the pot into the
pressure cylinder. The machine is now ready for the next cycle as the two halves of the die are
closed.
The term ‘goose neck machine’ sometimes is also applied to this type of machine because
of its hollow ‘U’. These machines are also known as submerged plunger machine.
Casting up to 25 kgs. Could be produced in hot chamber machines. These machines
generally operate at 50 to 500 shots per hour. The shot cylinder is usually provided with liners to
provide for different shot capacities.
 Fig no.1
Cold chamber machines
The metal is heated to pouring temperature in separate holding furnaces and transferred
to the shot cylinder by ladling. The metal injection chamber is separated from the melting pot
and is not heated to the melting temperature of the alloy. These machines are also called plunger
casting machines.
These cold chamber machines are subdivided into two types based on the position of the
injection chamber as
Horizontal cold chamber machines
Vertical cold chamber machines
Horizontal cold chamber machines
The shot chamber is mounted horizontal with pouring hole at the top of the chamber wall.
The operating cycle of the horizontal cold chamber shot system starts with the die closed
and locked and the cylinder plunger in retarded position. The molten metal is loaded through the
pouring hole of the shot chamber. Then the injection cylinder is actuated moves the plunger
forward. The plunger tip first closes off the pouring hole and then forces the metal into the die.
After solidification of the metal in the cavity, the die is opened and the plunger moves in the
direction of initial travel to complete its full stroke. This final forward travel of the plunger tip
forces the casting from the cover die. The plunger retracts the casting, which is ejected from the
ejector die. The machine is ready for next cycle after the two halves of the die are closed and
locked. In the shot cylinder of the horizontal injection machine, the plunger tip should be
adjusted to be very near the pouring hole. Most plunger tips are made of beryllium or nitrided
alloy steels. Shot chambers are generally made of H13 tools steel or nitriding alloy steel to resist
heat and wear.

Fig.no-2
HORIZONTAL COLD CHAMBER SYSTEM
Vertical cold chamber machines
In this machine the injection system consists of a vertical shot chamber connected
directly to the cover die half by a sprue bushing. There are two plungers. The lower plunger
covers the bushing hole in the vertical cold chamber while metal is being ladled into the chamber
from above. After the metal has been ladled, the upper or shot plunger is actuated. As the
pressure builds up, the lower plunger retracts, uncovering the sprue bushing into the die. After
dwell cycle for metal solidification, the upper plunger is withdrawn while the lower plunger
raises and shears off the remaining slug of metal and ejects it.
The molten metal in a vertical chamber machine moves in a compact mass as the plunger
advances. This minimizes metal turbulence and castings of low porosity could be produced.
Castings with high-density specifications, or where the use of inserts is required and the parts
that can best be made with center gating and better finishing the die-castings are recommended
to be made in vertical machines. Some examples of castings for which gating is most convenient
or most effective are those having thick center hubs and thin outer sections, such as fans, wheels
and blower impellers.

Advantages

1. Very high surface hardness of the order of 1150 VPN / 65 HRC may be obtained.
2. Since nitrided parts are not quenched, this minimizes distortion or cracking.
3. Good corrosion and wear resistance.
4. Good fatigue resistance.
5. Whereas in a carburised part, hardness begins to fall at about 2000C, a nitrided part
retains hardness up to 5000C.
6. No machining is required after nitriding.
7. Some complex parts which are not carburized satisfactorily can be nitrided without
difficulty.
8. The process is economical when large numbers of parts are to be treated.

Disadvantages:
1. Long cycle times (40 to 100 hours.)
2. Only special alloy steels (containing Al, Cr, V) can be satisfactorily treated.
3. High cost of the nitriding process.
4. Technical control is required.
5. If a nitrided component is accidentally over heated, the surface hardness will be lost
completely and the component must be nitrided again.
 DIE DESIGN CALCULATIONS

ALUMINUM

TONNAGE CALCULATION
Projected area of one component (a) = 7492.47 mm2
Number of cavities(n) = 1
Projected area of Casting(A) = axn = 7492.47 mm2

Area of slide:
Projected Area of Slide 1 =7250.64mm2
Wedge Angle(α) =2 deg
Final Projected Area of slide 1 (A1) = 7250.64 x tan 2 = =253.19 mm2
Projected Area of Slide 2=7725.5mm2
Wedge Angle(α) =2deg
Final Projected Area of slide 2 (A2) = 7725.5 x tan 2=269.78 mm2
Projected area including overflows and feed system (AF) =A x c/100 = =7492.47 x
40/100=2996.988 mm2
Total Projected area= A +A1+A2+AF= 7492.47+253.19+269.78+2996.988
=11012.48 mm2
Specific Injection pressure =800 kgf/cm2 =800x 10-2 kgf/ mm2
Total force acting on the die plate (F) =Projected area x Injection Pressure =11012.48x 8 kgf
=88.09T

Considering machine efficiency of 80%,

Locking tonnage required =F x 1.2 =88.09 x 1.2 =105.72T =106T
Hence according to locking tonnage we can select 250T

SHOT WEIGHT CALCULATION

One component volume (v)= 9.10 x 105mm3
Total component volume(V) = v x n mm3=9.828 x 105mm3
Volume of component + Volume of overflow and feed system (Vt) = V x (1 + c/100)
=9.828x105 x(1+ 40/100)
= 1375920 mm3
PLUNGER DIAMETER CALCULATION
Actual shot volume = Vt + Пd2h/4
Where h is biscuit thickness and d is the plunger diameter
Stroke length for 800 T machine (l) = 420 mm
Effective stroke length (L) = l – biscuit thickness = 420 –(42-15) =401mm
Assume fill ratio =0.50
Volume delivered by machine = πd2 x (L/4) x f
i.e. Vt + π d2 x (h/4) = πd2 x (L/4) x f = πd2 x (401/4) x 0.50
Vt = π/4 x d2 (l x f - 15) = π/4 x d2 (401 x 0.5 - 15)
1372920 = 173 d2
d=98 mm
Available plunger sizes in 250T machines are 100 mm(This value is taken from stranded value).
Hence we can select 90 mm plunger tip
Shot volume = Vt + πd2h/4 = 1375920 +π (100) 2 x15/4 = 1493729.72 mm3
Shot weight = Shot volume x density = 1493729.72x2.7x10-6=4033g=4.03kg
From machine manual, for 250T machine, shot weight capacity for 100 mm
plunger is 9.2 kg. Hence according to shot capacity also 250T machine is suitable.

FILL RATIO CALCULATION

Fill ratio (f) = Metal volume/Shot sleeve volume= (Vt + π d2h/4)/π d2 x (L/4)
=149372972/π (100)2 x (401/4) = 0.47
This value for fill ratio is acceptable for the process

FILL TIME CALCULATION

Fill Time = k [Ti – Tf + sz] T/[Tf – Td]
Where k, empirically derived constant = 0.0346
Ti, Temperature of molten metal as it enters the die= 6400c
Tf, Minimum flow temperature of metal =5800 c
Td, Temperature of die cavity surface just before the metal enters =2000c
S, percent solid fraction allowable in the metal at the end of filling =30%
Z, Units conversion factor = 4.8
T, casting thickness = 9.78mm
Therefore t = 0.0346[640–580+30x4.8]x 9.78/[580 – 200] = 0.182 seconds = 182milli seconds

PQ2 CALCULATION :
Maximum Accumulator Pressure = 150 kgf/cm2
Diameter of cylinder =155 mm
Plunger diameter=100 mm
Dry Shot Velocity=4.5 m/sec
Maximum Static Metal Pressure = MAP x (Cylinder Dia)2/(Plunger Dia)2=100 x (155)2/(100)2
=360.375 Kgf/cm2
Dry Shot Flow Rate = (Plunger Dia) x π x DSV/4 =(100) x π x 4500/4 = 35342917.35mm3/sec
2 2

=35342.92cm3/sec

Metal Pressure (Max) = Density x Gv2/2 x Ag x Cd2

Where
Cd is coefficient of discharge = 0.3
Gvmax is maximum gate velocity = 40 m/sec
Ag is acceleration due to gravity = 981 cm/sec
= 2.7 x (4000)2/2 x 981 x (0.3)2=244648.31gm/cm2=244.64
2
Kgf/cm
Metal Pressure (Min) = Density x Gv2/2 x Ag x Cd2
Gvmin is minimum gate velocity = 20 m/sec
Metal Pressure (Min)= Density x Gv2/2 x Ag x Cd2= 2.7 x (2000)2/2 x 981 x
(0.3)2=61162.079gm/cm2
= 61.16 Kgf/cm2

Flow rate, Q= Volume of metal through gate/ Fill time

Volume of metal through gate = V x (1 + c/100) = 9.828 x 105 x (1 + 40/100)=1375920 mm3
Fill time =0.182 sec
Flow rate, Q = 1375920/ 0.182 = 7560000 mm3 /sec

Material – Magnesium

TONNAGE CALCULATION
Projected area of one component (a) = 7492.47 mm2
Number of cavities(n) = 1
Projected area of Casting(A) = axn = 7492.47 mm2

Area of slide:
Projected Area of Slide 1 =7250.64mm2
Wedge Angle(α) =2 deg
Final Projected Area of slide 1 (A1) = 7250.64 x tan 2 = =253.19 mm2
Projected Area of Slide 2=7725.5mm2
Wedge Angle(α) =2deg
Final Projected Area of slide 2 (A2) = 7725.5 x tan 2=269.78 mm2
Projected area including overflows and feed system (AF) =A x c/100 = =7492.47 x
40/100=2996.988 mm2
Total Projected area= A +A1+A2+AF= 7492.47+253.19+269.78+2996.988
=11012.48 mm2
Specific Injection pressure =800 kgf/cm2 =800x 10-2 kgf/ mm2
Total force acting on the die plate (F) =Projected area x Injection Pressure =11012.48x 8 kgf
=88.09T

Considering machine efficiency of 80%,

Locking tonnage required =F x 1.2 =88.09 x 1.2 =105.72T =106T
Hence according to locking tonnage we can select 250T
SHOT WEIGHT CALCULATION
One component volume (v)= 9.10 x 105mm3
Total component volume(V) = v x n mm3=9.828 x 105mm3
Volume of component + Volume of overflow and feed system (Vt) = V x (1 + c/100)
=9.828x105 x(1+ 40/100)
= 1375920 mm3

PLUNGER DIAMETER CALCULATION

Actual shot volume = Vt + Пd2h/4
Where h is biscuit thickness and d is the plunger diameter
Stroke length for 800 T machine (l) = 420 mm
Effective stroke length (L) = l – biscuit thickness = 420 –(42-15) =401mm
Assume fill ratio =0.50
Volume delivered by machine = πd2 x (L/4) x f
i.e. Vt + π d2 x (h/4) = πd2 x (L/4) x f = πd2 x (401/4) x 0.50
Vt = π/4 x d2 (l x f - 15) = π/4 x d2 (401 x 0.5 - 15)
1372920 = 173 d2
d=98 mm
Available plunger sizes in 250T machines are 100 mm(This value is taken from stranded value).
Hence we can select 90 mm plunger tip
Shot volume = Vt + πd2h/4 = 1375920 +π (100) 2 x15/4 = 1493729.72 mm3
Shot weight = Shot volume x density = 1493729.72x2.7x10-6=4033g=4.03kg
From machine manual, for 250T machine, shot weight capacity for 100 mm
plunger is 9.2 kg. Hence according to shot capacity also 250T machine is suitable.

FILL RATIO CALCULATION

Fill ratio (f) = Metal volume/Shot sleeve volume= (Vt + π d2h/4)/π d2 x (L/4)
=149372972/π (100)2 x (401/4) = 0.47
This value for fill ratio is acceptable for the process

FILL TIME CALCULATION

Fill Time = k [Ti – Tf + sz] T/[Tf – Td]
Where k, empirically derived constant = 0.135
Ti, Temperature of molten metal as it enters the die= 6500c
Tf, Minimum flow temperature of metal =5950 c
Td, Temperature of die cavity surface just before the metal enters =2000c
S, percent solid fraction allowable in the metal at the end of filling =30%
Z, Units conversion factor = 4.8
T, casting thickness = 9.78mm
Therefore t = 0.135[650–595+30x4.8]x 9.78/[595 – 200] = 0.665 seconds = 665milli seconds

PQ2 CALCULATION :
Maximum Accumulator Pressure = 150 kgf/cm2
Diameter of cylinder =155 mm
Plunger diameter=100 mm
Dry Shot Velocity=4.5 m/sec
Maximum Static Metal Pressure = MAP x (Cylinder Dia)2/(Plunger Dia)2=100 x (155)2/(100)2
=360.375 Kgf/cm2
Dry Shot Flow Rate = (Plunger Dia) x π x DSV/4 =(100) x π x 4500/4 = 35342917.35mm3/sec
2 2

=35342.92cm3/sec

Metal Pressure (Max) = Density x Gv2/2 x Ag x Cd2

Where
Cd is coefficient of discharge = 0.3
Gvmax is maximum gate velocity = 40 m/sec
Ag is acceleration due to gravity = 981 cm/sec
= 1.85 x (4000)2/2 x 981 x (0.3)2=167629.40gm/cm2=167.6
2
Kgf/cm
Metal Pressure (Min) = Density x Gv2/2 x Ag x Cd2
Gvmin is minimum gate velocity = 20 m/sec
Metal Pressure (Min)= Density x Gv2/2 x Ag x Cd2= 1.85 x (2000)2/2 x 981 x (0.3)2=41907.35
gm/cm2 = 41.907 Kgf/cm2

Flow rate, Q= Volume of metal through gate/ Fill time

Volume of metal through gate = V x (1 + c/100) = 9.828 x 105 x (1 + 40/100)=1375920 mm3
Fill time =0.665 sec
Flow rate, Q = 1375920/ 0.170 = 2069052.63 mm3 /sec=2069.052 cm3/sec

CAD/CAM IN DIE DESIGN

In the die casting scenario the advent of digital computers has facilitated the
improvement of productivity and elimination of costly rework. Here before the physical
realization of the die, the design can be redefined and the parameters can be decided which
would yield good results. Variety of feed systems and combination of ideas can be selected. This
is an analytic approach to estimate the validity of the design. Thus it gives enormous confidence
to the designer even before the tool is manufactured.

CAD
The acronym, CAD/CAM refers to general application of computers in graphic design,
programmed machining, structural engineering, and even factory wide process planning. But
CAD/CAM as it applies to die casting design and machining is fast becoming a specialized
discipline.
On the CAD side, CRT screens linked to computers now provide three dimensional
representations of parts and companion tooling, generate new size and shape variations at the
touch of few keys, and permit exact replication of complex cores and cavities. New computer
graphics capabilities include “solid modeling”. Rather than just displaying a “wire-frame” three
dimensional representation or isometric image as in old software. Some CAD system permit the
part or the cavity being designed to be shown as it would appear in reality-complete with shades
and contour. Specialized CAD software is also being refined to optimize metal flow in the tool
as well as die cooling. Minimizing the material consumption by shortening runners, simplifying
debugging of difficult dies, and trimming die-cooling times are the primary benefits provided by
the metal flow analysis software.

CAM
The CAM portion of computer aided design and manufacturing is somewhat mature than
CAD graphics. Computerized numerical control (CNC) of milling machines is quickly
becoming common place and permits far more accurate tolerances than with manual milling.
Programmed through punched tape, CNC machines follow computer controlled machine paths
with upto five axis milling and automatic cutter changing capabilities. The latest technological
stride in computerized machining involves dispensing with punched tapes altogether.
“Distributed” CNC employs a coaxial cable between main frame computer and CNC milling
machine to control cutter paths from the computer memory.
Computer controlled electrical-discharge machining (EDM) is another growing
technology, which many feel eventually replace most mechanical machining of core and cavities.
Using CNC equipment to machine complex electrodes, mold makers are producing intricate
cavity details with tight tolerances not possible with standard equipment. Wire feed EDM is also
gaining acceptance for machining cavities for gears and other parts with geometries that allow
cutting completely through the mold plate involved. In operation, a continuously fed wire
electrode travels between spool above and below the plate, Precise shapes are burned by
computers controlled movement of the table holding the steel rather than by manipulating the
wire electrode. The next EDM advance reportedly will be the machine with multiple electrodes
in different shapes and sizes that will follow computerized cutting paths in much the same way
as CNC milling equipment.
PRO/ENGINEER MANUFACTURING (MOLD EXTRACTION)
What You Can Do with Pro/MOLDESIGN and Pro/CASTING
Pro/Moldesign is an optional module for Pro/ENGINEER that provides the tools to simulate the
mold design process within Pro/ENGINEER. This module lets you create, modify, and analyze
the mold components and assemblies, and quickly update them to the changes in the design
model.
Pro/CASTING provides tools to design die assemblies and components and prepare castings for
manufacturing.
Pro/MOLDESIGN and Pro/CASTING, together with Pro/ENGINEER Foundation, provide tools
to do the following:
Design Part Creation and Modification
Create models in Pro/ENGINEER including features requiring Pro/SURFACE
Import and repair geometry if necessary
The import functionality can be used with the following: See Data Doctor Option and Interface
for Pro/ENGINEER
Analyze if a design part is moldable, using Draft Check and Thickness Check capabilities
Automatically create parting lines and detect undercuts using Silhouette Curve functionality
Fix problem areas by creating draft, rounds, and other features as needed
Cavity Creation
Assemble and orient design model dynamically while checking draft and projected area
Apply a shrinkage that corresponds to design part material, geometry, and molding conditions
Automatically create the workpiece stock from which core, cavity, and inserts will be split
Create parting geometry, including sliders, inserts, automatic parting lines, and automatic parting
surfaces
Automatically split the workpiece to create cores, cavity, and inserts as solid models
For casting, create and assemble sand cores
Mold Layout Creation
About Mold Layout
The Mold Layout application provides a dynamic environment for designing and assembling
single or multi-cavity tooling in an assembly. Mold Layout also provides efficient tools for fast
and robust design of single or multi-cavity molds. You can easily populate your assembly with
cavity subassemblies, a mold base assembly, standard components, and an injection molding
machine. You can also create some mold-specific features.
The Mold Layout application is mold functionality that is accessible from Assembly mode. You
create or open a regular assembly (.asm) file to use this application.
You can switch from working on a multi-cavity mold assembly to working on an individual
cavity. To do this, use a regular assembly structure where the multi-cavity mold assembly model
is a top level assembly and each cavity model is a subassembly. These cavity subassemblies are
represented by Mold or Cast assemblies
You can make changes in one cavity assembly model appear in all cavity assembly models in the
multi-cavity mold assembly.
The cavity population tool allows flexible patterning of the cavities according to rectangular,
circular, and user defined pattern rules. You can add, remove, move, or reorient each cavity
pattern member individually, or even replace any cavity model with a family table instance.
Other functions specific to Mold Layout are as follows:
Selecting and placing mold bases with the Mold Base Selection dialog box
Selecting and placing Injection Molding Machine models
Creating runners at the assembly level
Creating waterlines at the assembly level
Creating ejector pin holes at the assembly level
Using the standard component Catalog to add, redefine, delete, trim, and cut components
Opening the mold by defining steps, deleting, modifying, reordering, and exploding
The Mold Layout application contains the same basic Mold Opening information as the Mold or
Die Opening process. Click Mold or Die Opening Process in the Help Table of Contents for more
information.
Create top level mold assembly
Placement and patterning of mold cavities to allow multi-cavity molding
Online selection and automatic assembly of standard mold bases
Modification of mold base plates to allow for assembly of mold cavity
Online selection and automatic assembly of ejector pins and other Mold Catalog items
Automated creation of runners
Automated creation of waterlines, including 3-D waterline interference checks
Define and simulate mold opening and check for interference between mold components
Drawing Creation
Create complete production drawings, including dimensions, tolerances, automatic bill of
materials (BOMs) with or without balloon notes
 Use of drawing templates

About Splitting to Volumes

Instead of creating a volume, you can split the workpiece into one volume or two volumes using one of the
following Split commands:
 MOLD > Feature > Workpiece > Solid Split

 MOLD > Mold Volume > Split

Features resulting from the splitting are created as assembly features.

Splitting does not alter workpiece or die block geometry. Whenever a workpiece or die block is
split, the system copies the workpieces or die blocks into one or two volumes that you can then
use in creating mold components or die blocks.
You can split the workpiece or die block, or a mold or cast volume using a surface, a parting
surface, or a volume. You can specify that you want to ignore one of the volumes and create a
volume to one side of the parting surface only.

About Extracting Mold Components or Die Blocks

Mold components or die blocks are produced by filling previously defined mold volumes with
solid material. This process, performed automatically, is called extracting.
An extract feature looks for mold or die volumes at the assembly level for extraction into parts.
When a split results in more than two volumes, the system prompts you to classify the extracted
part as belonging to one volume or another.
Once extracted, the mold components or die blocks are fully functional Pro/ENGINEER parts;
they can be retrieved in Part mode, used in drawings, machined with Pro/NC. New features can
be added, such as chamfers, rounds, cooling passages, draft, gating, and runners.
About Applying Shrinkage
You must consider the shrinkage of the material and proportionally increase dimensions of the
reference model before you start molding the reference model. You can apply shrinkage to the
reference model in Mold (Cast) mode and depending on the method of applying shrinkage, it
may propagate to the design model. You can also apply shrinkage to the design model or
reference model in Part mode.

The two methods of applying shrinkage are:

By Dimension—Allows you to set up one shrink coefficient for all model dimensions, and
specify shrink coefficients for individual dimensions. You can choose to apply shrinkage to the
design model.

By Scaling—Allows you to shrink the part geometry by scaling it with respect to a coordinate
system. You can specify different shrinkage ratio for the X-, Y-, and Z-coordinates. If you apply
shrinkage in Mold (Cast) mode, it applies only to the reference model and does not affect the
design model.

Pro/ENGINEER uses two formulae to calculate shrinkage. The formula 1/(1–S) allows you to
specify a shrinkage factor that is based upon the final geometry of the reference part once
shrinkage is applied. The formula 1+S uses a pre-calculated shrinkage factor that is based upon
the original geometry of the part.

To Specify a Shrinkage Formula

Click MOLD (CAST) > Shrinkage. The SHRINKAGE menu appears.
Note: If you are in the part mode, click Edit > Setup. The PART SETUP menu appears. Click
Shrinkage. The SHRINKAGE menu appears.
Click By Dimension or By Scaling. Alternatively, you can click or on the toolbar. The
Shrinkage by Dimension or Shrinkage by Scale dialog boxes open, respectively.
Under Formula, select 1+S or 1/(1-S) to calculate the shrinkage ratio.
1+S—Specifies a pre calculated shrinkage ratio based on the original geometry of the part. This
is the default.
1/(1–S)—Specifies a shrinkage ratio based on the resulting geometry of the part, after shrinkage
is applied.

CORE & CAVITY DESIGN WITH PRO/ENGINEER

CORE CAVITY PREPARATION

Note:- 1.Check draft angle along ejection side.

2. add shrinkage

Select create new object option

Select following order

Apply shrinkage value to the component

Create work piece

Create parting surface

Select mould volume option from menu manager

Select split option

DonE

Select parting surface

Ok

Enter file names for the volumes

Select mould component option

Select extract

Then split volumes will be added to model tree

Save the file

Open core & cavity

CAVITY1:-
CAVITY2:-
SIDE INSERT1
SIDE INSERT2
SIDE INSERT3

SIDE INSERT4
SIDE INSERT5
TOTAL ASSEMBLY OF DIE
 2D DRAWINGS OF DIE

CAVITY 1
CAVITY 2

SIDE INSERT1
SIDE INSERT2

SIDE INSERT3
SIDE INSERT4

SIDE INSERT5
 TOTAL ASSEMBLY

COMPUTER AIDED MANUFACTURING IN PRO/ENGINEER

By using the fundamental abilities of the software with regards to the single data source
principle, it provided a rich set of tools in the manufacturing environment in the form of tooling
design and simulated CNC machining and output.

Tooling options cover specialty tools for molding, die-casting and progressive tooling design.

Manufacturing lets you set up and run NC machines, create assembly process sequences, create
bills of material, and generate inspection programs for Coordinate Measuring Machines
(CMMs).
Use the Manufacturing area is about streamlining the NC programming process for production
milling of prismatic parts and multisurface three-axis milling. Manufacturing shows you how to
program and set up your NC machines, create process flows that cover the NC operations as well
as other operations, and define CMM inspection programs that probe manufactured parts.

PROCEDURE OF MANUFACTURING

For Cavity1

Select New – Manufacturing – NC Assembly – Enter name – Select units – ok

Retrieving the cavity in to manufacturing
Creating Workpiece

Set up the machine tool by selecting type of machine, cutting tool, Machine zero and retract.
For roughing,
Select NC sequence – Machining – Volume – Done – Select tool and enter parameters like Cut
feed, Step depth, Step over, Profile stock allow, rough stock allow, scan type and spindle speed.
Create volume.
Select Playpath
After completing Playpath, Select NC check
Machining → CL data → NC sequence → sequence → file → MCD file.
Done. Enter name . ok . Done.
NC Program for roughing
%
G71
O0001
(D:\parts\FINS\cylinder_fin_body\roughing_ca1_.ncl.1)
(03/21/11-02:05:59)
N0010T1M06
S5500M03
G00X-66.809Y-8.
G43Z5.H01
Z2.
G01Z-2.F2500.
X-101.387
Y-9.999
X-66.809
Y-11.999
X-101.387
Y-13.998
X-66.809
Y-15.997
X-101.387
Y-17.997
X-66.809
Y-19.996
X-101.387
Y-21.995
X-66.809
Y-23.994
X-101.387
Y-25.994
X-66.809
Y-27.993
X-101.387
Y-29.992
X-66.809
Y-31.992
X-101.387
Y-33.991
X-66.809
Y-35.99
X-101.387
Y-37.99
X-66.809
Y-39.989
X-101.387
Y-41.988
X-66.809
Y-43.987
X-101.387
Y-45.987
X-66.809
Y-47.986
X-101.387
Y-49.985
X-66.809
Y-51.985
X-101.387
Y-53.047
G02X-101.442Y-53.984I-8.012J.001
G01X-66.754
G03X-66.251Y-55.983I7.957J.938
G01X-101.945
G02X-103.089Y-57.983I-7.454J2.937
G01X-65.107
G03X-63.28Y-59.686I6.31J4.937
G01X-63.047Y-59.838
Y-59.982
X-105.149
Y-61.981
X-63.047
Y-63.981
X-105.149
Y-65.98
X-63.047
Y-67.979
X-105.149
Y-69.978
X-63.047
Y-71.978
X-105.149
Y-72.51
G02X-105.285Y-73.977I-7.998J0.
G01X-62.911
G03X-62.257Y-75.976I7.861J1.467
G01X-105.94
G02X-107.309Y-77.976I-7.207J3.466
G01X-60.887
X-60.852Y-78.014
G03X-57.921Y-79.975I5.81J5.511
G01X-110.275
G02X-113.154Y-80.51I-2.879J7.473
G01X-188.001
Y-81.974
X-8.
Y-83.974
X-188.001
X-50.265Y-115.46
G03X-50.097Y-114.065I-6.593J1.501
G01X-49.819
Y-113.96
Y-112.091
X-50.096
Y-110.117
X-49.819
Y-108.144
X-50.096
Y-106.96
G03X-50.143Y-106.17I-6.755J-.001
G01X-49.777
X-49.666Y-105.46
G02X-49.815Y-104.196I7.262J1.5
G01X-50.1
X-50.096Y-103.96
Y-102.222
X-49.819
Y-100.248
X-50.096
Y-98.275
X-49.819
Y-96.96
X-49.79Y-96.301
X-50.128
G03X-50.265Y-95.46I-6.723J-.66
X-50.106Y-94.327I-6.593J1.501
G01X-49.81
X-49.819Y-93.96
Y-92.353
X-50.096
Y-90.379
X-49.819
Y-88.406
X-50.096
Y-86.96
X-50.117Y-86.432
X-49.8
G02X-49.666Y-85.46I7.407J-.53
X-49.803Y-84.458I7.262J1.5
G01X-50.114
X-50.096Y-83.96
Y-82.484
X-49.819
Y-80.51
X-50.096
Y-83.96
G02X-50.265Y-85.46I-6.762J.001
X-50.096Y-86.96I-6.586J-1.501
G01Y-93.96
G02X-50.265Y-95.46I-6.762J.001
X-50.096Y-96.96I-6.586J-1.501
G01Y-103.96
G02X-50.265Y-105.46I-6.762J.001
X-50.096Y-106.96I-6.586J-1.501
G01Y-113.96
G02X-50.265Y-115.46I-6.762J.001
X-50.096Y-116.96I-6.586J-1.501
G01Y-121.96
X-49.819
Y-116.96
G02X-49.666Y-115.46I7.426J-.002
X-49.819Y-113.96I7.262J1.5
G01Y-106.96
G02X-49.666Y-105.46I7.426J-.002
X-49.819Y-103.96I7.262J1.5
G01Y-96.96
G02X-49.666Y-95.46I7.426J-.002
X-49.819Y-93.96I7.262J1.5
G01Y-86.96
G02X-49.666Y-85.46I7.426J-.002
X-49.819Y-83.96I7.262J1.5
G01Y-80.51
X-50.096
Z5.
M30
%

For finishing
Select NC sequence – Machining – Finishing – Done – Select tool and enter parameters like Cut
feed, Step depth, Step over, Profile stock allow, scan type and spindle speed.
Create volume.
Select Playpath
After completing Playpath, Select NC check
Machining → CL data → NC sequence → sequence → file → MCD file.
Done. Enter name . ok . Done.
NC Program for Finishing
%
G71
O0002
(D:\parts\FINS\cylinder_fin_body\finishing_ca1.ncl.1)
(03/21/11-03:02:01)
N0010T1M06
S2347M03
G00X-133.853Y-116.832
G43Z5.H01
Z-50.849
G01Z-51.349F1500.
X-125.625
X-125.401Y-116.96Z-51.341
X-125.266Y-117.037Z-51.346
X-125.199Y-117.068Z-51.348
X-125.088Y-117.118Z-51.341
X-124.994Y-117.16Z-51.347
X-124.89Y-117.207Z-51.345
X-124.169Y-117.096Z-51.315
X-124.096Y-117.095Z-51.311
X-123.093Y-117.085Z-51.224
X-122.337Z-51.124
X-121.581Z-50.994
X-120.826Z-50.834
X-120.074Z-50.645
X-119.326Z-50.425
X-118.584Z-50.175
X-117.851Z-49.896
X-117.127Z-49.587
X-116.415Y-117.088Z-49.249
X-115.716Y-117.092Z-48.883
X-115.032Y-117.096Z-48.49
X-114.365Y-117.099Z-48.071
X-113.716Y-117.102Z-47.627
X-113.086Y-117.105Z-47.158
X-112.477Y-117.109Z-46.667
X-111.89Y-117.112Z-46.154
X-111.326Y-117.114Z-45.621
X-110.72Y-117.118Z-44.997
Y-123.814
X-111.326Y-123.816Z-45.621
X-111.89Y-123.818Z-46.154
X-112.477Y-123.82Z-46.667
X-113.086Y-123.822Z-47.158
X-113.716Y-123.824Z-47.627
X-114.365Y-123.826Z-48.071
X-115.032Y-123.828Z-48.49
X-115.716Y-123.83Z-48.883
X-116.415Y-123.832Z-49.249
X-117.127Y-123.834Z-49.587
X-117.851Y-123.835Z-49.896
X-118.584Z-50.175
X-119.326Y-123.834Z-50.425
X-120.074Z-50.645
X-120.826Y-123.833Z-50.834
X-121.581Z-50.994
X-122.337Y-123.832Z-51.124
X-123.093Z-51.224
X-124.149Y-123.831Z-51.314
X-124.843Y-123.741Z-51.344
X-124.921Y-123.746Z-51.345
X-124.971Y-123.783Z-51.346
X-124.994Y-123.81
X-125.088Y-123.922Z-51.341
X-125.12Y-123.96
X-125.2Y-124.056Z-51.347
X-127.55Y-124.093Z-51.349
X-142.097Y-124.088
X-142.45Y-124.055Z-51.347
X-142.571Y-123.975Z-51.342
X-142.593Y-123.96Z-51.34
X-142.669Y-123.91Z-51.338
X-142.783Y-123.835Z-51.329
X-142.874Z-51.32
X-143.322Z-51.25
X-143.661Z-51.169
X-144.Z-51.062
X-144.335Z-50.93
X-144.665Y-123.831Z-50.77
X-144.986Y-123.828Z-50.585
X-145.294Y-123.824Z-50.375
X-112.819Y-102.477
X-112.752Y-102.41
X-112.515Y-102.229
X-112.452Y-102.166
X-112.214Y-101.985
X-112.152Y-101.922
X-111.932Y-101.756
X-111.875Y-101.697
X-111.655Y-101.53
X-111.598Y-101.472
X-111.392Y-101.317
X-111.34Y-101.262
X-111.135Y-101.108
X-111.083Y-101.053
X-110.891Y-100.91
X-110.843Y-100.858
X-110.654Y-100.717
X-110.605Y-100.665
X-110.42Y-100.527
X-110.376Y-100.479
X-110.201Y-100.349
X-110.157Y-100.301
X-109.983Y-100.172
X-109.939Y-100.124
X-109.773Y-100.001
X-109.732Y-99.956
X-109.57Y-99.836
X-109.531Y-99.792
X-109.374Y-99.677
X-109.337Y-99.634
X-109.196Y-99.531
Y-96.96
X-109.171Y-96.849
X-109.1Y-96.76
X-108.997Y-96.711
X-105.723Y-96.708
X-105.664Y-96.65
X-105.626Y-96.631
X-105.484Y-96.503
X-105.448Y-96.486
X-105.191Y-96.265
X-105.155Y-96.248
X-104.574Y-95.764
X-104.537Y-95.746
X-103.849Y-95.187
Z5.
M30
%

For Cavity2

Select New – Manufacturing – NC Assembly – Enter name – Select units – ok

Retrieving the cavity in to manufacturing
Creating Workpiece
Set up the machine tool by selecting type of machine, cutting tool, Machine zero and retract.
For roughing,
Select NC sequence – Machining – Volume – Done – Select tool and enter parameters like Cut
feed, Step depth, Step over, Profile stock allow, rough stock allow, scan type and spindle speed.
Create volume.
Select Playpath
After completing Playpath, Select NC check
Machining → CL data → NC sequence → sequence → file → MCD file.
Done. Enter name . ok . Done.

NC Program for roughing

%
G71
O0001
(D:\parts\FINS\cylinder_fin_body\ca2_roughing.ncl.1)
(03/21/11-05:03:24)
N0010T1M06
S10000M03
G00X-89.549Y-3.
G43Z1.H01
G01Z-1.F7620.
X-134.258
Y-4.
X-89.549
Y-5.
X-134.258
Y-6.
X-89.549
Y-7.
X-134.258
Y-8.
X-89.549
Y-9.
X-134.258
Y-10.
X-89.549
Y-11.
X-134.258
Y-12.
X-89.549
Y-13.
X-134.258
Y-14.
X-89.549
Y-15.
X-134.258
Y-16.
X-89.549
Y-17.
X-134.258
Y-18.
X-89.549
Y-19.
X-134.258
Y-20.
X-89.549
Y-21.
X-134.258
Y-22.
X-89.549
Y-23.
X-134.258
Y-24.
X-89.549
Y-25.
X-134.258
Y-26.
X-89.549
Y-27.
X-134.258
Y-28.
X-89.549
Y-29.
X-134.258
Y-30.
X-89.549
Y-31.
X-134.258
Y-32.
X-89.549
Y-33.
X-134.258
Y-34.
X-89.549
Y-35.
X-134.258
Y-36.
X-89.549
Y-37.
X-134.258
Y-38.
X-89.549
Y-39.
X-134.258
Y-40.
X-89.549
Y-41.
X-134.258
Y-42.
X-89.549
Y-43.
X-134.258
Y-44.
X-89.549
Y-45.
X-134.258
Y-46.
X-89.549
Y-47.
X-134.258
Y-48.
X-89.549
Y-49.
X-134.258
Y-50.
X-89.549
Y-51.
X-134.258
Y-52.
X-89.549
Y-53.
X-134.258
Y-53.096
G02X-134.397Y-54.I-3.001J0.
G01X-89.409
G03X-88.867Y-55.I2.862J.904
G01X-134.939
G02X-135.578Y-55.582I-2.32J1.904
X-136.318Y-55.952I-1.836J2.744
G01X-136.471Y-56.
X-87.335
G03X-86.62Y-56.109I.807J2.89
G01X-86.547Y-56.103
X-86.528Y-56.11
X-85.796
Y-57.
X-138.01
Y-58.
X-85.796
Y-59.
X-138.01
Y-60.
X-85.796
Y-61.
X-138.01
Y-62.
X-85.796
Y-63.
X-138.01
Y-64.
X-85.796
Y-65.
X-138.01
Y-66.
X-85.796
Y-67.
X-138.01
Y-68.
X-85.796
Y-69.
X-138.01
Y-70.
X-85.796
Y-71.
X-138.01
Y-72.
X-85.796
Y-72.51
X-85.756Y-73.
X-138.051
G02X-138.406Y-74.I-2.96J.49
G01X-85.4
G03X-84.47Y-75.I2.604J1.49
Y-149.86
X-42.013
Y-139.86
Z0.
X-54.347
G02X-57.347Y-136.86I0.J3.
G01Y-131.596
X-62.594Y-128.769
G03X-65.347Y-126.96I-2.753J-1.191
G01X-65.949
X-161.412Y-75.51
X-161.808
G02X-164.491Y-73.851I0.J3.
G01X-167.678Y-72.134
Y-63.64
G03X-170.678Y-60.64I-3.J0.
G01X-189.003
Z-2.
X-150.003
Y-59.64
X-189.003
Y-58.64
X-150.003
Y-57.64
X-189.003
Y-56.64
X-150.003
Y-55.64
X-189.003
Y-54.64
X-150.003
Y-53.64
X-189.003
Y-52.64
X-150.003
Y-51.64
X-189.003
Y-50.64
X-150.003
X-189.003
Y-60.64
X-150.003
Y-50.64
Z0.
Y-60.64
X-161.808
G03X-164.808Y-63.64I0.J-3.
G01Y-72.51
G03X-161.808Y-75.51I3.J0.
G01X-141.011
G03X-138.01Y-72.51I0.J3.
G01Y-56.11
X-137.278
X-137.259Y-56.103
X-137.186Y-56.109
G03X-136.318Y-55.952I-.092J2.999
X-135.578Y-55.582I-1.096J3.114
X-134.258Y-53.096I-1.681J2.486
G01Y-52.724
X-85.796Y-59.136
Y-72.51
G03X-82.795Y-75.51I3.J0.
G01X-60.431
G03X-57.431Y-72.51I0.J3.
G01Y-63.64
G03X-60.431Y-60.64I-3.J0.
G01X-74.423
Z-2.
X-35.423
Y-59.64
X-74.423
Y-58.64
X-35.423
Y-57.64
X-74.423
Y-56.64
X-35.423
Y-55.64
X-74.423
Y-54.64
X-35.423
Y-53.64
X-74.423
Y-52.64
X-35.423
Y-51.64
X-74.423
Y-50.64
X-35.423
X-74.423
Y-60.64
X-35.423
Y-50.64
Z1.
M30
%

For finishing
Select NC sequence – Machining – Finishing – Done – Select tool and enter parameters like Cut
feed, Step depth, Step over, Profile stock allow, scan type and spindle speed.
Create volume.
Select Playpath
After completing Playpath, Select NC check

Machining → CL data → NC sequence → sequence → file → MCD file.

Done. Enter name . ok . Done.
NC Program for Finishing

G71

O0021

(D:\parts\FINS\cylinder_fin_body\ca2finishing.ncl.1)
(03/21/11-05:17:23)

N0010T1M06

S3500M03

G00X-131.91Y-180.674

G43Z1.H01

Z.409

G01Z.209F1200.

X-131.903Z.009

X-132.188Z0.

X-195.717

Y-180.474

X-132.188

X-131.903Z.009

Y-180.274

X-132.188Z0.

X-195.717

Y-180.074

X-132.188

X-131.903Z.009

Y-179.874

X-132.188Z0.

X-195.717

Y-179.674
X-132.188

X-131.903Z.009

Y-179.474

X-132.188Z0.

X-195.717

Y-179.274

X-132.188

X-131.903Z.009

Y-179.074

X-132.188Z0.

X-195.717

Y-178.874

X-132.188

X-131.903Z.009

Y-178.674

X-132.188Z0.

X-195.717

Y-178.474

X-132.188

X-131.903Z.009

Y-178.274

X-132.188Z0.

X-195.717
Y-178.074

X-132.188

X-131.903Z.009

Y-177.874

X-132.188Z0.

X-195.717

Y-177.674

X-132.188

X-131.903Z.009

Y-177.474

X-132.188Z0.

X-195.717

Y-177.274

X-132.188

X-131.903Z.009

Y-177.074

X-132.188Z0.

X-195.717

Y-176.874

X-132.188

X-131.903Z.009

Y-176.674

X-132.188Z0.
X-195.717

Y-176.474

X-132.188

X-131.903Z.009

Y-176.274

X-132.188Z0.

X-195.717

Y-176.074

X-132.188

X-131.903Z.009

Y-175.874

X-132.188Z0.

X-195.717

Y-175.674

X-132.188

X-131.903Z.009

Y-175.474

X-132.188Z0.

X-195.717

Y-175.274

X-132.188

X-131.903Z.009

Y-175.074
X-132.188Z0.

X-195.717

Y-174.874

X-132.188

X-131.903Z.009

Y-174.674

X-132.188Z0.

X-195.717

Y-174.474

X-132.188

X-186.076

Y-47.64Z.009

X-186.276

Y-48.142Z-.007

X-186.476

Y-47.64Z.009

X-186.676

Y-48.142Z-.007

X-186.876

Y-47.64Z.009

X-187.076

Y-48.142Z-.007

X-187.276
Y-47.64Z.009

X-187.476

Y-48.142Z-.007

X-187.676

Y-47.64Z.009

X-187.876

Y-48.142Z-.007

X-188.076

Y-47.64Z.009

X-188.276

Y-48.142Z-.007

X-188.476

Y-47.64Z.009

X-188.676

Y-48.142Z-.007

X-188.876

Y-47.64Z.009

X-189.076

Y-48.142Z-.007

X-189.276

Y-47.64Z.009

X-189.476

Y-48.142Z-.007
X-189.676

Y-47.64Z.009

X-189.876

Y-48.142Z-.007

X-190.076

Y-47.64Z.009

X-190.276

Y-48.142Z-.007

X-190.476

Y-47.64Z.009

X-190.676

Y-48.142Z-.007

X-190.876

Y-47.64Z.009

X-191.076

Y-48.142Z-.007

X-191.276

Y-47.64Z.009

X-191.476

Y-48.142Z-.007

X-191.676Y-47.962Z-.001

Y-47.64Z.009

X-191.876
Y-47.765Z.005

Z1.

M30

For Side Insert

Select New – Manufacturing – NC Assembly – Enter name – Select units – ok

Retrieving the cavity in to manufacturing
Creating Workpiece
Set up the machine tool by selecting type of machine, cutting tool, Machine zero and retract.
For roughing,
Select NC sequence – Machining – Volume – Done – Select tool and enter parameters like Cut
feed, Step depth, Step over, Profile stock allow, rough stock allow, scan type and spindle speed.
Create volume.
Select Playpath
After completing Playpath, Select NC check
Machining → CL data → NC sequence → sequence → file → MCD file.
Done. Enter name . ok . Done.

NC Program for roughing

%
G71
O0001
(D:\parts\FINS\cylinder_fin_body\roughing.ncl.1)
(03/21/11-03:13:07)
N0010T1M06
S3456M03
G00X-2.Y-2.
G43Z2.H01
Z1.
G01Z-2.F2200.
X-98.
Y-3.974
X-2.
Y-5.948
X-98.
Y-7.922
X-2.
Y-9.895
X-98.
Y-11.869
X-2.
Y-13.843
X-98.
Y-15.817
X-2.
Y-17.791
X-98.
Y-19.765
X-2.
Y-21.739
X-98.
X-2.
Y-23.713
X-9.895
G02X-9.425Y-25.I-1.53J-1.287
G01Y-25.686
X-2.
Y-27.66
X-9.425
Y-29.634
X-2.
Y-31.608
X-9.425
Y-33.582
X-2.
Y-35.556
X-9.425
Y-37.53
X-2.
Y-39.503
X-9.425
Y-41.477
X-2.
Y-43.451
X-9.425
Y-2.
X-2.
Y-23.713
X-9.895
G02X-9.425Y-25.I-1.53J-1.287
G01Y-25.686
X-2.
Y-27.66
X-9.425
Y-29.634
X-2.
Y-31.608
X-9.425
Y-33.582
X-2.
Y-35.556
X-9.425
Y-37.53
X-2.
Y-39.503
X-9.425
Y-41.477
X-2.
Y-43.451
X-9.425
Y-45.425
X-2.
Y-47.399
X-9.425
Y-49.373
X-2.
Y-51.347
X-9.425
Y-53.32
X-2.
Y-55.294
X-9.425
Y-57.268
X-2.
Y-59.242
X-9.425
Y-61.216
X-2.
Y-63.19
X-9.425
Y-65.164
X-2.
Y-67.138
X-9.895
G03X-9.425Y-65.85I-1.53J1.288
G02X-11.425Y-67.85I-2.J0.
G01X-68.875
G02X-70.875Y-65.85I0.J2.
G01Y-25.
G02X-68.875Y-23.I2.J0.
G01X-11.425
G02X-9.425Y-25.I0.J-2.
G01Y-65.85
Z2.
G00X-98.Y-2.
Z-47.
G01Z-48.204
Y-88.85
X-2.
Y-2.
X-98.
Z2.
M30
%

For finishing
Select NC sequence – Machining – Finishing – Done – Select tool and enter parameters like Cut
feed, Step depth, Step over, Profile stock allow, scan type and spindle speed.
Create volume.
Select Playpath
After completing Playpath, Select NC check
Machining → CL data → NC sequence → sequence → file → MCD file.
Done. Enter name . ok . Done.
NC Program for Finishing

G71

O0004

(D:\parts\FINS\cylinder_fin_body\finishing.ncl.1)

(03/21/11-03:17:01)

N0010T1M06

S10000M03

G00X-49.959Y-89.773

G43Z2.H01

Z-48.904
G01Z-49.204F2100.

X-98.342

X-98.894Y-89.221

Y-1.24

X-98.344Y-1.073

X-1.541Y-1.077

X-1.106Y-1.235

Y-89.226

X-1.576Y-89.773

X-49.959

X-50.002Y-89.761

X-50.073Y-89.684

X-50.116Y-89.673

X-98.301

X-98.794Y-89.179

Y-1.304

X-98.295Y-1.167

X-97.777Y-1.177

X-1.559

X-1.206Y-1.305

Y-89.189

X-1.622Y-89.673

X-49.943
X-49.986Y-89.661

X-50.057Y-89.584

X-50.1Y-89.573

X-98.259

X-98.694Y-89.138

Y-1.371

X-98.246Y-1.262

X-97.786Y-1.277

X-1.576

X-1.306Y-1.375

Y-89.152

X-1.668Y-89.573

X-49.927

X-49.97Y-89.561

X-50.041Y-89.484

X-50.084Y-89.473

X-98.218

X-98.594Y-89.097

Y-1.44

X-98.198Y-1.358

X-97.794Y-1.377

X-1.594

X-1.406Y-1.446
Y-89.115

X-1.714Y-89.473

X-49.911

X-49.954Y-89.461

X-50.025Y-89.384

X-50.068Y-89.373

X-98.177

X-98.494Y-89.055

Y-1.513

X-98.151Y-1.455

X-97.803Y-1.477

X-1.611

X-1.506Y-1.516

Y-89.078

X-1.76Y-89.373

X-49.895

X-49.938Y-89.361

X-50.01Y-89.284

X-50.053Y-89.273

X-69.769Y-66.319

X-69.855Y-66.092

X-69.884Y-65.85

X-69.88Y-65.81
X-69.881Y-25.025

X-69.855Y-24.758

X-69.769Y-24.531

X-69.631Y-24.331

X-69.448Y-24.169

X-69.233Y-24.056

X-68.997Y-23.998

X-68.745Y-24.

Z-49.155

X-11.303Y-23.998

X-11.067Y-24.056

X-10.862Y-24.164

X-10.669Y-24.331

X-10.531Y-24.531

X-10.445Y-24.758

X-10.419Y-25.025

X-10.423Y-65.793

X-10.416Y-65.85

X-10.445Y-66.092

X-10.531Y-66.319

X-10.669Y-66.519

X-10.852Y-66.681

X-11.067Y-66.794
X-11.303Y-66.852

X-68.997

X-69.233Y-66.794

X-69.448Y-66.681

X-69.631Y-66.519

X-69.769Y-66.319

X-69.855Y-66.092

X-69.884Y-65.85

X-69.88Y-65.81

X-69.881Y-25.025

X-69.855Y-24.758

X-69.769Y-24.531

X-69.631Y-24.331

X-69.448Y-24.169

X-69.233Y-24.056

X-68.997Y-23.998

X-68.745Y-24.

Z2.

M30

%
 CONCLUSION

In our project we have modeled a cylinder fin body for 150cc engine and die set for
manufacturing.

In the next step we have done Die calculations for the casting tool.

From the above caliculations we have prepared the mould set parts and prepared core and cavity
using pro/engineer.

Total force acting on the die plate is 88.09Tons. So we selected 250Tons Machine. Plunger dia is
98mm and shot volume is 9.2kg.

Fill time for magnesium is 0.665secs and heat to be removed is 2069.052cm3/sec.

Fill time for Aluminum is 0.182secs and heat to be removed is 7560 cm3/sec.

We have done manufacturing processes for the two cavities and side insert and generated CNC
Program.

We conclude that we can produce megnisium and aluinium fin bodys on the same mould by
modifying cooling chanels without any additional investment.
 BIBILOGRAPHY
 Machine Design by R.S. Khurmi and J.K. Gupta

 Theory of Machines by R.S. Khurmi and J.K. Gupta

 Theory of Machines by P.L. Ballney

 Pro/Engineer WildFire 2.0 by Steven G. Smith

 Handbook of Die design by By Ivana Suchy

 Product Design and Manufacturing by R.C. Gupta and A.K. Chaitle