DIE-CASTING

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• Q1: What is Die Casting?
  Ans: Die casting is a manufacturing process in which molten metal is forced into a mold (die) under pressure to produce metal parts.
• Q2: Briefly explain the process of Die Casting.
  Ans: In die casting, molten metal is injected into a metal mold under high pressure.
  After cooling and solidifying, the casting is removed from the die.
• Q3: Briefly explain the process of Gravity Die Casting.
  Ans: In gravity die casting, molten metal is poured into the mold using gravity without applying pressure.
  The metal fills the mold and solidifies naturally.
• Q4: Briefly explain the process of Pressure Die Casting.
  Ans: In pressure die casting, molten metal is injected into the die under high pressure.
  This ensures better filling and accurate shape of the casting.
• Q5: State any six uses of Die Casting.
  Ans: Uses of die casting are:

  • ➔ Automobile parts
  • ➔ Electrical components
  • ➔ Machine parts
  • ➔ Household equipment
  • ➔ Toys and hardware items
  • ➔ Aircraft components
• Q6: State any six advantages of Die Casting.
  Ans: Advantages of die casting are:

  • ➔ High production rate
  • ➔ Good surface finish
  • ➔ Accurate dimensions
  • ➔ Less machining required
  • ➔ Strong and durable products
  • ➔ Complex shapes can be made
• Q7: State any four disadvantages of DIe Casting.
  Ans: Disadvantages of die casting are:

  • ➔ High initial cost of equipment
  • ➔ Not suitable for small production
  • ➔ Limited to low melting point metals
  • ➔ Possibility of air trapped in casting
• Q8: State the die materials used for Die Casting.
  Ans: Die materials used are:

  • ➔ Tool steel
  • ➔ Alloy steel
  • ➔ Cast iron
• Q9: State the properties of Die Materials.
  Ans: Properties of die materials are:

  • ➔ High strength
  • ➔ Heat resistance
  • ➔ Good wear resistance
  • ➔ Good thermal conductivity
  • ➔ Resistance to thermal shock
• Q10: State the names of Die Casting Machines.
  Ans: Types of die casting machines are:

  • ➔ Hot Chamber Die Casting Machine
  • ➔ Cold Chamber Die Casting Machine
  • ➔ Submerged Plunger Type Machine
  • ➔ Direct Air Pressure Machine
• Q11: Briefly explain the working of Hot Chamber Die Casting Machine.
  Ans: In hot chamber machine, the melting furnace is attached to the machine.
  Molten metal is injected into the die through a plunger directly from the chamber.
• Q12: Briefly explain the working of Cold Chamber Die Casting Machine.
  Ans: In cold chamber machine, molten metal is first poured into a chamber.
  Then it is injected into the die using a piston under pressure.
• Q13: Briefly explain the working of Submerged Plunger Types Casting Machine.
  Ans: In this machine, the plunger is submerged in molten metal.
  It pushes the metal into the die cavity under pressure.
• Q14: Briefly explain the working of Direct Air Pressure Die Casting Machine.
  Ans: In this machine, compressed air is used to force molten metal into the die.
  The air pressure ensures proper filling of the mold.
• Q15: Briefly enlist the steps involved in Die Casting.
  Ans: Steps involved in die casting are:

  • ➔ Preparation of die
  • ➔ Melting of metal
  • ➔ Injection of molten metal
  • ➔ Cooling and solidification
  • ➔ Removal of casting
  • ➔ Finishing of product