Design and Fabrication of Die Back Door for Manufacturing of Cylinder Liners

The centrifugal die casting process was observed at VACPL, at Vijayawada in India. In the present observation, for the production of cylinder liners, resin sand was used at the front door of the centrifugal die casting machine, and also, resin sand was dressed at the inner surface of the die. However, no resin sand is used at the back door, which results in the direct melt to metal contact at the back door and which increases the hardness of the casting excess than required, due to rapid cooling rate between the casting and die back door zone. Due to this hot spot, defects appear on the back door, and it decreases life of the back door and increases the scrap rate. The chilling length is removed by the parting operation, which increases the cost of production. In this research work, to eliminate that hot spot defect, the die back door was design and fabricated to introduce resin sand, and also, the temperature distributions of the die back doors were simulated by using ANSYS 18 software. Both old and new rear-end casting samples can be examined using the FE-SEM and EDX technique for microanalysis. Result in, no direct metal to metal contact, increasing the life of back door and the hardness of the cylinder casting is limited to as per requirement, parting operation and hot spot defects are eliminated. Instead of parting operation, facing operation is adopted. The time required for facing operation is 1/6th of the parting operation.