Design and Analysis of Pressure Die Casting Die for Side Differential Cover of Mini truck

Abstract

The design of die-casting dies requires considerable skill and expertise based on experience. The designer proposes designs of dies employed to cast parts from various alloys, and perform a variety of other operations. Every new job requires original thought in its design and the solving of individual problems in its manufacture.
The objective here is to design dies to be fit for the purpose, operate at optimum shot rate and is of reasonably simple construction. The main purpose of this report is to present the systematic design procedure for pressure die-casting dies. Die-casting dies like any other type of tooling can be very simple or very complex. How difficult they are to design and build depends entirely on the parts they produce.
The function of these SIDE DIFFERENTIAL COVER (part of gear box casing) is to protect and guide the gears used in power transmission. In this casing, power transmission is done by regulating the speed of driving wheels through crank shaft to rear axle. In this project we are also conducting static structural analysis for validating the design. Software used for analysis is Ansys.
Keywords: Side Differential Cover; Core and Cavity Dies; Pro-Engineering; Ansys