Aluminium Casters' Association (ALUCAST)R, India
Innovative & Creative World of Aluminium

ALUCAST Zonal Events - Delhi

Training program on "HPDC, Die Simulation, LPDC,GDC Die Design and Maintenance of die casting Plant"

Training program "HPDC, Die Simulation, LPDC,GDC Die Design and Maintenance of die casting Plant" held On 15th & 16th of March 2018 at The Pllazio Hotel, Sector-29, Gurugram, Haryana.

This training program was an attempt made by ALUCAST faculty to touch upon the die design aspects of all the three types of die casting namely HPDC, LPDC and GDC. Simulation is something dear to all die casters and they got a clear understanding of the various aspects related to simulation through visual depictions on screen and coloured prints on the training manual.

Metallurgy and the role of additives is another distinct topic covered in the training program. A brush with the Aluminium/Silicon phase diagram and then a session on the defects of die casting and trouble-shooting were other welcome topics. All those who understand the dies were happy with the run through on the PQ2 diagram.

The session on the neglected subject -maintenance was a kind of eye-opener for the process and design participants. A brief touch on hydraulics, electricals, layout design and autonomous maintenance helped the cause.

The faculty :
Sajal Sen : BE(Mech) 1975, Over 30 years experience in Die design and manufacture, Process Control in die casting units of auto majors like Bajaj, ENDURANCE, ROCKMAN. Involved in new part development. Trained under NADCA Instructors. Certified Auditor for TS 18949. Currently Management Consultant in New product development, Process Optimisation, Cost Control.
Rajesh Aggarwal : Ex-General Manager, Casting Product Development Center & Tool Room at Endurance Technologies. National (ALUCAST) and International (NADCA) Award winning die designer, with over 25 years of experience, working with large die casting and die manufacturing units, backed by Masters' Degree in Industrial Engineering.
Anil Kumar Saroha : Rich experience in maintenance of Electrical, Electronic, ,Mechanical and Hydraulic Control Systems in Die Casting machines. Programming skills on PLC, HMI, SCADA and other systems.

Felicitation :
The program came to an end with the distribution of certificates and a photography session with the organizers and faculty. More than the 150 page training manual, the participants carried with them the memories of an excellent training session. We sincerely hope that the learning would be cherished by them in the years to come.


Training program on "Basics of Die Casting Dies"

Faculty :
Mr. Tej Bambra, Die Casting Consultant

Dignitories :
Mr. P. N. Sadhu, Patron – ALUCAST Delhi Center, Past President ALUCAST
Mr. Supreet Jain, President – ALUCAST Delhi Center.
Mr. Dilip Panjikar, Head Technical Training and Education - ALUCAST

ALUCAST Delhi center conducted a One-day Training Program on "Basics of Die Casting Dies-(Pressure Diecasting)" at Gurgaon. The program was conducted at The Epicenter hall, Gurgaon on 12th of April 2014.

The Training program participation was limited to a maximum of 40 participants in the interest of quality of Training, however, due to an overwhelming response from the industry, the forum had to accommodate 46 training participants. Although this program subject was earmarked for Shop-floor Supervisors, Engineers and Sr.Engineers only, there were a few entrepreneurs also who participated with full enthusiasm.

Eventually, we had a full-house of 46 participants representing 15 organizations including some from Faridabad, Chandigarh and Delhi apart from Gurgaon. The major participating companies included Maruti Suzuki, Hero Motocorp and Sunbeam Auto to name a few.

Mr.Supreet Jain, chairman, Delhi Center giving introduction of Mr.Tej Bambra

Mr.Tej Bambra, Faculty for training

Delegates at the training programme

The morning session started with a welcome note and a brief introduction of the presenter Mr.Tej Bambra by Mr.Supreet Jain, the Chairman ALUCAST Delhi Center. This was followed by a brief note by Mr.P.N.Sadhu – Patron ALUCAST Delhi, who also inaugurated the training session for the day officially.

A Handbook on Basics of Die Casting Dies compiled by Mr.Bambra consisting 175 pages was distributed to each of the participants covering the entire training content.

The "A" session was highly informative on the various aspects of Die designing including the feed system, Cavity layouts, the calculations of the Locking force, various types of runners and gates, Overflows and Air Vents.


Mr. Sadhu distributing certificate & prize

Mr. Tej Bambra Distributing Certificate

The post-lunch Technical session "B" focused on the Die Casting process control for optimum running of a Die and included the functions of the 3 Stage Injections system and the setting parameters of the Shot. This also included the various factors involved in the setting of a Die Casting Die on the machine for efficient performance. The 3rd and the last session "C" focused on the care and maintenance of the Die Casting Dies and also explained the various causes of failure of Dies and the preventive measures for a longer Die life.

A small Quiz contest comprising 20 questions based on the training content was organized as a part of the training session. The first three winners were distributed prizes by Mr.Sadhu.

The program ended with the distribution of participation certificates to all the participants, a vote of thanks from Mr.Supreet Jain and sharing of thoughts by Mr.Sadhu.

ALUCAST Delhi Center has proposed to organize such training sessions every 3 months on various topics pertaining to the Die Casting field and shall be inviting experienced faculty from the various industries from the Northern region.