What’s The Essential Factors of Die-Casting Machined Process?
At Creatingway, we practice the different types of pressure die casting with a well-adapted and dedicated team of expert engineers to the process. Hence, with confidence, we can assist you with the client in deciding what is best for our esteemed customers. To better understand pressure, die casting, it mostly involves forcing molten metal into a steel mold under high pressure into a mold cavity. It then solidifies, forming an intended net shape. The steel molds (dies), are fabricated to produce castings with specific shapes in a way that is accurate and repeatable. Aluminum, copper, zinc, and magnesium are the most commonly die casting alloys materials.
How does the die-casting machined process work?
To have a better understanding of the entire process, below is an overview of the 4 basic steps of die casting.
The initial step in pressure die casting is clamping. However, cleaning and lubrication of the dies occur in this step. They are essential before in aiding step two, injection. Therefore, once we thoroughly clean and lubricate the dies, we close and clamp the die halves together with pressure.
Transfer of molten metal from a furnace into a ladle follows. We then pour molten metal from the ladle into a shot chamber where it is ready to be injected into the initially clamped die. While, using extremely high pressure, we force the molten metal into the die. The high pressure holds the metal in the die for a duration until it solidifies.
Unclamping of the die halves follows once the cooling process is over. An ejection mechanism then pushes the solidified casting out of the die.
It is the last step in the die casting process. During the cooling process, we remove the excess metal in the runner and sprue along with any flash that has transpired. From the final casting, we also trim away extra material. Metal form the trimmed sprue, runners, and flash, is useful in recycling and reused in the die casting process.
Why is die-casting a process for you?
The possess a significant advantage over other manufacturing processes. At Creatingway, we have noted its added benefit in cost savings, not only in the part price itself but also in the overall cost of production. Other benefits include:
- Creation of complex shapes net shapes
- Variable wall thickness
- Tighter tolerances
- Fewer steps from raw material to finished part
- Fast production cycle times
- Reduction in material scrap
- Long tool life, especially for zinc and magnesium
Which metal alloy suits your design needs?
Die casting typically makes use of non-ferrous alloys. Therefore, we commonly use four alloys in our die casting processes. so that they are shown below alongside their unique properties as included below:
Aluminum alloys of characterized
- Low density
- Good corrosion resistance
- High thermal and electrical conductivity
- High dimensional stability
- Relatively easy to cast
- Use of a cold chamber machine
Magnesium alloys of characterized
- Very low density
- High strength-to-weight ratio
- Excellent machinability after casting
- Use of both hot and cold chamber machines
- Higher strength and toughness
- High corrosion and wear resistance
- High dimensional stability
- Highest cost
- Low die life due to high melting temperature
- use of a cold chamber machine
- High density
- Higher ductility
- Good impact strength
- Excellent surface smoothness allowing for painting or plating
- Requires such coating due to susceptibility to corrosion
- Easiest to cast
- Can form very thin walls
- Long die life due to low melting point
- Use of a hot chamber machine
At Creatingway, we assist you in deciding which metal alloy best suits your quote. The selection of a material for dies casting is dependent upon several factors, including the melting point, density, strength, cost, and corrosion resistance. The material used may also affect the part design. For example, the use of zinc alloys, a highly ductile metal, allows for thinner walls and a better surface finish than many other alloys. The properties of the material also impact on machining and tooling. Materials with a higher melting temperature require the use of a cold chamber machine. Alloys with this property include aluminum and copper alloys. However, materials with low melting temperatures can die-cast in a hot chamber machine. Zinc alloy is known to possess this property. Hence, the melting temperature also affects the tooling, as a higher temperature will have a more significant adverse effect on the life of the dies.
Applications of die-casting machined process
- Kitchenware such as pressure cookers
- Aerospace castings
- Cabinets for the electrical industry
- General hardware appliances such as plumbing part and pump parts
- Automotive parts like wheels, manifolds, and cylinder heads
- Bicycle parts
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