Tlpcasting is Die Casting Manufacturer from China

  • Weight: 0.5kg – 1000kg

  • Capability: 50 ton per month

  • Machining tolerance: +-0.01-0.03mm

  • Surface Roughness: 3.2 Ra um/125 Ra uinches

  • MOQ: 500 pcs

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Die casting can also refer gravity casting. Die casting is a manufacturing process in which molten metal is poured or forced into steel reusable molds. The non-ferrous alloy such as aluminum or zinc is melted in the furnace and then injected into die casting machine.

There are two main types of die casting machines – hot chamber machines (used for alloys with low melting temperatures, such as zinc) and cold chamber machines (used for alloys with high melting temperatures, such as aluminum).

Aluminum die casting alloys are lightweight and possess high dimensional stability for complex part geometries and thin walls. Aluminum has good corrosion resistance and mechanical properties with high thermal and electrical conductivity.

Advantage of Aluminum

  • Rapid production
  • Highly conductive
  • Corrosion resistant
  • Lightweight and Durable
  • Recyclable and Reusable in Production
  • Defined, smooth and textured-surfaced metal parts

Advantage of Zinc

  • Thinner wall sections
  • Highly conductive
  • Corrosion resistant
  • Thinner wall sections
  • High production rates
  • High dimensional accuracy
  • Full recyclability
  • High tensile strengths

Die Casting Process

1.Clamping

The initial stage is preparation and clamping of the two halves of the die. Step one is cleaning the residual metal from previous injection and lubricating the tool to facilitate the injection of the next component. After lubricating, the two die parts are secured inside the die casting machine, and then clamp together. The machine will apply sufficient pressure to keep the die secured during the injection.

2.Injection

To warm up the furnace at a set temperature, the machine will transfer the molten metal to the chamber and inject into the die. The pressures range is from 1000 to 20,000 psi. The machine will apply sufficient pressure to holds the molten metal during the solidification.

3.Cooling

The molten metal is injected into the die and begin to cool and solidify. After the entire cavity is filled and the molten metal solidifies, the final shape would be formed within a short time. The cooling time can be affected by thermodynamic properties of the metal and the maximum wall thickness of the casting.

4.Ejection

After the predetermined cooling period elapses, the operator can open the two die halves and ejection mechanism will push the casting out. The period time of opening the die is be determined by the dry cycle time of the machine and the size of the casting’s envelope. The ejection mechanism will apply adequate force to eject the part due to the shrinkage and adherence to the die after cooling. After ejection, tthe operator can clamp the die shut for the next injection.

5.Trimming

After the cooling period, the excess material and flash always come with parts due to injection with pressure. The workers will trim the excess material manually via cutting or sawing. The scrap material can be either discarded or can be recycle in the die casting process.

Die casting is a special casting method which develops rapidly in modern metal processing technology. The three main elements of die casting are machine, mould and alloy.

The unification of velocity pressure and time is the basis of this process. It is the process of filling the mold with molten metal at high pressure and high speed and crystallizing and solidifying to form the casting under high pressure. High pressure and high speed is the main characteristic of die casting. Using die casting has the advantages of high production efficiency, simple working procedure, high tolerance grade of casting, low surface roughness, high mechanical strength and less chip. Saving a lot of machining process and equipment, as well as raw material. It has become an important part of the foundry industry.

The die casting process also has some disadvantages. For example, it is easy to produce small porosity, finished part has low plasticity which is not suitable for working under impact load and vibration, When the melting point of the alloy is high, the die life will be reduced.

Die casting was first applied to the automobile industry and instrumentation industry, and then gradually expanded to various industries, such as agricultural machinery, machine tool industry, electronics industry, national defense industry, computer, medical equipment, and daily hardware and other industries.

We not only pay attention to casting structure technology, advanced mould, die casting machine performance and excellent structure, die casting alloy selection adaptability and smelting process standardization, but also pay more attention to the important role of pressure, temperature and time process parameters on casting quality.These parameters should be controlled effectively in the process of die casting.

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