Precision Machined Component
Complete Bible of Die Casting Die casting is a process in which molten metal is forced under high pressure into the mold cavities. The metal solidifies in order to bring a desired shape. Recently, plastic moldings have replaced casting, since they are less expensive and lighter than die-cast parts. Can be cast using a cold chamber or hot chamber process. About die casting Die casting is a widely used non-process consumables, wherein the metal to be forced into the mold cavity under high pressure. The mold can be used repeatedly as a stamp is known to produce castings in a wide variety of sizes, shapes and wall thicknesses. The wells are designed with intricate patterns, which enable the production of complex shapes with accuracy, surface quality and attractiveness. History of Die Casting In the early days of the cast only low-pressure injection method was used, but today, high pressure casting process like squeeze casting and semi-solid die casting methods are used to cast more than 4500 pounds per square inch. Initially, only tin and lead were dying caste, but now magnesium, copper and other alloys are also throwing this very popular procedure. The casting process In this process, molten metal or other materials are forced under high pressure into the voids in the steel mold. Matrices are two forms of which are made of alloy tool steel - The Fixer mold half and ejector mold half. The die or mold with the image of the component produced is molded. There are four types of forms: Single cavity to create a component Several cavities to produce a number of identical parts Unit dies to produce different parts at once Combinations die to produce different parts of an assembly
The molten metal is injected into the mold under high pressure and high speed, which helps in the manufacture of a casting part, which is smooth and precise as the original shape. The pressure maintained on the mold until the hot metal is established. When the metal has hardened the mold is opened to remove the casting. There are several variations on the basic process; the castings can be produced for special applications. These include: Squeeze casting - A method by which molten alloy without turbulence and gas entrapment under high pressure to high-quality, dense, heat treatable components are converted result. Semi-solid molding - A process in which semi-cast metal billets to provide dense, heat treatable castings with low porosity. Alloys Aluminum, copper, lead, zinc and tin, and alloys used mainly in die casting. Automation In today's demanding die casting machines are used that ensures consistent quality control. Each machined cast differs in the method, is poured into the molten meal into the mold. Automation can be used to lubricate the molds, pouring the metal into the chamber, etc. Two processes known hot chamber and cold chamber is used for die casting methods. Applications Die casting is the most suitable for casting parts with complex medium detail. Die casting is the largest casting technique used to load is produced, commercial and industrial products such as automobiles, toys, parts sink faucet, plug housing, gears, etc. Most die castings of non-ferrous metals such as aluminum, magnesium done, etc. Benefits Economical process that can be used for a variety of complex applications Parts have longer life, dimensional accuracy and close tolerance Post processing can be completely eliminated A process that can be fully automated Mold can be used repeatedly. Disadvantages Litter weight must be between 30 grams.
Casting must be less than 600 mm (24 in) High cost. Limited to high fluidity metals.
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Published on Jun 21, 2013
Published on Jun 21, 2013
Die casting is a process in which molten metal is forced under high pressure into the mold cavities. The metal solidifies in order to bring...