Precision Machined Component
Strength and Limitation of Sand Casting and Investment Casting Components Die casting is a process in which molten metal is forced under high pressure into the mold cavities. The metal hardens to achieve the desired shape. In recent times, plastic molded parts have been replaced casting because they are cheaper and lighter than the castings. Casting can be done with a cold chamber or hot chamber process. About Die Casting Process Die casting is a non- extended consumable in which the metal is forced into the mold cavity under high pressure. Die casting mold is known as matrices can be used repeatedly to produce castings in a variety of sizes, shapes and wall thicknesses. The mold cavities are designed with intricate designs which allows the production of complex shapes with accuracy, surface finish and attractive. Casting history In the early days of casting method using only low pressure injection , but today casting techniques of high pressure such as compression and melting casting methods semi - solids are use to emit more than 4500 pounds per square inch . Initially, only tin and lead were dying breed but now of magnesium, copper and other alloys are also cast using this highly popular. Die casting process In this process, molten metal or other materials are forced under high pressure into the mold cavities of steel. Dies are two part molds which are made of alloy tool steel - fixative matrix and half die ejector. The die or mold is made from the impression of the component to be issued. There are four types of matrices: Single cavity to produce a component Multiple cavities to produce a number of identical Die unit to produce different parts at once Combinations die to produce several different parts of an assembly
The molten metal is injected into the mold under high pressure and high speed which helps in the production of a casting is smooth and precise as the original mold. The pressure is kept in the mold until it solidifies hot metal. When the metal has hardened, the matrix is opened to remove the casting. There are several variations on the basic process may be used to produce molded parts for specific applications. These include: Squeeze casting - A method by which the molten alloy is cast without turbulence and gas entrapment at high pressure to produce high quality, dense treatable components and heat. Semi -solid molding - A procedure in metal ingots semi - solids melt to provide dense heat treatable castings with low porosity. Alloys used Aluminum alloys, copper, lead, zinc and tin are mainly used in die casting. Automation In modern times, sophisticated die casting machines are used to ensure consistent quality control . Each machining casting differs in the method in which pours molten metal into the mold. Automation is used to lubricate molds, pour the metal into the chamber etc. Two processes called hot chamber and cold chamber methods used for casting. Applications Die casting is best suited for casting medium sized parts with complex details. Die - casting is the largest casting technique is used for the manufacture of consumer products, industrial and commercial such as cars, toys, sink faucet parts, connector housing, gears, etc. Most are made from castings nonferrous metals such as aluminum, magnesium etc. Advantages -
Economic process that can be used for a wide range of complex application
Parties have a longer life , dimensional accuracy and tolerance
Post machining can be totally eliminated
A process that can be fully automated
Mold can be used repeatedly.
Casting weight should be between 30 grams.
Delivery must be less than 600 mm (24 in.)
High initial cost.
Limited to high- fluidity metals.
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Die casting is a process in which molten metal is forced under high pressure into the mold cavities. http://www.vijayind.com/