Production of the die casting mold

Production of the die casting mold is one of the three elements, structure reasonable mold die-casting production can proceed smoothly, prerequisites, and guarantee the quality of castings hand ( machine under qualified rate ) plays an important role in.

Due to the characteristic of the die casting process, the correct selection of the process parameters is getting high-quality casting decision factors, while the mold is able to correctly select and adjust the parameters of the premise, the mold design is essential to die casting production of various possible factors are expected to reflect the integrated. Aluminum Die Casting If the mold design is reasonable, it is encountered in the actual production problems, the high qualified rate of casting machine.

die casting mold
die casting mold

Conversely, the mold design is not reasonable, case casting design moving mould parcel force is basically the same, but mostly in the fixed mold gating system, and put the shot after punch can not feed the die casting machine production, cannot be produced normally, castings have been stuck on the fixed die. Although the fixed mold cavity finishes playing very light, because the cavity is deep, still stuck in the fixed mold phenomenon. So in the process of design, we must make a comprehensive analysis of casting structure, familiar with the die-casting machine ‘s operating process, to understand the die casting machine and process parameters can be adjusted odds, lies in the different situations and to consider the mold filling characteristics, processing methods, drilling and fixed form, in order to design a practical, satisfy the production requirements of the mold.

The beginning has been told, the filling time is very short, the liquid metal pressure and the flow rate are very high, the die is an extremely poor working condition, coupled with the rapid cooling and heating of the alternating stress impact, both on the service life of the die has a great influence on. Aluminium Die Casting The service life of the die is usually through careful design and manufacture, under normal use, combined with good maintenance under the natural damage cannot be repaired, in which the scrapped before, die-casting module (including the casting production of scrap number).

Features of magnesium die casting machine parts

The use of top standard parts of the magnesium die casting machine is important to the efficiency and economic advantages of magnesium casting. Die casting continues to provide different advantages for designers and developers which are unparalleled by other producing processes. It provides the capability to make complex shapes within a narrow tolerance level while decreasing the need for retooling. There are key features that all high standard magnesium casting machine parts have in general.

Decrease expansion and contraction in high temperatures

The primary feature is related to expansion and contraction in high temperatures. Only top standard goosenecks and melting pots have the capability to decrease expansion and contraction at high temperatures. This is critical to promise against casting defects which are general when lower standard parts are used. A key advantage of magnesium casting machines is the capability to accurately make identical complex shapes. This can just be achieved if the melting pot and gooseneck do not expand and contract as temperatures changes.

If you are looking for aluminium die casting or zinc/Zamak die casting parts, you can contact us

Abrasion resistance

Abrasion resistance is equally vital features of high standard warm chamber magnesium die machining parts. By reducing the abrasion of the properties of materials used in the making process is maintained. It makes sure the materials used to make the gooseneck and crucible do not gradually seep or flake into the product being made. Additionally, the deficiency of abrasion resistance significantly rises the danger that oxides will be produced via the magnesium alloy melting process, thus diluting the purity of the finished item.

Aluminium die casting
Aluminium die casting

Erosion resistance

Shock resistance and erosion resistance work hand-in-hand. Throughout the die casting procedure, there are different chances for important components to slowly erode. Not only does this dilute the purity of the finished process but it also shortens the lifespan of individual parts. Low standard parts fast undermine the reliability and constancy of magnesium die casting machines.

Shock resistance

Shock resistance is generally overlooked as an important feature of top standard magnesium dies casting machine parts. Shock resistance is particularly vital for melting pots and goosenecks as these parts are put under remarkable strain during the casting process. The shock resistance feature makes sure a long lifespan of the most vital parts of the die machine.

Internal design consistency The internal design consistency is a melting pot that is vital but it is even more vital for goosenecks. Internal design consistency is what permits the magnesium die casting process to economically and efficiently produce 1000s of copies of hard shape with minimal variance. A deficiency of internal design consistency can lead to early wear and tear on individual parts. want to know more about die casting you are welcome to our home page by https://www.aludiecasting.com/



Pressure Die Casting

Content.

  1. Introduction
  2. Cold chamber Die casting
  3. Advantages & limitations of cold chamber Die casting
  4. Application of cold chamber die casting
  5. Hot chamber – gooseneck type
  6. Hot chamber – plunger type

Introduction

History:

  • Pressure Die casting is believed to have begun sometime during middle of 19th century.
  • According to records, Sturges patented the first manually operated pressure Die casting machine during 1849.
  • Various compositions of tin & lead were first Die casting alloys.
  • Their importance and use declined with the development of zinc alloys & the Mg a Cu followed.

Introduction content

  • Pressure Die casting types:
  • Cold chamber pressures die casting.
  • Hot chamber pressure die casting.

Specialty of Die casting process:

A “metallic mold” is used to prepare sand mold with which larger number of casting are made. The metallic mold is known as “die”.

Cold chamber Die casting

  • In this machine, the metal is melted separately in the furnace and transferred to these by means by small ladle. After closing the die, the molten metal is forced into the die cavity by a hydraulically and pressure is maintained till solidification. These machines can either have vertical plunger or horizontal plunger for forcing molten metal into die These machines can either have a vertical plunger or flat plunger for driving liquid metal into biting the dust.
  • Advantages & limitations

Advantages of cold chamber die casting:

Straightforward development Thus the expense of the gear isn’t extremely high.

Limitations of cold chamber Die casting:

Slower cycle time due to the need to transfer the molten metal from furnace to the cold chamber machine. Hence, the rate of production will be less.

Alloys cast with cold chamber die casting:

  1. Aluminum alloys:

A360 alu die casting, A383, A384, A290, A413, A418, A380 aluminum die casting,

  • Zinc alloys with larger proportion of aluminum:

ZA-12, ZA-27

  • Magnesium alloys:

AZ91D, AM60A, AS41A

  • Copper alloys

Hot chamber pressure die casting

Hot pressures die casting types:

  • Gooseneck air injection type
  • Submerged plunger type

Goose neck air injection type

In this machine, the goose neck container is operated by lifting mechanism. Initially it is submerged in molten metal and filled by gravity, and then it is raised so as to bring the nozzle in contact with die opening and is looked in that position. Compacted air at that point powers the metal into the bite the dust and weight is kept up till hardening. When solidification is complete, the goose neck is lowered down and casting is removed by ejector pins after opening the dies.

Plunger type

I this machine, the goose neck type container always remain immersed in metal pot. The molten metal from metal container is forced inside the die with help of plunger submerged in molten metal comes up and fills the cylinder and when plunger moves down, the metal is forced into die. The moveable die platen is synchronized such that when plunger is moving up, the moveable die platen moves away and casting is removed.

Gravity die casting

Content:

  1. Introduction
  2. Die casting machine
  3. Gravity die casting
  4. Advantages compared to sand molding
  5. Limitations
  6. Applications

Introduction:

  • Die casting process

Main drawback of sand molding process:

Mold needs to prepare for each casting produced.

The specialty of die casting process:

A “metallic mold” is used to prepare sand mold with which larger number of casting is made. The metallic mold is known as “die”.

Die casting process:

  • Mold material: metal or alloy.
  • Types of die casting process:
  • Gravity Die casting (permanent molding).
  • Pressures die casting.
  • Cold chamber pressure Die casting
  • Hot chamber die casting
  • Unlike gravity die casting in pressure die casting the molten metal is forced into a permanent mold cavity under pressure.
  • The pressure varies from 20 to 2000 kg/sq.cm. And is maintained till the solidification stage is reached. The weight is for the most part acquired by compacted air or using pressurized water.
  • Die casting machines
  • Die casting machines perform the following functions.
  • Holding the two die halves firmly together. Closing the die
  • Injection molten metal into the die casting mold
  • Opening the die
  • Ejecting the die casting out of die

Gravity Die casting

  • The casting is called gravity die casting because the molten metal is poured into the mold under gravity only, no external pressure is applied to force the liquid metal into the mold cavity (opposite to die casting).

Permanent molds

  • Permanent molds are made of grey cast iron in two halves (having high resistance to thermal shocks), alloy steels (for very high temp. and withstanding surface erosion) or non-ferrous alloys.
  • The inner surface of the molds is coated first with refractory and with lamp black or core oil. This is done in order to reduce the chilling effect on cast prevents the adherence of molten metal to the mold.
  • Pouring cups, risers, gates, sprues are present in the mold.

Advantages

  • Compared to sand casting following are merits
  • Closer dimensional tolerances.
  • Smoother surface and better appearances.
  • Fine-grained metal structure. (Because of the chilling effect.)
  • Mass production is more economical.
  • Low shrinkage and gas porosity.

Think – “climate toys can be delivered with this procedure.”

 Limitation

  • Lasting mold costs were substantially more than sand for
  • Suited for small/ medium-sized non-ferrous casting only.
  • Several defects like stress and surface hardening may be produced due to surface chilling effect.
  • Since the gating system is cut in mold halves, once machined, it cannot be changed.
  • The extremely high temp of molten metal makes this method unsuitable for steel casting.

Applications

  • Carburetor bodies.
  • Refrigeration casting.
  • Oil pump bodies.
  • Connecting rods and automotive pistons.
  • Typewriter segments, etc.