Die Casting Service
For customers who need mass production of metal products/hardware parts and cost control, die casting manufacturing is definitely a good choice. Like extrusion processing, die casting is also a form of “equal material” manufacturing or forming manufacturing. The difference is that die casting requires the metal raw materials are first melted and then injected into the die-casting machine. After being formed in a high-temperature and high-pressure dies/molds, they are cooled, and some require secondary finishing like CNC machining and surface treatment. JHMOCKUP has accumulated more than decades of experience in die-casting manufacturing and dies design/mold design, and has helped a large number of customers from automotive parts, aerospace, consumer electronics manufacturers, precision instruments and other industries.
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What is Die Casting?
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into mould/mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process.
Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Casting equipment and metal molds imply huge capital costs, which often limit the
process of mass production.Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is specially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process.Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
The traditional die casting process is mainly composed of four steps, including dies preparation, filling, ejection and shakeout, which is also the basis of various improved die casting processes. Lubricants are sprayed into the cavity during preparation. Lubricants help to control the temperature of the dies/molds as well as the casting demoulding. The dies/molds can then be closed and the molten metal injected into the dies/molds at high pressure, ranging from about 10 to 175 megapascals. When the molten metal is filled, the pressure is maintained until the casting solidifies. The push rod pushes out all the castings, and since there may be multiple cavities in an die/mold, there may be multiple castings per casting process. The doffing process involves separating the residue, including the die/ mold mouth, runner, gate, and fly edge. This process is usually accomplished by extruding the casting with a special dressing die. Other methods of sand removal include sawing and grinding. If the gate is fragile, you can directly beat the casting, which can save manpower. The excess mold opening can be reused after melting.
High-pressure injection causes the mold to be filled with materials very quickly, so that the molten metal fills the entire mold before any part solidifies. In this way, surface discontinuities can be avoided even in thin-walled sections that are difficult to fill. However, this also leads to air entrapment, as it is difficult for air to escape when filling the mold quickly. This problem can be reduced by placing vents on the parting line, but even very precise processes can leave porosity in the center of the casting. Most die castings can complete some structures that cannot be done by casting through secondary processing, such as drilling,
Advantages of Die Casting:
>Excellent dimensional accuracy (dependent on casting material).
>Smooth cast surfaces (Ra 0.8—3.2um).
>High material utilization. The material utilization rate is about 60%--80%, and the blank utilization rate is 90%.
>Thinner walls can be cast as compared to sand and permanent mould casting (approximately 0.75 mm or 0.030 in).
>Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing surfaces).
>Reduces or eliminates secondary machining operations.
>Rapid production rates. Because of high speed mold filling, mold filling time is short, metal industry solidification is fast, die casting operation cycle speed.
>In all kinds of casting process, die casting method has the highest productivity, suitable for mass production.
>Casting tensile strength as high as 415 megapascals (60 ksi).
>Die casting fluid length is unaffected by solidification range, unlike permanent molds, sand castings, and other types.
>Corrosion rates for die castings are slower than those for sand castings due to the smoother surface of the die castings.
Disadvantages of Die Casting:
>Manufacturing in small quantities can be costly due to casting equipment and dies are expensive.
>There will be porosity/air holes in the die casting and mechanical properties will decrease.
>The porosity/Air holes can also prevent any heat treatment or welding.
>The size of die-casting parts is limited, and large die-casting parts cannot be die-casting because of the limitation of die-casting machine locking force and mold size.
>The type of die casting alloy is limited, because the die casting mold is limited by the temperature, it is mainly used for die casting zinc alloy, aluminum alloy, magnesium alloy and copper alloy.
Typical die temperatures and life for various cast materials:
>Zinc has a maximum die life upto 1,000,000 cycles with Die temperature
[C° (F°)] 218 (425) and Casting temperature [C° (F°)]400 (760).
>Aluminium has a maximum die life upto 100,000 cycles with Die temperature
[C° (F°)] 288 (550) and Casting temperature [C° (F°)] 660 (1220).
>Magnesium has a maximum die life upto 100,000 cycles with Die temperature
[C° (F°)] 260 (500) and Casting temperature [C° (F°)] 760 (1400).
>Brass has a maximum die life upto 10,000 cycles with Die temperature
[C° (F°)] 500 (950) and Casting temperature [C° (F°)] 1090 (2000).
The most common applications for Die casting:
Die casting can be made for die casting of auto parts, die-casting car engine fittings, die casting, air conditioning accessories, die-casting cylinder of engine cylinder head casting, die casting valve rocker arm, die-casting valve bearings, electrical accessories, die-casting motor end cover, die casting, die casting, die casting, pump shell shell building parts, die-casting parts, die-casting guardrail accessories, die-casting wheel parts, etc.,
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3D printing rapid prototyping
In this new era of great changes, many things around us are constantly improving and perfecting. Only technological products that are constantly innovating and changing are more popular. That is to say, our product technology rapid prototyping has a very high speed and efficiency, product production effect is very good. Ming, do not stick together, so how does this rapid prototyping technology compare to traditional technology? Today we’ll take a look.
The rapid prototyping technology adopted by the rapid prototyping device can adapt to the difficulty of manufacturing and processing of various materials in our life, and can obtain excellent materials and structural properties of parts.
As mentioned above, the rapid prototyping technology of materials involves materials, forming methods and structural forms of parts. The essence of rapid prototyping mainly includes the chemical composition of the forming material, the physical properties of the forming material (such as powder, wire or foil) (melting point, thermal expansion coefficient, thermal conductivity, viscosity and fluidity). Only by recognizing the characteristics of these materials can we choose the right material compared with the traditional rapid prototyping technology. What are the characteristics of rapid prototyping technology?
3d printing material rapid prototyping technology mainly includes material density and porosity. In the production process, can meet the performance requirements of molding material microstructure, molding material precision, parts precision and surface roughness, molding material shrinkage (internal stress, deformation and cracking) can meet the specific requirements of various rapid prototyping methods. The precision of the product will directly affect the structure of the product, the roughness of the surface of the product will affect whether there are some defects on the surface of the product, and the shrinkage of the material will affect the precision requirements of the product in the production process.
Rapid prototyping technology for the products produced. It also ensures that there is no big gap between what is produced and what is put on the market. Material rapid prototyping technology mainly includes material density and porosity. In the production process, can meet the performance requirements of molding material microstructure, molding material precision, parts precision and surface roughness, molding material shrinkage (internal stress, deformation and cracking) can meet the specific requirements of various rapid prototyping methods. The precision of the product will directly affect the structure of the product, the roughness of the surface of the product will affect whether there are some defects on the surface of the product, and the shrinkage of the material will affect the precision requirements of the product in the production process.
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The role of mold rapid prototyping technology
Mold manufacturing rapid prototyping technology also plays an important role in the increasingly competitive market economy, mold manufacturing rapid prototyping technology also plays an important role, is an important part of the advanced manufacturing technology group. It focuses on computer aided design and manufacturing technology, laser technology and material science and technology, in the absence of traditional mold and fixture, quickly create arbitrary complex shape and have a certain function of the 3D entity model or parts, about the cost of new product development and mold manufacturing, repair. Section is used in aviation, aerospace, automotive, communications, medical, electronics, household appliances, toys, military equipment, industrial modeling (sculpture), architectural models, machinery industry and other fields. In the mold manufacturing industry, the rapid prototyping made by rapid prototyping technology is combined with silica gel mold, metal cold spraying, precision casting, electrocasting, centrifugal casting and other methods to produce molds.
So what are its characteristics? First, it adopts the method of increasing materials (such as coagulation, welding, cementation, sintering, aggregation, etc.) to form the required parts appearance, because of the RP technology in the process of manufacturing products won’t produce waste cause the pollution of environment, so in today’s modern pays attention to the ecological environment, this also is a green manufacture technology. Secondly, it has solved many problems in traditional processing and manufacturing for laser technology, numerical control technology, chemical industry, material engineering and other technologies. The wide application of rapid prototyping technology in China has played a supporting role in the development of manufacturing enterprises in China, enhanced the rapid response ability of enterprises to the market, improved the competitiveness of enterprises, and also made a significant contribution to the national economic growth.
Advantages of 3D printing prototypes
1. With good complex manufacturing capability, it can complete manufacturing difficult to be completed by traditional methods. The product is complex, and only through multiple rounds of design – prototype machine production – test – modification design – prototype machine reproduction – re-test process, through the prototype machine repeated test can timely find problems and correction. However, the output of the prototype is very small, and it takes a long time and high cost to adopt the traditional manufacturing method, resulting in a long development cycle and high cost.
2. Low cost and fast speed of small batch manufacturing can significantly reduce the development risk and shorten the development time. 3D printing ingot casting with planks do not need to traditional manufacturing mode, system, mold and die forging process, can rapid prototype production, low cost, and digital, the entire production process can be modified at any time, at any time, in a short time, a large number of verification test, thus significantly reduce the risk of developing, shorten the development time, reduce the development cost.
3. High material utilization, can effectively reduce the production cost. The traditional manufacturing is “material reduction manufacturing”, through the raw material billet cutting, extrusion and other operations, remove the excess raw materials, processing the required parts shape, the processing process of the removal of raw materials difficult to recycle, the waste of raw materials. 3D printing only adds raw materials where it is needed, and the material utilization rate is very high, which can make full use of expensive raw materials and significantly reduce the cost.
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How to realize custom products
Customized service of products design and manufacturing is our key core capability. Different product customizations have different customization standards, such as partial product customization, overall product customization, partial customization of product hardware, partial customization of product software, and customization of product electrical control. The custom manufacturing and fabrication service is based on a comprehensive understanding of the customer’s product function, material strength, material processing technology, surface treatment, finished product assembly, performance testing, mass production, cost control and other factors before comprehensive evaluation and program design. We provide a complete supply chain solution. Probably your product does not use all the services at the current stage, but we will help you consider the scenario that may be needed in the future in advance, which is what differentiates us from other prototype suppliers.
Examples of Die Casting Service
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