What’s the most cost-effective way to cast metal parts with minimal machining?
Die casting.
Die casting allows you to create sharply defined smooth – or textured – surface metal parts from a durable range of non-ferrous metals, such as zinc, magnesium, aluminum, and an array of composite materials at high-speed and with precision. The type of metal chosen to fabricate the part determines whether it will require the hot chamber or cold chamber method to inject the metal into the die. Die casting enables the production of components with fine details like lettering, textured surfaces, and other features without the need for additional processing.
The main benefits of the die casting process include:
•High quality: Die cast parts deliver a long service life.
•High reliability: Exceptional uniformity of mass-produced parts.
•Quick production: Die cast tooling requires minimal maintenance.
•Versatile: Die casting can create virtually any size, part geometry, surface texture, or luster.
•Minimal assembly: Assembly features such as studs, drill holes, and bosses can be integrated into the mold design.
What effects die casting the most?
Part geometry.
The initial part design is crucial and determines how parts fill and cool – part geometry affects the porosity, grain structure, and internal stress states. Stress concentrators, such as those found at sharp corners, are also geometry-dependent and can reduce a part’s working strength. Parts whose geometry has been optimized for die-casting–in terms of filling, cooling, and ejection–will have substantially different microstructures and internal stress states than comparable machined or spin-cast parts.
Geometry planning works as an important influential tool on casting designs. Proper geometry planning will ensure time is not lost re-casting and counterbalance problems like:
•Defects
•Poor fluid life
•Shrinkage
•Solidification
•Temperature maintenance and effects
•Hot cracking
•Strength issues (compressive strength, impact strength, and tensile strength)
•Slag formation tendency
Advantages of proper geometry designs:
•It avoids defects: Reduces the need for multiple post casting quality checks, and reduces the number of rejected castings.
•Increases energy efficiency and reduces environmental impacts: an effective geometry design influences how much energy consumption is needed for cooling and lighting temperatures used in the manufacturing.
•Improves overall quality and life of the casting: with reduced defects and reduced lead-time to produce a casting, the overall quality and operational life of the casting is increased.
Our job at A&B Die Casting is to guide our customers to the best, most efficient process for their needs. With design for manufacturability in mind, we work with our customers to create features and sub-assemblies that fit into a single part while keeping the number of parts to a minimum. Through our rapid prototyping services, complete visualization of your concept is available to implement revisions if necessary before full production runs. By incorporating innovative engineering and state-of-the-art technologies, we take pride in designing and manufacturing the highest quality tools and parts at the right price.
Contact A&B Die Casting to get started on your next project today!