Expand Your Knowledge Limit about Die Casting

In today’s modern industrial fields, in metal manufacturing die casting is an important technology. In this article, you will have an insight into the principle, mechanism, and characteristics of the die casting process as well as its classification and application. In conducting a feasible and efficient die casting process and in reducing design and development lead-time development CAE simulation is an efficient method.

Through an injection process melted metals are introduced at a high speed into the water-cooled metal die or mold. When in contact with the cool water the molten metal turns into a solid. When there is the completion of the solidification and mold casting process, the mold is then opened and the ejection of parts is initiated via a mechanical activation of the ejector pins. The die casting factory is then closed, air-exposed, sprayed with lubricant, and once again into the die, the molten metal is injected to complete the cycle. The production costs are increased by the die damages and the casting quality is reduced. The die can even cost more.

Using the gravitational die casting process or high pressure die casting (HPDC), about half of the global aluminum alloy casts are produced. The major benefits of the process include fine intricate details at high production rates, the production of castings with smooth surface finishes, close dimensional tolerances. However, die casting dies are subjected to severe damage, including gross cracking, erosion, chemical attack, and thermal cracking because of the thermal and mechanical cyclic loadings and reactions with the introduced molten metal.

The production costs are increased by the die damages and the casting quality is reduced. The damage to the dies becomes a serious problem with the increasing amount of die casting of aluminum. Die-casting is an economical way of producing large quantities of complicated shaped products of light metals that too with high precision. The benefits of die casting services are offset to some extent. This is due to the high cost of the die based on its intricacy and complexity. As compared to the machinery used to operate it, the die can even cost more.