Few Things That You Need to Consider During Part Design

It becomes very much important to consider which manufacturing process you’ll use to produce an aluminum part while you are on your way to design it. You will come across different methods for forming aluminum, and aluminum die casting is one such option that designers consider.

For many automotive, industrial, and telecommunications products, metal die casting is the method of preference. It can even be used to produce lighting and electrical and hydraulic components.

While designing the part for casting there are a few considerations that you need to take into account.

Firstly, the mold should be designed in a way so that the solidified aluminum part can easily come out. A parting line is a line where the two halves of the mold come apart and you must consider it in the early stages of die design.

The location of injection points is another important consideration. There is the possibility of designing the die with several injection points but only when the molten metal solidifies before reaching every crevice in the die. This even helps if cavities are included in the design as you can surround them with the help of aluminum and still can get the part when the mold is separated.

The thickness of the part’s walls needs to be considered by the metal die casting supplier. For a minimum wall thickness, there are no guidelines given and it is all because of recent technology developments, but walls that have consistent thickness are highly preferred.

Different Options for Machining and Finishing

Minimal machining is generally required by die-cast aluminum arts, and there are various options available for surface finishing. Die casting has a very good surface finish but there is still the possibility of having imperfections, like metal seams. But you can address a rough surface or other imperfections with the help of sanding, sandblasting, or orbital sanding.

To improve fatigue resistance, the cold working process of shot peening is used on die-cast aluminum. To the finished part you can also apply protective or decorative coating such as a powder coat. After casting a few other types, the metal die casting company makes use of modifications such as drill tapping.

Follow us on Facebook

The Process of Metal Parts Casting You Must Know About

Hot chamber die casting

During the process of hot chamber Metal Die Casting, the metal die casting machine contains the necessary equipment required for heating the metal to a molten state. As it is a self-contained system, it is much faster than the alternative but it is only suitable for a selection of casting materials, which includes zinc, tin, and lead alloys.

Cold chamber die casting

The cold chamber die casting process may need to use a separate furnace to heat the metal. This slows down the process, as the molten metal can be brought to the die casting machine with the help of a ladle. However, because a separate furnace is much more powerful than a hot chamber die casting machine, metals with high melting points can be cast. For aluminum casting, this method is suitable and is preferred by Metal Die Casting Company.

The metal die casting process typically proceeds as follows regardless of whether a hot chamber or cold chamber machine is used:

• Shakeout
• Filling
• Ejection

Mold preparation

During mold preparation, the interior surfaces of the two die halves have to be coated with a lubricant so that it can facilitate ejection once the castings are complete. With locking pins, the die halves can then be closed and secured.

Using a pressure system, the filling of the mold can be achieved. In both cases, the result is a molten metal that is being forced into the mold cavity via the sprue. In a hot chamber, high pressures up to 35 megapascals and in a cold chamber 140 megapascals make sure of a fast and comprehensive filling, which in turn leads to consistent cooling that prevents uneven shrinkage and consequent part deformation. During cooling, pressure is highly maintained. 

The two die halves are then opened and to remove the castings the ejector pins are used. Typically, the dies are then immediately re-closed and then they are ready for the next shot. Meanwhile, the finished castings are ready for the next shakeouts which are then supplied by a Metal Die Casting Supplier. It includes removing scrap sections of the shot such as sprues, runners, and flash (seepage of material at the parting line). Using manual tools, tumbling, or with a hydraulic trim die this material removal can be achieved.

Follow us on Twitter