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Die Casting Process Details
The die casting process is very short, lasting about a minute from the beginning to end, and is made up of six main stages as follows:
1. Clamping
This step involves the clamping of the two parts of the die where the metal will be injected. The two halves are cleaned and lubricated to facilitate the ejection of the mold. The two die halves are then securely clamped together to withstand the injection of the molten metal. This process is often automated.
Closed die casting molds are made by cutting an original mold into two separate blocks, tooling them back together with their cavities aligned and spraying the new mold with a lubricant that helps regulate temperature and makes parts removal easier. Closed die casting molds can open and close, though, as their name suggests, they must be closed at the start of the die cast process.
2. Injection
Once closed, molten metal is poured into a shot sleeve and, under high pressure, injected into the die with a plunger. To prepare it for injection into the die, the metal is moved into a chamber before injection. The transfer method varies depending on the type of die being used, whether hot or cold chamber machine. The molten metal is injected at high pressure and at high speed to ensure even solidification. The injection time varies depending on the properties of the metal being used.
3. Cooling
The metal begins cooling and solidifying almost as soon as it enters the mold cavity. It cannot open until it cools and hardens completely. The molten metal injected into the die will cool and solidify in the predetermined shape set. The die will hold it as it cools, and the time taken to solidify will vary depending on the metal, the thickness of the casting, and the complexity of the design cast.
4. Ejection
When a mold cast part has solidified, pressure drops, the die opens and ejector pins push out the solidified metal shape, which is called a “shot,” rather than a part. The clamped die halves are opened after the predetermined cooling time has passed, and the casting is pushed out of the die cavity. The time taken before ejecting the die is estimated based on the properties of the metal and the size of the casting container. The ejection must ensure that no parts of the casting adhere to the die as it is readied for the next injection.
5. Trimming
Once the shot is ejected from the die, it is tooled and deburred to remove any excess material. Excess material usually forms in leakage areas between the die mold cavities and in channels leading to the die mold, taking the shape of flash, sprue, runners and gate.
The material in the die solidifies in the shape of casting along with any excess material, which is known as flash. The flash is trimmed from the casting either by sawing, cutting, or using a trimming press. The excess material scrapped may be reused in the die casting process after reconditioning or discarded altogether.
Flash is excess metal on a die cast part that extends past the die set’s parting line and blocks other metal from flowing past it and filling the mold.
Sprue transfers molten metal to the runners, which are horizontal mechanisms connected to the sprue for the purpose of transferring molten metal to the mold.
Finally, gate refers to both the passage molten metal takes from the runners to the die cavity and the complete ejected content of a die.
6. Finishing/Secondary Processing
As noted above, sometimes, this excess material requires more than tooling and deburring, and undergoes more secondary processes, such as CNC machining, surface finishing and plating. Such processes may accomplish a variety of things, like the removal of blisters and blow holes, surface strengthening and the increase of conductivity or compatibility.
Hot tags:Precision die casting motor bracket, die casting bracket, die casting aluminum bracket, Precision die casting motor part, China, manufacturers, factory, Customized, suppliers
Die Casting Process Details
The die casting process is very short, lasting about a minute from the beginning to end, and is made up of six main stages as follows:
1. Clamping
This step involves the clamping of the two parts of the die where the metal will be injected. The two halves are cleaned and lubricated to facilitate the ejection of the mold. The two die halves are then securely clamped together to withstand the injection of the molten metal. This process is often automated.
Closed die casting molds are made by cutting an original mold into two separate blocks, tooling them back together with their cavities aligned and spraying the new mold with a lubricant that helps regulate temperature and makes parts removal easier. Closed die casting molds can open and close, though, as their name suggests, they must be closed at the start of the die cast process.
2. Injection
Once closed, molten metal is poured into a shot sleeve and, under high pressure, injected into the die with a plunger. To prepare it for injection into the die, the metal is moved into a chamber before injection. The transfer method varies depending on the type of die being used, whether hot or cold chamber machine. The molten metal is injected at high pressure and at high speed to ensure even solidification. The injection time varies depending on the properties of the metal being used.
3. Cooling
The metal begins cooling and solidifying almost as soon as it enters the mold cavity. It cannot open until it cools and hardens completely. The molten metal injected into the die will cool and solidify in the predetermined shape set. The die will hold it as it cools, and the time taken to solidify will vary depending on the metal, the thickness of the casting, and the complexity of the design cast.
4. Ejection
When a mold cast part has solidified, pressure drops, the die opens and ejector pins push out the solidified metal shape, which is called a “shot,” rather than a part. The clamped die halves are opened after the predetermined cooling time has passed, and the casting is pushed out of the die cavity. The time taken before ejecting the die is estimated based on the properties of the metal and the size of the casting container. The ejection must ensure that no parts of the casting adhere to the die as it is readied for the next injection.
5. Trimming
Once the shot is ejected from the die, it is tooled and deburred to remove any excess material. Excess material usually forms in leakage areas between the die mold cavities and in channels leading to the die mold, taking the shape of flash, sprue, runners and gate.
The material in the die solidifies in the shape of casting along with any excess material, which is known as flash. The flash is trimmed from the casting either by sawing, cutting, or using a trimming press. The excess material scrapped may be reused in the die casting process after reconditioning or discarded altogether.
Flash is excess metal on a die cast part that extends past the die set’s parting line and blocks other metal from flowing past it and filling the mold.
Sprue transfers molten metal to the runners, which are horizontal mechanisms connected to the sprue for the purpose of transferring molten metal to the mold.
Finally, gate refers to both the passage molten metal takes from the runners to the die cavity and the complete ejected content of a die.
6. Finishing/Secondary Processing
As noted above, sometimes, this excess material requires more than tooling and deburring, and undergoes more secondary processes, such as CNC machining, surface finishing and plating. Such processes may accomplish a variety of things, like the removal of blisters and blow holes, surface strengthening and the increase of conductivity or compatibility.
Hot tags:Precision die casting motor bracket, die casting bracket, die casting aluminum bracket, Precision die casting motor part, China, manufacturers, factory, Customized, suppliers
