Aluminium high pressure die casting

Aluminum High pressure die casting is a manufacturing process in which molten metal (aluminum) is injected with a die casting machine under force using considerable pressure into a steel mold or die to form products. Because of the excellent dimensional accuracy and the smooth surfaces, most high pressure die castings require no machining except the removal of flash around the edge and possible drilling and tapping holes. High pressure die casting production is fast and inexpensive relative to other casting processes.

die casting china
die casting china

There are many types of aluminum alloys, GC mold is a Die Casting China Company uses for high pressure die casting parts with different mechanical properties and chemical breakdowns. Aluminum is used in 80-90% of the high pressure die casting alloys available in the world today. In many cases aluminum high pressure die casting can replace steel, increasing strength and reducing part weight. We produce high pressure die casting parts in small sizes of less than an ounce up to large sizes of 10 pounds. We usually can produce and ship high pressure die casting parts within two weeks of receipt of your purchase order if we have the high pressure die casting die already and have completed our first article inspections. In this process, the liquid metal is injected at high speed and high pressure into a metal mould. A schematic view of high pressure die casting is given in Figure 5. Figure 5: Schematic view of high pressure die casting

There are several aluminum alloys Kinetic Die Casting Company uses for high pressure die casting parts with different mechanical properties and chemical breakdowns. Aluminum is used in 80-90% of the high pressure die casting alloys available in the world today. In many cases aluminum high pressure die casting can replace steel, increasing strength and reducing part weight. We produce high pressure die casting parts in small sizes of less than an ounce up to large sizes of 10 pounds. We usually can produce and ship high pressure die casting parts within two weeks of receipt of your purchase order if we have the high pressure die casting die already and have completed our first article inspections. In this process, the liquid metal is injected at high speed and high pressure into a metal mould. A schematic view of high pressure die casting is given in Figure 5.

Figure 5: Schematic view of high pressure die casting machine This equipment consists of two vertical platens on which bolsters are located which hold the die halves. One platen is fixed and the other can move so that the die can be opened and closed. A measured amount of metal is poured into the shot sleeve and then introduced into the mould cavity using a hydraulically-driven piston. Once the metal has solidified, the die is opened and the casting removed. In this process, special precautions must be taken to avoid too many gas inclusions which cause blistering during subsequent heat-treatment or welding of the casting product. Both the machine and its dies are very expensive, and for this reason, pressure die casting is economical only for high-volume production. From the earliest application of die casting in manufacturing, the process has evolved from the original method of low-pressure injection into the development of high pressure die castings. The methods employed for creating high pressure die castings result in components that come out of the die in close to finished condition, with superior finishes and shape.

While high pressure die castings can be slightly more expensive, because of the excellent results and elimination of the need for secondary machining, high pressure die casting can be an economical choice for high volume production applications. The experts at Cascade Die Casting Group are ready to assist you in developing a customized approach to your component needs. We have the equipment, know how, and capability to apply the benefits of the high pressure die castings process to the parts you need for your application.

Die Casting Technology

There are three main forms of mold failure

1 thermal fatigue crack damage failure

Thermal fatigue cracking failure of die casting production, mold repeatedly stimulated cooling and heating effect, the molding surface and internal deformation are involved, and the repeated cycles of thermal stress, leading to tissue structure of two injuries and loss of toughness, causing cracks appeared, and continue to expand, once a crack expanding, and molten metal liquid impact, coupled with repeated mechanical stress crack accelerated expansion. Therefore, on one hand, die casting mold must be fully preheated starting. In addition, in the production of the die casting die in must be kept in a certain temperature range, so as to avoid the early cracking. At the same time, to ensure the mold production and manufacturing of internal no problem. Because of the practical production, the majority of the ineffectiveness of the die thermal fatigue cracking.

2 invalidity

Fracture failure of the shot under the action of force, die in the weak point of crack, especially the molding surface scribing traces or electric machining marks are not polished optically, or molded clear corner will appear first fine crack, when the grain boundary exists brittle phase or coarse grains, which is easy to break. And brittle fracture crack growth quickly, the mould invalidity is very dangerous factors. Therefore, on one hand where mold surface scratches, electric machining marks must be polished light, Zinc Die Casting even when it is in the gating system position, must also be polished. Additional requirements by use of the mold material of high strength, good plasticity, impact toughness and fracture toughness were good.

3 corrosion failure

Molten failure previously said, conventional die casting alloy zinc alloy, aluminum alloy, magnesium alloy and copper alloy, but also pure aluminum die-casting, Zn, Al, Mg is the more active metal elements, they and the die materials has the good affinity, especially Al easy to bite mold. When the mold hardness is high, then the corrosion resistance is better, and the molding surface if the soft point, then on the corrosion resistance of adverse.

The die failure of many factors, both external factors (for example, whether the mold casting temperature preheating, water paint spraying quantity, die casting machine, die size matching tonnage, high-pressure gate speed too fast, cooling water open and die-casting production synchronization, casting materials and components, the discretion of Fe the casting dimension shape, size, wall thickness of coating type, etc. ). There are internal ( cases of mold material metallurgical quality, blank forging process, the mold structure and the rationality of the design of gating system, the rationality of the design, mold machine ( EDM ) generated during the processing of internal stress, the mold heat treatment technology, including a variety of matching precision and smoothness requirements ). Die if the early failure, need to find out what the internal or external, for future improvement. But in actual production, corrosion is only die locally, cases of gate directly flushing part ( core, cavity) prone to corrosion phenomenon, and the hardness is easy to appear soft aluminum die casting alloys adhesive die.

AMBA Finds Optimism in US Mould Industry

Results of the American Mold Builders Association (AMBA) Summer 2005 business forecast show continuing optimism in the US mould making trade as business remains steady. Of the 124 survey respondents, 21% reported that current business is excellent (compared with 14% in the Summer 2004 forecast), 49% reported business to be good, and 26% said business is fair. Only 4% found business to be poor, and no one said it was bad.

Three-month projections solicited by the AMBA survey were roughly the same as last year: a large plurality of respondents (46%) expect their company’s business to remain the same, while 36% expect to do moderately better over the short term. Only 6% of companies participating in the survey projected any three-month decline in business.

Twenty-seven percent reported that quoting was up compared with three months before, 50% said quoting was the same, and 23% reported that quoting was down. Shipments were up for 41% of the respondents and the same for another 45%.

The forecast notes that profits are up for 27% of the respondents (compared with 21% a year ago) and about the same for 57%. Though profits were down for 17% of the respondents, that was a better report than the 21% who said in the Summer 2004 forecast that profits had declined.

Employment figures also are holding steady; 34% of the companies responding to the AMBA survey reported employment up and only 7% down, with the rest unchanged. Survey participants have an average of 22 shop employees and 4 design and engineering employees. The former work 46 hours per week, while the latter put in 48 hours.

AMBA is the largest industry trade association in the United States for mould manufacturers and affiliated companies, serving 325 member companies in chapters throughout the country.

GTMA Organizes Funded Trade Visit to China

The Gauge and Tool Makers Association (GTMA) is organizing a trade mission to Beijing, China, for which it has secured funding of £750 from UK Trade & Investment for each eligible company participating. Firms that are not GTMA members are welcome to join the mission, which takes place October 15–22, 2005.

The trade mission coincides with the 2nd International Die & Mould Conference in Beijing. Participants in the GTMA delegation are invited to join the itinerary arranged by the China Mould and Die Association, which includes visits to mould making and plastics companies. Alternatively, they may make their own arrangements.

The GTMA is the UK’s leading trade association representing toolmaking, metrology, precision machining, rapid product development, and tooling technologies. In addition to sponsoring trade missions, the association develops engineering standards, technology seminars, and training initiatives, and collects UK and global market intelligence on relevant industry topics. It is a founding member of the International Special Tooling & Machining Association and the European Length Measurement Association.

Missler Announces Launch of 2006 Version of TopSolid’CAM

At EMO, Missler Softwareannounced that it will launch the 2006 version of TopSolid’Cam in the last quarter of 2005. This new version will include important improvements for production machining, especially for the mold making and aeronautical domains.

TopSolid’Cam is an integrated CAM software for the manufacturing of machined parts. Based on the automatic recognition of topological properties, TopSolid’Cam identifies individual shapes and can thus suggest the best machining method to use. Machine simulation, collision checks, management of the stock, spindle synchronization, raw part updating and visualization of material removal are important elements of TopSolid’Cam for tool path programming.

Key improvements in TopSolid’Cam 2006:

  • The automatic transformation of 3-axis tool paths into 5-axis tool paths.
  • This function, a significant improvement for mold makers, permits the use of shorter tools to machine the part, which in turn favors good cutting conditions, a decrease in possible vibrations, and a significant reduction in cycle times.
     
  • TopSolid’Cam 2006 automates the emptying of 5-axis pockets, which in turn considerably reduces the number of steps necessary to perform this action. The new version of TopSolid’Cam automatically evacuates the holes followed by a pocket wall finishing using the swarf machining technique.
     
  • Drilling on wire-frame geometry, allowing the machining of identical holes not modelled in the CAD file which have different orientations. In addition, this function enables faster 5-axis drilling.
     
  • TopSolid’Cam 2006 gives the operator the possibility to manage production by “assembling” several different parts and their machining processes on the same machine. In other words, the operator can assemble parts already programmed without needing to reprogramme the parts. In case of a machine breakdown, for example, the operator can change machines without reprogramming the parts.
     
  • TopSolid’Cam 2006 offers turning cycles adapted to Swiss turn lathes. In fact, all turning cycles such as roughing, finishing and breakdown have been adapted to the Swiss turning process.
     
  • Tool length management by separating 3D machining processes, an improvement that lets mold makers make surface and cutting condition improvements. This function automatically divides the machining operations in such a way that they are carried out by both a short and long tool. Thus, cutting conditions are optimised and cycle times are reduced.
     
  • TopSolid’Cam 2006 manages ¾ gun drills used for deep drilling. This new function offers special cycles for ¾ gun drills, which are mainly used by mold makers in the drilling of cooling circuits in mold plates.

Missler Software is one of the leading global suppliers of CAD, CAM and ERP solutions. The company’s product lines include TopSolid, TopManufacturing, and Goélan. Missler offers a uniquely integrated solution for the mechanical engineering industry (general mechanical design, special machinery, tooling, and boilerwork) and for the sheet metal and wood industries.

Big Metalworking Trade Fair Set for Southeastern China in October 2006

The seventh edition of the metalworking industry’s leading trade fair for southeastern China, Metal Working China 2006 (MWC), will offer suppliers from around the world a dynamic international market showcase when it is held in Shanghai October 10–13, 2006. MWC focuses on machine tools, sheet metal–working machines, wire-working machines, pipe-machining equipment, metal-forming machines, precision tools, and tool and mould making.

MWC is the only trade fair in the southeastern Chinese economic zone to cover the whole spectrum of metalworking and related processing. Many world-famous companies have used the fair as a platform for growth. A record 500 exhibitors are anticipated in 2006 (compared with 377 in 2004), filling around 35,000 m² of floor space. Some 50,000 visitors attended in 2004.

National pavilions for Europe, Germany, Switzerland, the Czech Republic, Italy, Spain, France, South Korea, the USA, China, and Taiwan will offer smaller companies access to the promising Chinese market. China, the world’s sixth economy and third-leading trading nation, is now the largest market for machine tools.

Leading industry associations on the consumer side are supporting MWC, including the China Automotive Industry Association, China Aviation Industry Corp., and China National Machinery & Equipment Corp. Major national machine tool associations taking part include the German Machine Tool Builders’ Association (VDW), the Association of Spanish Machine Tool Factories (AFM), the Swiss Mechanical and Electrical Engineering Industries (Swissmem), and the Korea Machine Tool Manufacturers’ Association (KOMMA).

MWC is organized by Hannover Messe International GmbH, Hannover Fairs China Ltd., Shanghai, and China National Machine Tool Corp. The venue for this exhibition, as well as for four simultaneous trade fairs whose topics tie into the capital goods focus of MWC, is the state-of-the-art Shanghai New International Expo Centre in Pudong, which was inaugurated in 2001 as a pioneering joint venue for the Hannover, Düsseldorf, and München trade fair companies and their Chinese partners.

A supporting programme highlighting key developments and market trends in the sector while addressing practical issues will feature the Metal Working Summit, company presentations, forums, and plant visits.

“Nowadays, no export-oriented machine tool producer can afford not to be a player on the Chinese market,” commented Wolfgang Lenarz, CEO of Hannover Messe International GmbH.

New CEO Announced at Dapra Corp.

Dapra Corp., which supplies the metalworking industry with cutting tools, workholding and positioning equipment, and part marking equipment, has a new CEO: Linda Pilvelis, who had been the company’s chief financial officer since 1991. She succeeds Tom Watson, who will continue as a member of Dapra’s board of directors.

During the past 29 years, Pilvelis has been actively involved in every aspect of the Dapra business. She was appointed to the board in 1989 and has been directly involved in the management of all aspects of Dapra’s business since 1997.

Pilvelis leads a management team that includes Richard Pentz, vice president, business development; Michael Bitner, product manager, cutting tool and workholding/positioning products; and Chris Davis, vice president of Dapra Marking Systems, a division of Dapra Corp. that specializes in direct part marking, reading and verification solutions.

During the past 21 years, Pentz has been actively involved in cutting tools sales—most recently as general manager of Dapra Marking Systems until his appointment as vice president, business development. He is an advisory director of the company.

Bitner’s product manager position combines product development, technical support and sales management. He has 15 years of experience in the mold and die industry. He, too, is an advisory director of the company.

Davis is a recent addition to the Dapra team. He has 25 years of sales, sales management and general management experience in several technology-based companies.

Dapra was founded 50 years ago and is a supplier of cutting tools, permanent part-marking solutions, workholding/positioning equipment and Biax scrapers and air tools.

Winners in Design Award Announced by VDID, DSM Somos

Last fall’s EuroMold 2002 trade fair in Germany was the occasion to announce the winners in the professional designer and student categories of the 2002 ProtoFunctional® Design Competition. Sponsored jointly by the Association of German Industrial Designers (VDID) and prototyping materials specialist DSM Somos®, the international contest attracted interest and entries from around the globe to compete under the theme Alleskönner (Truly Functional).

First prize in the professional designer category went to Victor Massip and Laurent Lebot of Faltazi Studio in Nantes, France, for their “Jellynoctil” egg beater. First prize in the student category was won by Ozge Kandemir of Anadolu Universitesi in Güzel, Turkey, for the “Coffee Bean,” an all-in-one unit consisting of receptacles for different-flavored beans and a stove for making the coffee.

The Association of German Industrial Designers (VDID) represents the interests of industrial designers in Germany. The VDID is a member of both BEDA (Bureau of European Designers Associations) and ICSID (International Council of Societies of Industrial Design).

DSM Somos® has commercialized an entire range of ProtoFunctional® resins to respond to the needs of new product development and industrial design. It also offers materials for selective laser sintering and is noted as the first manufacturer of powder elastomeric polymer that can be sintered to produce highly flexible parts with rubber-like characteristics.

D-M-E North American Catalog to Offer Metric Components for First Time

Starting in September, the D-M-E. Company will be offering a comprehensive European-standard, metric mold components product line to customers in North American. The expansion is in response to the continuing growth of metric molds and components in North America.

“As companies continue to react to global competitive pressures and opportunities, we are seeing more molds being transplanted from region to region, from country to country,” says Chuck Azzopardi, D-M-E’s product manager for mold components. “When metric molds are transplanted to North America, tool builders there need a quick and reliable source for service components.”

D-M-E expects metric components to play an even bigger role in North America in the future.

A new 21-page D-M-E Metric Components Catalog details everything from metric surface definitions to metric fit tolerances. These metric tolerances and standards are not familiar to some North American mold builders, so the catalog includes seven appendices, compiled by D-M-E, which include detailed charts and diagrams to assist those who may be inexperienced with metric tolerances and standards.

EOS Moving to New Facilities near Munich by End of October

By the end of October, the entire staff of EOS GmbH, one Europe’s leading manufacturers of rapid prototyping (RP) systems, will have moved to new facilities in Krailling, Germany, close to Munich. The move is in full swing—and, EOS adds, so is its research and development work. New products continue to be launched to further promote batch-size, optimized production. Users can look forward to seeing the latest rapid prototyping and manufacturing innovations at this year’s EuroMold trade show (December 4–7) in Frankfurt.

For example, the new EOSINT S750 is an extremely high-productivity system that uses EOS’s patented DirectCast® process for boxless manufacture of molds and cores for sand casting. The twin lasers of the EOSINT S750 system scan the internal regions of the laser-sintered parts at a much higher speed, increasing output considerably. The system has successfully completed beta testing.