Die Casting - Important Process In The Engineering Industry

Update:May 24 2017
Summary:

Die casting is a widespread non-expendable technique in […]

Die casting is a widespread non-expendable technique in which metal are forced into the mold cavity under high pressure. Die casting mold that are known as dies can be used repeatedly to produce castings in a variety of sizes, shapes and wall thickness. The mold cavities are designed with intricate designs that enables in producing complex shapes with accuracy, surface finish and attractiveness..

Die Casting Process:

In die casting there are four steps involved and it is a must that each phase is completed thoroughly before getting on to the next phase As it allows perfection in the end product. The die worker must be certain that the die casting machine is at the required temperature. There are several possibilities for it to get wrong if the die is cold when the molten metal is injected because it will solidify too quickly without conforming to the correct shape. Heating will take some time according to the size of the designed cast so only after the die reaches the right temperature the casting should begin.

The very first step in die casting:

The mold is sprayed with lubricant and then closed. Lubricating helps to regulate the temperature inside of the die, at the same time it also allows helps in trouble-free removal of the cast.

In the next step the molten metal is injected into the die and then the metal is inserted at an enormously high pressure, thereby it allows the metal to conform to the fixed figure of the die, devoid of the risks of puffiness or air pockets inside the product.

After that the mold is allowed to cool and thereby the metal gets solidified. It differs according to the level of the stage. The mold is immersed or sprayed with cold water to ease the casting turn out solid but, this happens in some cases only. Still the high-pressure is maintained inside the mold such that metal doesn't change properties. Finally the die opened and the solid cast removed.

Advantages:

1) Excellent dimensional accuracy

2) Reduces or eliminates secondary machining operations.

3) Rapid production rates.

4) It has the ability to deliver complex shapes with high levels of tolerance.

5) Identical castings can be mass-produced in thousands before you are required to add any new casting tools.

Like die casting plastic injection molding is also an important process in the engineering industry and through this small and complex parts are produced with accuracy.