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PROCESS
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Die casting is a highly mechanized casting process, with high production rates and close tolerances. It produces castings which are often net shaped rather than near net shape; that is, by careful design and good process engineering, components can be produced which require little or no subsequent operations before being put into services. How close one gets to this ideal depends to some extent on the designer. 

Die casting is a process in which molten metal is forced, at high pressure and high velocity, into a hardened steel die to make close tolerance, thin walled and complex shapes. Depending on casting sizes and the number of cavities, hundreds and even thousands of parts can be produced each hour.

Since the size of the casting may vary from parts for watches or instruments weighing only a few grams to automobile engines and transmission cases, the size of the die casting equipment varies widely. The machine consists of three parts:

1. The clamping mechanism, which is usually a horizontal toggle-action press and which holds the die halves together against the considerable opening force of the injected metal.

2. The die-casting die itself, which consists of at least two parts (moving and fixed) containing the impression of the casting shape, and which may be fitted with sliding cores to produce more complex shapes. It is normally water cooled and fitted with a mechanism for ejecting the finished casting.

3. The injection end of the machine. This is a high-pressure molten metal pump, either hot-chamber type for alloys such as zinc or magnesium, or cold chamber type for aluminum and brass alloy which dissolves the ferrous materials of a submerged pump.

The machines are often fitted with ancillary devices such as auto-ladles, automatic die lubrication and takeout arms or robots, for removing the castings. Castings may be air or water cooled before being automatically fed to a trimming press to remove runners and feeds. All the ancillary equipment is synchronized to provide a highly mechanized, automated, high speed production process with low labor involvement.

 
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