Die casting is a manufacturing process that has been used for decades and is still the most popular metal casting process. It involves melting metal, pouring it into a mold, and letting it cool and harden. The die determines the shape of the finished product. Your choice of manufacturer will depend on the type of business you have as well as your desired production volume. For example, if you’re producing a low-volume product with an emphasis on quality, you may want to find a company that specializes in hand-poured die castings. On the other hand, if you’re churning out mass quantities of low-quality products, then an automated die casting plant may be your best option for getting the job done quickly. Check out this article for tips on deciding which die caster is right for your needs!
Die Casting Manufacturing Process
During die casting, there are three components: the alloy, which is the raw material, the die casting machine, as well as the mold. In this process, molten alloy (melted metal) is poured into a mold by applying pressure in order to make a product in the shortest amount of time. Alloys poured at high pressure harden fast, and the product can be taken out.
Characteristics of Die-Cast Products
It is possible to mass-produce products with these outstanding qualities while maintaining consistent quality.
- Precise measurements
- Accurate finish
- Beautiful surface
- Excellent strength and irregular shape”
Die casting mold design, development and manufacturing process
- A casting mode is created by using rapid prototyping technology and 3D software to determine the casting shape, parting surface, injection location, and thermal balance system for the mold. The right casting shape is established using fast prototype technology and 3D software, which includes identifying the parting surface, injection system position, and mold thermal balance system. 2D casting designs are converted to 3D solid data to fit your requirements, and calculate an acceptable shrinkage rate based on casting complexity and wall thickness, parting position, and shape. The parting surface’s position and shape are determined by the die cast. The machine data selects the position and diameter of the injection punch, as well as the quantity of die-cast components per die, to create a rational die layout. The components of gate and overflow systems are cast and three-dimensionally modeled.
- Flow field and temperature field simulations are done to further optimize the mold injection system and mold heat balance system. After processing the casting, injection, and overflow system data, boundary condition data such as jade casting process parameters and alloy physical characteristics are included, and the simulation program may simulate trends with the alloy filling process. Liquid alloy solidification simulations and temperature field simulations in the mold cavity can be used to improve the gate system and establish the placement of the mold cooling points. The simulation results, which come in the form of photographs and images, represent information on the orientation of the liquid alloy and the temperature field distribution throughout the filling process, and any faults can be identified through analysis. To improve the filling effect and minimize or eliminate casting faults, subsequent versions have included features such as adjusting the position and orientation of the inner gate and adding a slag collection bag.
- Design the mold’s overall structure based on the D model. You can develop a basic mold layout that incorporates the following characteristics as the simulation progresses:
- Design the general layout of the mold based on data from the die casting machine.
- Create the molded insert as well as the core.
- Create the mold’s foundation and core-pulling mechanism.
- Heating and cooling channels are arranged, and thermal balance components are chosen.
- Design a launch mechanism.
- Design of a guide and positioning system.
- Vacuum, extrusion, and exhaust mechanisms are examples of other designs.
Understanding Die Casting Needs
The most important thing in the casting industry, as in other industries, is that the client is pleased with the outcome of this process, which is that the ordered products fulfill the demands of the consumers and the required quality. Due to the complexity of the process, having a basic knowledge of it might be beneficial. That is why it is important to understand your die casting needs.
Die casting is often done using metals such as steel, iron, and aluminum. For many years, these materials have been used to create durable and long – lasting products that customers can rely on. It’s vital to initially consider what you’ll be producing before deciding which materials to utilize.
Types of Die Castings
Die-cast alloys can be classified into three types: aluminum alloys, zinc alloys, and magnesium alloys. Other alloys, such as copper alloys, tin alloys, and lead alloys, are also used.
1. Aluminum alloy die casting
Die-casting aluminum alloys are the most commonly used alloys because they are lightweight, corrosion-resistant, and have little dimensional change over time. Over 97% of all die-cast alloys are made from this material, and it is used in a wide range of industrial fields.
2. Zinc alloy die casting
Zinc alloy die casting can make castings with thin walls and complicated shapes. It has good mechanical qualities and high dimensional accuracy. It has great surface treatment, such as plating, and is highly resistant to impact.
3. Magnesium alloy die casting
Due to its low specific density of roughly 1.8, magnesium alloy die casting is utilized as the main body cover for IT equipment such as mobile phones, laptops, and Desktop computers.
Other Alloy Die Casting
Copper alloys excel in “electrical / thermal conductivity,” “strength,” and “corrosion resistance,” among other qualities. Copper alloys are utilized in recharging cords, such as wiring and electric wires, connectors and terminals, and car parts, to name a few.
Lead alloy / Tin alloy
“Fire extinguisher” is a product made of lead and tin alloys. The reason for using a tin or lead alloy is that its melting point is low, and the die-cast product of the fire extinguisher melts between 66 and 70 degrees Celsius or higher, so it melts and water pours out in the case of a fire.
Considerations for Selecting a Die Caster
Taiwan is without a doubt Asia’s most competitive and diverse manufacturing provider. There are several die casting manufacturer taiwan to pick from. However, you won’t be able to make the right decision without first assessing each company. Making the right decision when selecting an aluminum die casting manufacturer in Taiwan can make all the difference in your business. There are several factors to consider when picking a die caster before deciding on which company to choose as your die casting manufacturer in Taiwan .
Your aluminum die-casting company should be capable of producing and delivering high-quality casting parts in a relatively short time. The faster the manufacturer can produce goods or services, the faster you can deliver them and earn more profits. You’ll also need a die casting company that can deliver products in a reasonable amount of time without sacrificing quality.
Consider a die casting manufacturer in Taiwan with experience with various metals and one that uses quality tools to produce consistent, stable products on time.
For a company to deliver products at an affordable price, the price must be examined. In order to select a company with an affordable rate, you need to be realistic. You must choose several companies that you believe can provide the necessary aluminum die-casting products.
A die-casting company’s services will be more great the more experience it has. A die casting manufacturer in Taiwan that is unable to provide high-quality die-cast products at a reasonable price will quickly become outdated.
During the die casting process, most clients want to engage with contractor manufacturers, suppliers, and designers. Your die caster should be able to tell you where you might be able to save money on part production and where you won’t be able to. You will be unable to obtain the desired finished products if your die casting manufacturer refuses to include your recommendations before, during, or after the project.
Importance of Quality
The quality of the product depends on the nature and performance that the customer requires. Customers are satisfied = quality is good, and it is a “rule” that measures the value of an item. A good product is not only one that is in good physical condition, but also one that is cost-effective and meets the delivery date, function, and performance requirements.
It will be a significant deal if there is a serious quality defect that injures the product’s user or causes a mishap. Even if it is only one flaw, a company’s credibility in public might be affected. If the impact is severe, business performance may suffer significantly, and employees may lose their jobs.
It is also believed that regaining a reputation that has been lost is quite tough. The beautiful idea of quality, which is “just one mistake,” might have an impact on a company’s longevity.