Die Casting The Process And The Techniques Part 2
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Die Casting: The Process and Techniques, Part 2
Overview
Die casting is a versatile and economical process for creating metal components, capable of producing pieces as thin as 1mm. This method often requires fewer secondary operations than those using stamping presses or multiple machine tools.
Understanding Die Casting
Once a casting is removed, several secondary steps might be necessary, such as trimming excess metal and smoothing rough edges. Despite this, die casting remains more efficient compared to other metalworking techniques.
The Role of a Die
A die casting die serves multiple crucial functions, but often cannot deliver a complete final product on its own. It holds liquid metal to form a cast while also allowing entry points for metal flow. As the metal cools, unwanted metal fragments, known as flash, may remain attached and need to be removed manually or with tools.
Flash Removal Techniques
Hydraulic presses are commonly used to eliminate flash, though manual sawing is an older method still in practice. Additional steps might include sanding or grinding to remove mold lines, and drilling extra holes if required.
Die Casting Machines
These machines apply substantial clamping force, ranging from 100 to 4,000 psi, and are categorized based on the metals they cast. Hot chamber dies are suited for metals with low melting points, like zinc, while cold chamber dies handle metals with higher melting points, such as aluminum.
Longevity of Dies
Though die casting dies are durable, repeated heating and cooling cycles can eventually affect their integrity. Dies for aluminum tend to have a shorter lifespan due to higher temperatures needed for casting. In contrast, cold chamber dies last much longer. Brass casting dies, however, are particularly short-lived and require frequent replacement, regardless of cast strength.
Overall, die casting remains a critical industrial process due to its efficiency and versatility in metalwork.
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