Die Casting’s Blog

NINGBO INNOVAW die casting is the world’s leader in precision die casting of zinc, aluminium and magnesium alloys.

View case studies from various industries with ideas for component improvement through die casting. Review ways to save money by applying value analysis and value engineering techniques and taking advantage of our free seminars.
Though INNOVAW’s roots lie in our proprietary multi-slide die casting process we are equally as strong in the manufacture of larger parts by conventional hot and cold chamber die casting methods.
Die casting is a fast, cost-effective manufacturing process for production of high volume, net-shaped, tight tolerance metal components. It has the benefit of increased quality and repeatability, often at lower costs compared to other processes.

The die casting process is the injection under high pressure into a steel mould (or tool) of a molten metal alloy, which solidifies rapidly (from milliseconds to a few seconds) to form a net shaped component and is then automatically extracted.

The die casting tool will typically produce any number of components from hundreds of thousands to millions, before requiring replacement.

Benefits of INNOVAW die castings:
1. Cost-effective high volume production
2. Value engineering achieves cost savings
3. Part consolidation eliminates operations
4. Manufacture of complex net shapes
5. Consistent quality over high volumes
6. Tight tolerances achieved as cast
7. Minimal draft angles on internal features
8. Long tool die life
9. Lower tool cost on multi-slide process

Casting first, with primer coating or painting to avoid rust, then secondary machining by CNC machine, drilling, tap, etc.

Truck and Forest Machinery Components

Truck and Forest Machinery Components

cordless drill | cnc machining | brass valve | Water Ionizer

Cast aluminum is a specific metal that has gone through one of the several processes known as casting. Essentially, cast aluminum is created when methods such as die casting, mold casting, or sand casting are used to temper the aluminum for use in creating components for many different types of products. Cast aluminum is used for a number of items around the house, as well as machinery and other products that are necessary to the manufacturing of a wide range of goods and services.

One of the more common applications of cast aluminum is in the creation of cookware. Just as cast iron is used for skillets, baking pans, and other kitchen essentials, cast iron can also be used for these items. Usually created using the die cast approach, the cookware can withstand the high temperatures required to cook food properly and will remain useful for a number of years with no more than minimal care.

Cast aluminum is also used to create outdoor furniture. While not quite as popular as cast iron furniture for the lawn, cast aluminum patio furniture is somewhat more lightweight and can be moved around the space with greater ease. Patio furniture made with cast aluminum includes such items as chairs, gliders, and tables.

In addition to cookware and cast aluminum furniture, the cast metal is also used to create a number of motor parts for land vehicles as well as boats and ships. Components such as connecting rods, pistons, housings, radiator tanks, and other essentials can be created using both die casting and mold casting methods. Even components such as compressors and various types of gears may be created using aluminum of this type.

Our engineers designed mould by PRO/ENGINEER, SOLIDWORKS, UNIGRAPHICS and simulation analysis software to be sure the quality and high efficiency before tooling machining. Mould cavity and frame will be machined by automatic CNC milling center, CNC turning lathe, EDM , wire cutting machines. Our experiences and technology will be great helpful for you.

Mould design by software: PRO/E, SOLIDWORKS, UNIGRAPHICS

solar modul injection moulding machine cnc machining

Aluminium is the choice metal for making light weight parts of vehicles, aerospace and transport industries. Casting of liquid aluminium alloys into metal moulds utilizing systems like gravity, low pressure and high pressure die casting is an economical way of making difficult shapes which need minimum machining. Australia’s auto industry supports a large local die casting business, manufacturing parts that include cylinders, pistons and engine sumps etc.

Rising demand in world auto market for aluminium die cast parts is producing great opportunity and challenge for Australian business which wants to emerge as a global player. By setting partnerships between Nissan and Ford, CAST has developed and produced new and latest technology that has been benefiting our partner’s products. In turn these skills have created IP that is poised on the verge of commercialization.

To increase production of high pressure die casting by lessening its time cycle by 30%. The cycle time has been reduced by more than 20% on certain parts at two industry partner plants. The project involves identifying places where cycle time may be reduced, and doing it practically to prove the findings of research. This made it essential to involve shop floor staff to implement the changes needed in systems. These trails are generally in variation with day to day production and due to true co-operation of shop floor staff it become possible to achieve targets.

The third year of project has seen the true spirit of co-operation between researches and industrial partners in which latest research results got through simulated trails have been done practically on shop floor with help and support of Ford and Nissan staff. The changes once tested during trials have been incorporated in production systems giving benefits of reduced costs by reducing time of each part manufactured. An example of reduced time achieved is at Nissan on a gearbox side cover made in twin cavity die has given successful results after many months; from an initial cycle time of 75 seconds down to 60 seconds. While research at Ford on a changer housing casting, has been successfully implemented by lessening cycle time from 90 seconds to 74 seconds.

In future the reduction of time cycle will be tried for other parts as well.

Automatic fault detection in aluminium die casting:
This involves developing a system to detect surface and sub surface defects.

A fully automatic fault detecting machine named CAST vision has been produced and a prototype process is in place for extended in-plant on-line trials. This is the third year of this project and it is giving good results. The result of algorithm which was designed and developed in 2nd year has been put to test now. By prototyping the CAST team had designed and developed a working system CAST vision. This can discriminate between good and defective parts.

Modeling is based on making core casting process requirements in determining a good method of modeling, ready to shape the material basis. Casting the accuracy of all of the production process and the economic effects will depend mainly on this procedure. In many modern casting workshop, modeling-made batteries have achieved a mechanized or automated. Sand commonly used form core-making equipment is high, medium and low pressure molding machine and threw sand machine, without me radio pressure molding machine, radio-core, cold and hot-box machines.

Since the casting mold in cooling pouring out after a gate, riser and metal spikes Phi slit, sand casting of the casting also adhesion of the sand, it must be clean-up process. Such devices are the work of the Blasting machine, gate riser cutting machines. Sand-casting sand clean-up is a poor working conditions processes, in the choice of modeling methods, should be taken into account for as much as possible with sand to create convenient conditions for clean-up. Casting a result of some special requirements, but also by casting post-processing, such as heat treatment, plastic surgery, anti-rust treatment, such as rough.

Casting is more economic methods of rough shape, the shape of more complex components demonstrated its economy. aluminum die casting Such as car engine block and cylinder head, ship propellers and exquisite works of art, and so on. Cutting some of the difficult parts, such as the combustion turbine parts do not have to nickel-based alloys casting method can not be forming.

In addition, the die casting of parts of the size and weight to a wide range of metal types of almost unlimited; parts in a general mechanical properties, it is also a wear and corrosion-resistant, shock-absorbing properties, and so is the other metal forming methods such as forging , Rolling, welding, salt, and so can not. Therefore, in casting machine manufacturing methods used in the production of rough parts, and the number is still on the tonnage is the largest.

Casting often use a variety of metal materials, coke, wood, plastic, gas and liquid fuels, such as modeling materials. Have the necessary equipment used in various metal smelting furnace, a Mixer with the various Mixer, a shape-made batteries used in various molding machine, machine-made batteries, cleaning up the castings used for loading sand, Shot Blasting Machine And so on. Casting is also available for special machinery and equipment, and many transportation and material handling equipment.

Casting and other technology have different characteristics, mainly wide adaptability, needed materials and equipment, pollution of the environment. Casting will have dust and harmful gases and noise pollution to the environment, compared to other machinery manufacturing processes to become more serious, need to take measures to control.

Casting product development requirements of the trend is casting a better overall performance, higher accuracy and less headroom and clean the surface. In addition, the requirements of energy-saving society and restore the natural environment of the call also getting higher and higher. To meet these requirements, the new cast alloy will be developed, the new smelting technology and new equipment will be corresponding.

Casting the mechanized production continuously improve the degree of automation in the same time, to be more flexible production development, to expand the volume and variety of different production adaptability. Conserve energy and raw materials of new technologies will be giving priority to the development, have little or no pollution of the new equipment, new technology will be the first attention. Quality control technology in all stages of testing and nondestructive testing, stress determination, there will be a new development

Bar grating is designed to for many applications. Bar grating casting is a strong choice for projects ranging from trenches to decking. Aluminum bar grating is a good choice when a lightweight, corrosion resistant material is desired. Choose from many options such as: flush top, rectangular bar, plank, and I-bar. Aluminum grating is available in the swage locked, pressure locked (dove tail) and riveted design. Carbon steel bar grating is a nice choice when your project requires a strong material and you are not going to expose the grating to an expressly corrosive environment. Choose from plain or serrated surfaces, galvanized or standard black, and light or heavy duty grating. Stainless steel bar grating provides a superior corrosive & oxidation resistant material in a material stronger than aluminum. Stair tread bar grating is typically offered in a welded construction and is made with a checkered plate nosing that is welded to the leading edge of the tread.

Gravity Cast Parts
1) Materials: aluminum, brass. 2) Applied software for specification drawings: Pro-E, Auto CAD 2000. 3) die casting Main equipment: vertical type casting machine, horizontal type casting machine, rock over. 4) Applications: auto parts, machine parts, plumbing products

Aluminum Die Casting leverages our experience in aluminum die castings, precision machining, assembly and program management philosophy in providing our customers with industry leading solutions.

Automation

Die Cast, with our commitment to continuous improvement, is currently 85% automated and will be 89% automated by the end of 2005. We continue to implement process automation enhancements.

Aluminum Die Casting Rimrock automation equipment:

Auto Ladle
Auto Spray
Auto Extract
Shot Monitoring
Automatic plunger lube application
Trim unloading

Process and work flow improvements including:

Special machines for high volume repetitive products.
Dedicated Work cells.
Cellular automation.
Trim stations/secondary operations at die cast machines.
Packaging at trim stations.
Part Conveying Systems.
Automation offers:

Improved quality through consistent processing.
Better equipment utilization.
Higher productivity with reduced labor.
Cleaner work environment.
Improved Morale.

Die-casting is similar to Permanent mold castings except that the metal is injected into the mold under high pressure of 10-210Mpa (1,450-30,500) psi . This results in a more uniform part, generally good surface finish and good dimensional accuracy, as good as 0.2 % of casting dimension. For many parts, post-machining can be totally eliminated, or very light machining may be required to bring dimensions to size.

Die-casting can be done using a cold chamber or   hot chamber process

1.In a cold chamber process, the molten metal is ladled into the cold chamber for each shot. There is less time exposure of the melt to the plunger walls or the plunger. This is particularly useful for metals such as Aluminum, and Copper (and its alloys) that alloy easily with Iron at the higher temperatures.

2.In a hot chamber process the pressure chamber is connected to the die cavity is immersed permanently in the molten metal. The inlet port of the pressurizing cylinder is uncovered as the plunger moves to the open (unpressurized) position. This allows a new charge of molten metal to fill the cavity and thus can fill the cavity faster than the cold chamber process. The hot chamber process is used for metals of low melting point and high fluidity such as tin, zinc, and lead that tend not to alloy easily with steel at their melt temperatures.

Die casting molds (called dies in the industry) tend to be expensive as they are made from hardened steel-also the cycle time for building these tend to be long. Also the stronger and harder metals such as iron and steel cannot be die-cast

Common Alloys in Die Casting

Aluminum, Zinc and Copper alloys are the materials predominantly used in die-casting. On the other hand, pure Aluminum is rarely cast due to high shrinkage, and susceptibility to hot cracking. It is alloyed with Silicon, which increases melt fluidity, reduces machinability. Copper is another alloying element, which increases hardness, reduces ductility, and reduces corrosion resistance.

Aluminum is cast at a temperature of 650 ºC (1200 ºF). It is alloyed with Silicon 9% and Copper about 3.5% to form the Aluminum Association 380 alloy (UNS A03800). Silicon increases the melt fluidity, reduces machinability, Copper increases hardness and reduces the ductility. By greatly reducing the amount of Copper (less than 0.6%) the chemical resistance is improved; thus, AA 360 (UNS A03600) is formulated for use in marine environments. A high silicon alloy is used in automotive engines for cylinder castings, AA 390 (UNS A03900) with 17% Silicon for high wear resistance. Common aluminum alloys for die casting are summarized as follows:

Zinc can be made to close tolerances and with thinner walls than Aluminum die casting, due to its high melt fluidity. Zinc is alloyed with Aluminum (4%), which adds strength and hardness. The casting is done at a fairly low temperature of 425 ºC (800 ºF) so the part does not have to cool much before it can be ejected from the die. This, in combination with the fact that Zinc can be run using a hot chamber process allows for a fast fill, fast cooling (and ejection) and a short cycle time. Zinc alloys are used in making precision parts such as sprockets, gears, and connector housings.

Copper alloys are used in plumbing, electrical and marine applications where corrosion and wear resistance is important.

Minimum wall thicknesses and minimum draft angles for die casting are :

Die-castings are typically limited from 20 kg (55 lb) max. for Magnesium, to 35 kg (77 lb) max. for Zinc. Large castings tend to have greater porosity problems, due to entrapped air, and the melt solidifying before it gets to the furthest extremities of the die-cast cavity. The porosity problem can be somewhat overcome by vacuum die casting

From a design point of view, it is best to design parts with uniform wall thicknesses and cores of simple shapes. Heavy sections cause cooling problems, trapped gases causing porosity. All corners should be radiused generously to avoid stress concentration. Draft allowance should be provided to all for releasing the parts-these are typically 0.25º to 0.75º per side depending on the material.