Die casting is an option that you can’t afford to skip when considering fabrication methods of metal parts. That’s because the technique provides a wide range of shapes with tight tolerance. Additionally, the technique is considered a perfect choice due to its cost-effectiveness. Die casting in China also utilizes advanced technologies.
Due to the high startup costs involved, die casting is suitable for high-volume production, where extensive scale manufacturing offsets the significant expenses involved in machinery and tooling. Obtaining die-cast prototypes and running low-volume production can be quite challenging, simply because die-casting industries prefer catering to clients with large-scale orders due to their economic incentives.
What Is Die Casting China?
Die casting is a process of forcing molten metal into a mold cavity using high pressure. The mold cavity is formed by two dies. The process has similar traits as plastic molding. Die-casting in China stands out as the best choice among other die-casting methods. And that’s due to its precision, high quality, and level of detail.
Metal casting, a longstanding practice spanning centuries, includes a diverse array of processes using molds to shape molten metal. In the past, the technique involved pouring liquid metal into molds aided by gravity. In contrast, modern die casting fills the mold cavity, using pressure rather than cavity.
Often, die casting china is referred to as high-pressure die casting as it involves high pressure to drive the metal into the mold cavity. The pressure usually ranges from 10 to 140 megapascals. Low-pressure die casting (LPDC) is another common method. However, the method is less prevalent. There are two main categories of die casting – hot chamber and cold chamber. These two die-casting methods are tailored to specific metal types. Additionally, we have other specialized variants such as semi-solid metal casting (SSM) catering to niche requirements.
How Does Die Casting China Work?
A die-casting mold comprises a minimum of two halves – the cover, affixed to a fixed plate, and the ejector side, mounted on a movable plate. Certain dies may also include extra sections such as slides and chores. This enables the production of intricate parts such as those with holes and threads.
The number of activities in die-casting mold varies based on the size of the manufactured parts. A mold may include multiple cavities to enhance the production of multiple parts in each cycle. These molds may either feature several identical cavities referred to as a multiple cavity die or a combination of different cavities to manufacture diverse parts referred to as a unit die.
The equipment needed for die casting must have exceptional strength and thermal resistance plus good wear resistance and durability. To satisfy these demands, manufacturers design them from efficient, hardened tool steels. These materials undergo heat treatment processes regularly. Through this robust construction, these equipment can endure numerous casting cycles throughout their lifespan. Most importantly die casting tools must maintain their optimal efficiency even when subjected to extreme forces.
Die-casting mold processes begin with computer-aided design (CAD) software, which is used with specialized casting design tools and simulation. Just like plastic mold, die-casting tooling needs crucial components such as sprue holes, runners, and gates to enhance the flow of molten material into the cavity. Locking pins and ejector pins are also integrated, enabling mold stability and part ejection. Complex shapes and precise tolerances can be achieved through digital mold designs.
CNC machining acts as a prevalent method for producing die-casting tooling. The process of crafting die-casting molds often starts with rough machining to shape the mold. The metal mold is further subjected to heat treatment and later proceeds to a round of precise finish machining. For prototype-grade dies, rapid tooling techniques such as CNC machining or alternative methods such as selective laser sintering (SLS) can also be used.
There are lots of industries are using die casting parts, such as wholesale flat irons companies use aluminum die casting for the hair brush tooth, air hair straightener heating elements, etc.
Casting metal parts
Just like injection molding, die-casting parts can be produced in the die-casting machines after mold making. The die-casting process includes four stages – filling, ejection, and shakeout.
Nevertheless, the casting method somehow differs based on the usage of either a hot or cold chamber. This variation in the high-pressure die-casting processes has distinct advantages – while the other excels in speed casting, the other enhances a broader range of casting materials.
Hot chamber casting
With hot chamber die casting, the metal die casting machine heats the metal until it reaches the molten state. This self-contained system runs at a remarkable speed than the alternatives, leading to shorter time cycles. However, it is specialized for certain casting materials such as zinc, tin, and lead alloys.
Cold chamber die-casting
The cold chamber die casting needs different a furnace for metal heating. This reduces production rates as the molten metal must be transported to the die-casting machine with the aid of a ladle. Nevertheless, owing to the high potency of a different furnace compared to a hot chamber die-casting machine, metals with high melting points can be effectively cast. This technique can be applied in aluminum die casting.
Irrespective of whether a hot chamber or cold chamber machine is used, the metal die-casting process follows the following procedures:
- Mold preparation
- Filling
- Ejection
- Shakeout
In the mold preparation process, a lubricant is applied to the inner surface of both die halves. This lubricant smoothens the ejection of the castings once they’re finished. Further, the die halves are closed tied, and secured using a locking pin.
The mold is filled using a pressure mechanism, with variation irrespective of whether it is a hot chamber or cold chamber system. Regardless of the type, molten metal is driven into the mold cavity through the sprue using a plunger. For the hot chamber system, the process operates under high pressure of up to 35 megapascals, and 140 megapascals for the cold chamber system. These extreme pressures offer swift and thorough filling, enhancing uniform cooling. This prevents irregular shrinkage and part distortion.
The castings are extracted using ejector pins once the two die halves are splatted. Often, the dies are promptly shut again to prepare the subsequent shot. Meanwhile, the resulting castings are poised for a shakeout. This process eliminates surplus sections such as sprues, runners, and flash. These excess materials can be eliminated using manual tools, tumbling, or hydraulic trim die.
The Bottom Line
Die casting is taking shape in the field of manufacturing. The technique is used by many industries to manufacture metal parts with numerous shapes. Using advanced technology, die-casting China has a high rate of production compared to other manufacturing methods.
GC Precision Mould is China mold company located in Dongguan city. We manufacture aluminum die casting molds, plastic molds of superior quality, and die-cast components from polymers, aluminum, magnesium, zinc, copper, and other substances.
In addition to casting, GC Precision Mould provides painting, silk-screen printing, and anodized aluminum subsequent to production. Our proficient engineers and technicians employ state-of-the-art technologies and methodologies to guarantee the excellence and accuracy of each product we manufacture.
Automotive, consumer electronics, medical, packaging, furniture, entertainment, construction, and industrial equipment are all sectors in which our product is utilized. We collaborate closely with customers in order to comprehend their requirements.
We are capable of producing outstanding outcomes for both tiny plastic molds and entire die casting manufacturing lines due to our capabilities and resources.
We offer cost-effective die casting services for anodized aluminum and mold suppliers from China for injection molding products, in addition to providing exceptional service.