Die Casting Machine – A Profitable Venture For Die Manufacturers

The process of casting metals in the requisite shape by forcing molten metal in a mould cavity with high pressure is referred as Die Casting. The dies are generally made up of hardened steel that has to cut into desired shapes through machining. The ones made up of non-ferrous metals include zinc, copper, aluminum, magnesium, lead, pewter and tin-based alloys. 

The large capital expenditures of casting equipments and metal dies tends to restrict the process for producing high volumes that lowers down the per item cost. This machine produces a very large quantity of castings ranging from small to medium size leading to an economical production. 

The two methods for die casting are pore-free die casting and direct injection die casting. The pore-free method eliminate gas porosity defects and the latter reduces scrap and increase yield along with zinc castings.

The modelling of die casting machines is done with the parts named as draft, fillet, parting line, bosses, ribs, holes and windows. Draft is the extent of tapering imparted to core and other parts of the cavity for easy exit of the casting. Proper drafts are easy to remove from the dies with high quality surface finish. The crossroads of the two surfaces meeting at sharp corners are termed as Fillets.

Two different sides of mold when come together form the parting line. It is the position of the parting line that defines which side of die is cover and which is ejector. The fastenings attached to the die castings serve as stand-offs. They also perform a roleplay of mounting points for those parts that are mounted. Their wall thickness should be uniform to achieve utmost integrity and strength in the die castings.

If high wall thickness is not required in those castings then ribs are added to support designs for maximum strength. The two types of Die Casting Machines by exporters these days are hot-chamber machines and cold-chamber machines. The hot chamber die casting machines are also termed as gooseneck machines that utilise a large pool of metal to feed the die. The speedy cycle time is the highlight of these hot chamber machines but has its limitation of using metals with low melting point for which aluminium cannot be considered as it tends to attract iron when in molten form.

In cold chamber machines the metal is melted in a furnace after which it is transferred to an unheated shot chamber that is driven by a hydraulic or mechanical piston with a short cycle time.