The die casting process can have considerable advantages over other making processes– like machining and stamping– resulting in significant expense savings in piece rate and general expense of production. With die casting, you can create complex net-shapes, including complex internal and external features with very little draft angles– minimizing secondary operations. As with any production process, there is a lot to find out before making a decision on which process would be best for you element.
In January of 2021, Kind Technologies hosted the first installment of Metal Solutions Webinar Series– EU. This webinar, An Intro to Precision Pass away Casting, provided by the European team, intends to assist our consumers on how to make the most of the advantages of die casting. Our webinars present participants with the opportunity to ask our specialists genuine concerns about the die casting procedure throughout our live concern and answer section. Have a look at a few of the most frequently asked questions listed below.
What is the minimum wall thickness for die cast elements?
The minimum wall density that we can accomplish depends on the part geometry and part design, but in an ideal situation, We can cast aluminum walls as thin as 0.3 mm. Generally, a minimum wall thickness of 0.5 mm– 1.0 mm is advisable to keep high strength.
What is the ideal wall thickness for die casting?
There is nobody suitable wall density for a die casting part. Rather, it is exceptionally crucial to preserve consistent wall thickness and decrease weight where possible for a strong, affordable element. The very best way to attain this is to develop enhanced gate and overflow places into your part style to avoid unnecessary porosity and maintain strength.
What is the tightest tolerance Suzubin can hold?
Suzubin prides itself on keeping the tightest tolerances in the industry, however likewise to wall thickness, the tolerance is mostly dependent on part geometry. For the most specific tolerances, generally in between ± 0.001″ and ± 0.002″ is possible for zinc, whereas aluminum can hold in between ± 0.002″ and ± 0.004″.
However, although a tolerance of ± 0.001″ is possible with Suzubin, producers should take care to prevent engineering unnecessary cost into the design. Too often, business will request exacting tolerances and minimal draft angles when such features are not required to maximize part efficiency. As a result, their castings stop working.
In addition to extending the life of your tool because there are fewer exact geometries that use down, enabling for tolerance zones also makes it easier to plan the tolerance stack-up of your entire element. This will help you to prevent machining and secondary operations wherever possible, making your design work for you to get the most out of the die casting process.
Which die cast metals are eco-friendly to produce and use?
All of the die cast materials that we use, zinc, magnesium, and aluminum are environmentally friendly since they are recycled. At Suzubin, our plants work in a closed loop cycle, using advanced re-melting capabilities to re-use any excess metal obtained from our runner systems in the passes away. After reclaiming the excess metal, Suzubin validates the chemical composition with spectrometers to ensure that they keep the mechanical and physical homes of recently sourced metal.
In terms of production, aluminum is the most eco-friendly of all the die casting metals. Aluminum is 100% recyclable, and 75% of all the aluminum ever produced is still in use today. Considering that aluminum can be recycled again and again with no degeneration in its physical or mechanical homes, it can serve the same applications with the same level of performance as primary aluminum extracted straight from bauxite ore– all while having a positive influence on the environment and your bottom line.
The mechanical and physical residential or commercial properties of aluminum make it the ideal option for parts that can be used in practically any market, including aerospace, defense, customer electronic devices, healthcare, automotive, and more. Find out more about out recycled aluminum abilities with our blog site.
What are the benefits of die casting over screw machining?
The advantages of die casting are largely connected with production speed and total piece cost savings. Suzubin’s multi-slide makers can be designed with several cavities and enable our engineers to cast incredibly complex parts, quickly. Our multi-slide die casting machines cycle at speeds of as much as 75 cycles per minute, delivering 4,500 shots per hour. In a two-cavity tool, this suggests 9,000 parts per hour.
A quicker cycle time adds to lowered general cost per piece. Furthermore, pass away cast tools guarantee unmatched intricacy of internal and external geometries, so there are fewer secondary operations related to die casting. With multi-slide die casting, you can cast complex geometries that would otherwise need to be manufactured from two or more pieces and assembled using any other procedures.
While screw machining offers a lower up-front tooling cost, pass away casting more than makes up for that in the general peice cost savings. On a perfect part (one that is little, high volume, and can be cast in zinc), the tool is paid back in full someplace between 10-14 months of production. Every part made after that is an earning towards your bottom line.
Do you have materials that are rust resistant without surface area treatment?
The level of ecological resistance offered depends on the material and your job requirements. Zinc, for example, is reasonably self-resistant in comparison to aluminum alloys, but you will get some zinc oxide, or white rust. If you need a high level of environmental resistance for your die cast part, we recommend using one of our surface treatments– from treatments and finishes that offer deterioration resistance, high-gloss ending up, painting, and more.
How can you identify if die casting is cost effective compared to other fabrication processes?
The cost effectiveness of the die casting procedure needs to be evaluated on a case-by-case basis. There are numerous cases in which transforming to pass away casting from screw machining, machining from strong, marking, and welding lead to lion’s share performance and better cost at full-scale production. We invite you to contact an engineer to determine if converting to pass away casting is the best option for you.