Die Casting: What is it?
Die casting is a casting method that uses a high pressure chamber to swiftly fill the cavity of a steel mould with a molten alloy liquid. The alloy liquid is then solidified under high pressure to create the casting. Rapid pressure and high speed are the primary characteristics of die casting that set it apart from other casting techniques.
Die cast items can only be produced with die casting machine. The level and quality of the products are determined by the skill level of the die-casting machinery.
How Die Casting Works?
In the commonly used permanent mold metal casting method known as “die casting,” liquid metal is poured into the mold, or “Dies,” where it hardens as a metal cast under pressures ranging from 0.7 to 700 MPa.this is die casting process.
To create durable, top-notch complicated components, nonferrous metals like aluminum, zinc, copper, magnesium, lead, pewter, and alloys based on tin are frequently employed. To produce the required metal’s chemical composition and fulfil some demanding requirements, several chemical components are added to the molten metal.
The procedure was first used to create components for the printing industry in the middle of the 19th century. With numerous technological developments since then, such as metallurgical control procedures to enhance manufacturing standards, it has become one of the most important manufacturing processes.
In order to save you time, lower production costs, and increase efficiency, we will discuss the price of each step in the die-casting manufacturing process in this post.
The following are the 3 main factors that have the most impact on the cost of the die casting manufacturing process, and we’ll give you some advice on how to cut these costs:
• Mold cost;
• Material cost;
• Production cost
How Much Should Materials Cost?
The cost of the material is determined by the needed material weight and the material’s unit price. Although the maximum wall thickness of the parts can also be effective, the weight of the material is undoubtedly affected by the part volume and material density.
The amount of material needed comprises the weight of the material used to fill the die channel. It takes more material to fill portions with thinner walls because a larger channel system is needed to ensure that the entire part fills fast and evenly.
However, due to the thinner walls, such additional materials are often less than the materials saved by partial volume reduction. Therefore, using thinner walls will result in cheaper material costs even with the larger channels.
There have kind of materials , which one is better material?which one is higher cost?In fact, the choice of aluminum depends on the needs and characteristics of the product, such as shrinkage, ductility
What Do You Need to Know About Production Costs?
The hourly rate and cycle time are the primary factors used to calculate manufacturing costs. It’s crucial to comprehend how the part’s design influences the machine choice because the hourly rate is inversely proportional to the size of the die casting machine. Die casting machines are often identified by the amount of clamping force they can provide in tones.
As a result, larger components need a stronger clamping force, which calls for a more expensive machine. Additionally, larger tonnage machines might be necessary for particular materials that need high injection pressures. The part’s size must also adhere to other machine requirements.
The type of machine (hot chamber vs. cold chamber) and its size also have an impact on price. Utilizing substances with high melting points, such as aluminum, would necessitate a pricier cold chamber machine.
Injection time, cooling time, and resetting time make up the cycle time. These periods can be cut down, which will lower production costs. Reducing the part’s maximum wall thickness will shorten the injection time.
Because molten metal must be ladled into a cold chamber machine process, which greatly lengthens production time, The cooling time is also influenced by the material’s thermodynamic characteristics.
So the die casting cost of die casting process for big parts will be expensive than small parts.
What Should You Know About the Price of Mold?
One of the most efficient and practical strategies to lower the cost of die casting in the industry of die casting is the optimization of mold design and reuse of existing molds.
Mold structure,mold cavity are one of the factors that determine tooling cost,the quality of tool metrial also have impact on tool life.
Cost Savings Through Mold Flow Analysis
Engineers’ expertise was once crucial to mold production and design. Repeated tests were necessary as part of the mold creation and design process, and the mold had to be continuously updated in response to the test results. The cost and length of the product development cycle rose with each trial.
With the evolution of CAD/CAE technology, engineers can now, through simulation analysis, view the actual flow and solidification of the liquid metal inside the die casting mold and pinpoint the location of flaws, optimizing the process and lowering costs.
Reduce Mold Costs by Using Core.
Numerous goods share design elements and can be utilized on different models with minor adjustments. We can think about assembling several components into a core for this kind of product and creating two molds to produce a range of goods. For instance, the natural gas joints on both ends of our standard natural gas meters come in many different varieties, one of which is a product joint.
We can split up the joints into various cores, which lowers the expense of having multiple sets of molds for various goods. It is feasible to quickly produce another product without having to create a new mold if the core has a quick-change structure.
Reduce Mold Expenses by Reusing Old Molds.
A duplicate mold method becomes necessary when numerous molds have reached the end of their useful lives, which will raise the price of a set of molds. We can utilize an old mold with a sturdy mold frame. To save on the expense of a set of mold frames, we simply need to redo one set of cores and use the new mold core with the old mold frame.
That is all there is to know about die casting’s price problem. It should be useful, we hope! Please get in touch with us if you have any inquiries!
Die Casting Recommendations
Before proceeding with die casting, a number of factors must be taken into account:
- Financial
The initial cost of injection molding products can be high given the cost of the equipment and the molds themselves.
- Number of products
It is important to determine how many parts you want to produce in order to decide if die casting is the most economical production method.
- Estimated factors
Minimizing the number of parts and simplifying the geometry of your products will make die casting easier. In addition, mold design is important to prevent defects during production.
- Manufacturing Considerations
Minimizing cycle times will help production as well as the use of hot runner machines and well-thought-out tooling. Small changes like this and the use of hot runners can save you money on your parts. There will also be cost savings by minimizing assembly requirements, especially if you produce many thousands and even millions of parts.
How to reduce mold costs?
Die casting can be an expensive process, but there are several ways to reduce mold costs, including:
- Elimination of undercuts
- Remove unnecessary features
- Use the core cavity approach
- Reduce cosmetic finish
- Design parts that self-mate
- Modify and reuse existing forms
- DFM Analysis Monitor
- Use multi-cavity or family mold
- Consider the dimensions of your parts
Summary
Die casting can create parts with intricate details and superior surface polish, as demonstrated below. Additionally, it is capable of competing with other manufacturing methods like sheet metal stamping, forging, and various casting techniques.
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