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Die Casting Technology

Plastic Molds & Die Casting Technology

Plastic Molds is the widely used tool products in manufacture. Without die injection mould, die casting mold, extrusion tool/mold, deep drawing die and stamping die, factories would be unable to produce plastic parts, alloy die castings, steel plate parts and forgings which are widely used and have a competitive price. In the mass production nowadays, losing high-level molds just means losing high quality products. And molds play an important role to improve production efficiency and reduce production costs. Nowadays, mold manufacturing has become an important part of advanced manufacturing technology.

Material for plastic mold, die casting mold or stamping tools

The material of mould usually is a kind of difficult-to-process material. At present, the domestic mold cavity generally adopt electric spark machining (EDM). However, the production efficiency of electric processing is very low. No matter on the side of development speed or on the aspect of manufacturing quality, it can never meet the requirements of modern mass production.

The occurrence of the high-speed machining technology has opened a new door for mould manufacturing technology. It is the inevitable trend that high-speed machining technology will instead of electric processing to improve the development and quality of mould manufacturing.

The advantages of high-speed machining mould

All of  stamping mold or plastic mold (including injection mould, extrusion die, blowing die, etc.), die casting mold need high strength wear resistant materials to produce some parts in order to improve their service lives (such as all kinds of brand of alloy structural steel, alloy tool steel and stainless steel, etc.). The hardness of these materials is very high after heat treatment. However, this is difficult to do by the method of conventional mechanical processing. For decades, special processing is the best way to deal with this kind of material.

In China, it is still the world of the electric spark machining, and it has been playing an important role in mould manufacturing. Along with the development of the production and upgrade of products, the requirement of production efficiency and manufacturing quality is higher and higher. Then the problems of electric spark machining exposed gradually. Its production efficiency is low and the quality is not stable. The problem of mold has been a key factor to the development speed of new products.
Compared with the electric spark machining, the high-speed machining technology has these main advantages:
1.    Good quality of products
2.    High production efficiency
3.    it can deal with the thin wall parts and the hard parts which have complicated shapes

In recent years, high speed machining technology has widely used in die and mould industry in overseas. According to statistics, there are 85% of mould electric spark forming process has been replaced by a high speed machining in the countries which have highly developed industries. High speed machining has been established the mainstream status in the international mold manufacturing process. Some famous companies which were engaged in electric processing equipment manufacturing originally (such as Company Agie in Switzerland) have already found the development trend of technology. In order to keep up with the market of mold equipment, these companies have taken measures to unite with high speed machine tool manufacturers (such as Mikron in Switzerland).

All of parts that need mold, aluminum die casting need high pressure die casting mold, plastic molding parts needs plastic mold, and mdifferent type of part need their molds for them.

Development prospect of the high-speed machining technology

The high speed machining has a high machining accuracy, and its surface quality is excellent, so the industry application is wide and effective. And it completely conforms to the development direction of mod manufacturing technology. It will be also the main trend in developing countries in future.

Aluminium Die Casting

The general Process and general information for making Aluminium Die Casting

Alloy & Tooling

Die Cast Alloys 380, 383, 384, 360, 413 & more

Cold Chamber tooling

Tooling consisting of hot half, eject half & slides
 

Process:

Cold Chamber Process – melting furnace & die cast injection system separate from each other.

Aluminum injection temperature – 1200 degrees F.

100+ machine cycles per hour

As cast surface readily machined, plated, anodized painted or powder coated per specifications
 

Applications &
Markets served:

Enclosures for Electronics Industry

Hand & Power tools

Pumps

Auto & Truck Industry

Communications, Computers & Printers

Exercise & Fitness Equipment

Home Appliances  
    & many more..

Die Casting Mold

what is the permanent mold casting?

The permanent mold casting process is the production of castings by pouring molten metal into permanent metal molds under gravity pressure.

    How to make permanent mold?Metal molds usually are made of high-alloy steel or ductile iron, and the life time is from 50,000 to 100,000 or more . The permanent molds should be machined by CNC center and to use some steel cores and sand cores to form cavities. 2D and 3D drawings are available for machining.
   What is the advantage of permanent mold casting?

A: Have finer dendrite arm spacing (DAS) and grain structure , so have better strength properties than die casting and sand castings, but less porous than die-castings.
B: Have better dimensional uniformity, machining allowances are smaller and holes are accurately located and dimensioned with metal cores.

C: Smooth surface finish is achieved right out of the mold, eliminating secondary polishing operations

   The main parameters of permanent mold casting as below:
Weight :the typical weight range from 50g to 20kgs
Wall thickness:the properly wall thickness is 3—20mm, the minimum wall thickness can be 2 mm for lengths under 50 mm, and some small detailed place can be 1.5mm thickness.
Radius:inside radius= nominal wall thickness, outside radius = 3 x nominal wall thickness
Draft angles:1 to 3º on outside surfaces, 2 to 5º on inside surfaces.
Surface :surface :finish ranges from 2.5 µm to 7.5 µm (100 µin to 250 µin).
   What typical parts are suitable for permanent mold casting?
Typical parts include valve body (air braking system valve and hand brake valve for automotive industry), pump body, wheels, gear housings, pipe fittings and couplers, fuel injection housings, automotive engine pistons, skate truck etc..

Aluminum Casting Mold

Aluminum Casting Mold

aluminumcasting.org is specializing in aluminum permanent mold casting, our products are mainly in various automotive brake valves, skate trucks and irrigation pipe couplers, our oversea market sales experience help us to understand customer¨s products well and keep our quality consistently. Making your cost lower, getting good quality parts and best service from China, Jinan Emerson MFG would like to help our customer to make cost lower, work together to build long term business and set up good friendship. Read more

Aluminum casting

Aluminum casting

  Aluminum casting machining is a specialized process, requiring careful attention to detail. Due to the ways in which castings are produced, machining them can be difficult. Although there are still some machine shops that specialize in manually machining castings, CNC machining has become the option of choice for today’s manufacturers.

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