Die Casting

Die casting is a commercial casting process used to create cast parts out of brass, aluminum, zinc, or magnesium. Most automotive parts of new energy electric vehicles use aluminum die-casting process.High pressure aluminum die casting is used to press th molten metal into the die, where it solidifies and is then automatically expelled. There are numerous cavities in a diecan for die casting. Due to the high production of the dies, series of anywhere between 300 and 400,000 molded pieces can be produced, depending on the die. Die casting enables the production of items with incredibly thin walls, smooth surfaces, and edges. Die casting is the ideal casting method for complicated components and demanding applications because to its high strength, excellent dimensional accuracy, and reproducibility, both in terms of quality and cost.

JieHuang as aluminum die casting manufacturer china has high-quality dies for small and medium-sized batches up to 50,000 shots on cold chamber and hot chamber die casting machines with clamping forces of up to 1250 tons. We complete the cast pieces with CNC machining centers to obtain excellent quality. If desired, we will assemble your die cast pieces into modules and assemblies after adding customized components to them in additional production phases.

For housings, coverings, fittings, or mountings, die cast components are utilized in many different industrial sectors. We provide die cast surfaces for ornamental purposes, enhanced corrosion protection, or enhanced wear resistance depending on the needs. Aluminium casting products may have the following surfaces depending on the alloy and finishing method: sandblasting, glass bead blasting, barrel finishing, brushing, polishing, phosphating, passivating, powder coating, wet painting, eloxating, copper plating, nickel plating, screen printing, or pad printing.

Die Casting Parts

DIE CASTING MOLD PROCESSING CAPACITY

CAD/CAM, CATIA V5, UG, Pro-E

In-House Tooling Design & Manufacturing

Moldflow Simulating

MOLD WORKSHOP

DIE CASTING MOLD DESIGN PROCESS

The die casting mold design process is a critical aspect of manufacturing that involves several meticulous steps to ensure the production of high-quality metal parts. Here’s a detailed overview of the process:

1. Design and Specification

The initial phase involves creating a detailed design of the part to be produced. Engineers and designers utilize CAD software to develop 3D models that incorporate the necessary geometries, tolerances, and features of the final component. This stage also includes determining the type of die casting machine to be used, either hot chamber or cold chamber, based on the material and design requirements.

2. Tooling and Mold Base Preparation

Once the design is finalized, the focus shifts to tooling and preparing the mold base. Skilled toolmakers craft the mold components, including the die cavity and core, using high-grade materials such as steel. Precision machining techniques, including CNC milling and Electrical Discharge Machining (EDM), are employed to ensure accuracy in the mold components.

3. Mold Assembly and Finishing

After the individual components are crafted, they are assembled meticulously. This involves aligning and securing various parts, ensuring proper venting and cooling channels, and integrating ejector pins and slides. Finishing touches, such as surface treatments, are applied to enhance durability and prevent corrosion.

4. Testing and Validation

Before full-scale production, rigorous testing is conducted to validate the mold's functionality and the quality of the cast parts. Trial runs help assess the mold's performance, and adjustments may be made to optimize its capabilities, ensuring it meets the required specifications.

5. Production and Maintenance

Once validated, the mold is ready for production. The die casting process involves injecting molten metal into the mold cavity under high pressure. Regular maintenance, including cleaning and inspections, is essential to prolong the mold's lifespan and maintain the quality of the produced parts

Key Design Considerations

Draft Angles: Essential for the smooth ejection of parts from the mold, draft angles must be carefully calculated based on wall angles and material properties.
Fillets: These rounded edges help reduce stress concentrations and improve the flow of molten metal, preventing defects.
Cooling Systems: Effective cooling is crucial for maintaining mold temperature and ensuring uniform cooling of the cast parts. The design often includes strategically placed cooling channels.
Venting Systems: Proper venting allows air and gases to escape during the injection process, reducing the risk of defects.
Simulation: Utilizing computer-aided engineering (CAE) software for simulations helps predict how the mold will perform during the casting process, allowing for early identification of potential issues.

The die casting mold design process is a blend of engineering precision, material science, and manufacturing expertise, crucial for achieving high-quality results in metal part production. As technology evolves, advancements in materials and design methodologies continue to enhance the efficiency and effectiveness of die casting processes.