13 May 2019 || By im@rk
Wondering how the sophisticated metal parts are being manufactured? What might be the systematic procedure to carve-out the mechanical parts of the machines that are made to fit into the machinery in exact sizes and dimensions!
Today in this post, we will demystify the manufacturing process called Die-Casting, used to mass produce the components of automobiles, locomotives, the agricultural and electronics industry at large. The few instances of its applications are pistons, bushings, engine -parts, propellers and so on!
So let’s dive into the basics of Die Casting and explore how the mechanical sector is reaping results from the application of its process!
Die-Casting is a process that involves the manufacturing of mechanical spare-parts. The components essentially required to carry-out a die-casting process are a furnace, metal (molten material), dies (molds) and a machine.
The metal used in the manufacturing process is generally of non-ferrous (that does not contain iron) nature like aluminum, copper, zinc, and magnesium etc.
A non-ferrous metal is melted in a furnace and is put into the die/mold, which on being solidified becomes the usable mechanical parts of the machinery.
Let us study it in detail and see how it works!
Depending upon the melting points/temperatures of the metals, the different variants of die-casting machines are put into use.
Hot Chamber Machines are typically injected with low melting temperature metal like zinc, tin, and lead etc. Metal is contained in the hot molding pot, which on being heated in the set temperature goes down to the shot chamber to reach its completion stage.
Cold Chamber Machines are filled with molten material of alloys having a high melting point. For instance, aluminum, brass, and magnesium.
Let’s look into the process of Die-Casting and see what stages does a metal go through to get into the shape of a spare-part!
Lubrication: The initiation of the process generally begins with the lubrication of the mold/dies. The water-based lubricants known as emulsions are considered as the best lubricants for the dies/molds. Post lubrication, the two halves of the die-machine are fastened together forming an enclosure for the molten material.
Infusion of Molten Material: The alloys are then converted into the molten form with the help of a furnace followed by injecting it into the Die-machine where it is left to solidify in a given period of time.
Cooling of metal: The molten-material once poured into the machine is left for the cooling process. Based on the property of the alloy/chamber machine, the due- time is given for it to become a mechanical spare part.
Extraction: On completion of the cooling process, the die-halves are then opened to extract the final casting from the machine.
Finishing Touch: Cutting the extra-edges or excess material to give it a final shape is the concluding/final step in the cycle of Die-Casting process.
Advantages of Die-Casting that makes it a popular application in the field of mechanical industry:
Accuracy: The primary advantage of Die-Casting is the accurate construct of the spare parts. The mold allows it to be of exact size and property in every attempt.
Productivity: High-productivity is another feature of Die-Casting process where the whole mechanism works in absolute precision to bring regular results.
Outright process: Die-Casting minimizes the need for secondary machining operations and concludes to be a complete process in itself.
This post is aimed at explaining the process of Die-Casting in the simplest form ever!
Now when you have a fair understanding of what Die-Casting is all about, its time is to simply take advantage of it!
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