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High Pressure Die Casting (HPDC) technology
So, casting means forcing molten metal under high pressure into reusable metal dies. It's often described as the quickest route between raw material and finished product. The completed product also called "die casting" is an accurately dimensioned, sharply defined, smooth or textured-surface metal part.
The process has a number of phases:
the production of a metal mould able to produce tens of hundreds of castings in a few seconds, which is divided into no less than two sections to allow the removal of the castings.
Mounting of the two sections onto a particular machine where one will be stationary (fixed die half) while the opposite is moveable (injector die half). They're then clamped tightly together.
Injection of molten aluminium into the die cavity where it quickly solidifies.
The 2 sections are drawn apart and the casting is ejected.
After all, depending on the complexity of the ultimate part, die casting dies can have moveable slides, cores, or other sections. The whole process is the fastest at present known able to produce precise non-ferrous parts.
Let’s focus now on the die castings die composition. They're made of alloy device steels and they have at the least sections:
The fixed die half, which is mounted on the side toward the molten metal injection system. It is specifically designed to include the sprue hole by means of which molten aluminium enters.
The ejector die half, which is mounted on the moveable platen of the machine. It adheres to the opposite part and it is removed when the die is opened. Usually, it comprises the runners (passage ways) and gates (inlets) which route molten metal to the die cavity (or cavities). Additionally it is related to an ejector box, which holds the mechanism to eject the casting from the die.
How ejection works?
The opening stroke of the machine entails the pins which are related to the ejector plate moving forward thus they force the casting from the cavity. They should be caretotally arranged so that any force positioned upon the casting throughout ejection will not cause deformation.
Then, when the die closes, return pins hooked up to the ejector plate return it to its casting position.
The die casting can be adjusted dependent on requirements. If the side of a die casting design requires a depression, one or more slides can be utilized to obtain the desired result without affecting the ejection of the casting.
Indeed, if the slides and cores aren’t caretotally fitted and securely locked into position during the process, molten metal might be forced into their slideways inflicting a disruption of operations.
Fixed and moveable cores are often used in dies. If fixed, the core axis have to be parallel to the direction of the die opening. If moveable, they have to be hooked up to core slides.
In conclusion, although slides and cores improve the complexity and the price of die construction, they allow adaptation of die castings to a wide number of configurations, usually more economically than another metalworking process.
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