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453 weeks ago




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The..hydraulically..powered..clamping..unit..actuates..clamping..bars..that..push..this..platen..towards..the..cover..die..and..exert..enough..pressure..to..keep..it..closed..while..the..molten..metal..is..injected…When..the..die..is..attached..to..the..die..casting..machine,..each..half..is..fixed..to..a..large..plate,..called..a..platen…It….has….superior….corrosion….resistance….too.Alloy….B390;….it….is….known….for….its….superior….wear….resistance….and….high….hardness…..Notes[edit]…This…makes…them…a…perfect…choice…for…nearly…all…applications.Rapid…or…high…speed…production…processWith…die…casting,…as…long…the…right…metal…alloy…and…manufacturing…process…has…been…chosen.The…final…product…can…be…realized…within…a…short…period…of…time.This…is…the…main…reason…why…it…is…highly…recommended…for…high…volume…production.The…tooling…process…is…simple…as…one…mold/die…can…be…used…to…produce…different…parts…of…the…same…specification.Again,…depending…on…the…desired…surface…finish,…an…appropriate…technique…can…be…chosen.Thus,…the…finishing…operations…can…be…minimal…if…not…eliminated…completely.Ideally,…thousands…of…parts…can…be…produced…without…necessarily…using…an…additional…tooling.It…doesnt…matter…whether…they…are…complex…shapes…or…those…with…higher…tolerances….Other…common…die…cast…parts…include…propellers,…gears,…bushings,…pumps,…and…valves….Die..cast..part..Return..to..top…..Adding…about…2%…of…lead…enhances…the…machinability…properties.Lead…is…a…perfect…choice…for…this…application…since…it…has…a…low…melting…point…than…both…copper…and…zinc.In…some…instances,…silicon…can…be…used…instead…of…lead.However,…brass…alloys…with…silicon…must…not…be…mixed…with…the…ones…having…lead.Corrosion…resistanceBrass…alloys…can…be…modified…to…offer…high…level…of…corrosion…resistance.A…good…example…is…the…dezincification…resistant…(DZR)…brass….Heating….a….metal….to….a….desirable….melting….temperature,….therefore,….the….metal….should….be….able….to….maintain….its….desirable….haracteristics….within….that….temperature….range,….otherwise,….the….whole….process….will….be….futile.2.Exerting….pressure,….the….metal….must….be….able….to….maintain….the….same….properties….when….subjected….to….these….high….pressures.In….this….chapter,….we….will….discuss….the….various….materials….that….can….be….manipulated….through….this….manufacturing….technique.This….will….act….as….a….guide….to….enable….the….readers….choose….the….right….material….for….a….specific….application.Moreover,….they….should….be….able….to….adopt….the….right….die….casting….technique….based….on….the….chemical….and….physical….properties….of….the….metals….or….alloys.Ideally….the….main….die….casting….alloys….that….are….commonly….used….in….industries….include….zinc,….magnesium,….tin,….lead,….aluminum….and….copper.However,….for….the….purpose….of….this….eBook,….we….shall….focus….on….the….following….key….materials:….zinc,….aluminum,….brass….and….steel.The….Die….Casting….Material….Selection….CriteriaThis….should….be….based….on….research….and….not….a….trial….and….error….or….unapproved….theories.It….is….through….a….proper….understanding….of….each….metal….or….metal….alloy….that….one….will….be….able….to….choose….the….right….material….and….die….casting….technique.As….a….matter….of….fact,….these….alloys….and….metals….have….different….mechanical….and….physical….properties.This….explains….the….reason….why….they….react….differently….when….subjected….to….certain….manufacturing….processes.It….is….advisable….to….work….closely….with….experts….to….establish….the….right….material….for….any….given….application.This….may….involve….a….simple….comparison….process….that….may….be….simplified….as:1.It….is….vital….to….consider….all….the….vital….mechanical….properties….of….those….materials.This….is….what….we….shall….also….expound….on….every….material.The….vital….mechanical….properties….include….elongation,….tensile….strength,….hardness,….impact….strength….and….yield….strength…..

That…is,…there…are…those…companies…that…use…the…automated…systems…whereas…other…use…the…manual…systems.Again,…the…weight…of…the…final…product…that…can…be…cast…depend…on…the…type…of…machine.The…gravity…die…casting…technique…has…been…adopted…by…most…companies…due…to…the…fact…that…it…reduces…the…production…cost.The…tooling…that…is…used…in…here,…is…cheaper…that…those…used…in…the…high…pressure…die…casting.A…company…that…has…all…the…above…manufacturing…techniques…can…always…examine…the…project…at…hand…and…subsequently…choose…a…technique…that…suits…their…customers.What…does…the…process…involve?Unlike…the…high…pressure…die…casting…where…the…molten…metal…moves…into…the…die…due…to…high…pressure,…this…die…casting…technique…depends…on…gravity.NOTE:…Theres…no…any…other…force…that…is…applied…to…facilitate…the…flow…of…molten…metal.This…metal…parts…manufacturing…process…is…suitable…for…non-ferrous…alloys….These..are..tangible..items..or..structures..that..we..use..or..see..in..our..daily..lives.Die..Casting..ExamplesDie..casting..is..one..kind..of..technology..that..we..have..lived..to..embrace..in..our..day-to-day..activities.This..is..a..popular..manufacturing..process..that..is..used..to..produce..a..number..of..metal..parts..both..for..industrial..and..domestic..applications.For..this..particular..section,..well..categorize..these..parts..based..on..where..they..are..used..i.e…In….addition….to….the….size….of….the….machine,….the….type….of….machine….(hot….chamber….vs…..The…high-pressure…injection…leads…to…a…quick…fill…of…the…die,…which…is…required…so…the…entire…cavity…fills…before…any…part…of…the…casting…solidifies….That..is,..it..doesnt..corrode..easily..when..it..is..subjected..to..any..adverse..environmental..conditions.LightweightIt..has..a..relatively..lightweight..than..a..number..of..building..materials…A….variation….in….the….cooling….rate….can….be….caused….by….non-uniform….wall….thickness….or….non-uniform….die….temperature…..The..two..types..of..die..casting..machines..are..a..hot..chamber..machine..and..cold..chamber..machine…This….prevents….over….heating….of….the….mould.Injection….and….ejection….system;….the….injection….system….operates….based….on….a….hydraulic….system…..

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