Generally one can say the diecasting process consists of 4 main region:
+ die casting machine
+ casting alloy
+ casting alloy
+ die
+ periperal equipment around the diecasting machine to mechanise the proses.
Considerable new developments have taken place during the past years in the regions of diecasting machine,alloys and peripheral equipment,however quality demands on the castings also dicatate increased.The ever increasing considerable effort has been spent in this area.As a proof,one may of die construction.
For the diecasting of suitable light or heavy metal alloy we have the following machine types available:
+ the horizontal cold chamber system
+ the horizontal cold chamber system for centre gating
+ vertical cold chamber system
+ the hot chamber system
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THE PRESSURE DIE CASTING
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A. Planing Stage
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Casting Pressures for Die Casting Alloy
Standart Part :
Al+Mg to 400 bar
Zn 100-200 bar
Ms : 300-400 bar
Technical Part :
Al+ Mg 400-600 bar
Zn : 200-300 bar
Ms : 400-500 bar
Pressure Tight Part :
Al+ Mg 800-1000 bar
Zn : 250-400 bar
Mg : 800-1000 bar
Electro Plating Parts :
Zn 220-250 bar.
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B. Design Stage
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Fs (kn) = A (cm2) x p (bar ) /100
F (kn) = 1,1-1,25 x (Fs+F1)
F1(kn) = tangential x Fk(kN)
A= Project Area (cm2)
F1 = Slide Force (Kn)
p = Spec Casting Pressure (bar)
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DIE STEELS
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Working Life
Insert Piece :
Al 100.000
Zn 300.000-500.000
Ms Brass 35.000
Small Piece :
Al 50.000
Zn 150.000
Brass 18.000
Shot Sleeve :
Al 80.000
Zn 500.000
Ms Brass 70.000
Plunger :
Al 20.000
Zn 100.000
Ms Brass 20.000
Nozlee :
Zn 250.000
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A. Heat Treatment
Recomendaions for the Hardening of Die Casting Dies
Die Plate :
Zink-Alloys 43-45 HRC
Al-Alloys 44-46 HRC
Al-,Mg-Alloys 44-46 HRC
Cu-Alloys 39-40 HRC
Insert :
Zink -Alloys 43-45 HRC
Al-Alloys 44-46 HRC
Al-Mg-Alloys 44-46 HRC
Cu-Alloys 39-40 HRC
Split Insert/Machining After/Heatreatment :
Zink-Alloys 41 HRC
Al-Alloys 43-45 HRC
Al-Mg-Alloys 43-45 HRC
Cu-Alloys 34-36 HRC
Round Core :
Zink-Alloys 46 HRC
Al-Alloys 46 HRC
Al-Mg-Alloys 48 HRC
Cu-Alloys 43 HRC
Cavity Core :
Zink-Alloys 43 HRC
Al-Alloys 44-46 HRC
Al,Mg-Alloys 44-46 HRC
CU-Alloys 36-37 HRC
Sprue Buhs/Speader :
Zink-Alloys 48 HRC
Al-Alloys 48 HRC
Al,Mg-Alloys 48 HRC
Cu-Alloys 39-40 HRC
Slide /Wedge Lock/Guides :
Zink-Alloys,Al-Alloys,Al-,Mg-Alloys =Case Hardening
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B. Diecasting Dies Built From Standart
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DIE TEMPERATURE CONTROL
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A. Practical Hints
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GATING TECHNIQUE FEED SYSTEMS
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A. General Rules
B. Centre Gatint System For Horizontal Cold Chamber Machine
C. 3-Plate System With Stripper plate Built In Die
D. 3-Plate System With Stripper Plate Built In Machine
E. System Loss And Gating Calculations
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DIE TRIAL
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A. Entry Inspection
B. Testing
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DIE MAINTENANCE
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