Advantages of Die Casting

Very often we receive RFQ from designers or purchasing people who are not sure if they need a die casting or another process for their project.

Quite often with a good design review process we can suggest the part as a die casting along with other components that are assembled onto the initial part, thus saving tooling and other purchased components.

This is one of the many advantages of die casting – creating a basic part with add-ons to eliminate assembly and machining, saving the customer money in the long run.

However, die casting is a high volume production process, so part requirements need to be more than a few hundred parts per year in order to amortize the initial tooling costs of the program.

Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique.  Parts have long service life and may be designed to complement the visual appeal of the surrounding part.  Designers can gain a number of advantages and benefits by specifying die cast parts.

Die casting component parts, decorative trim and/or finished products offer many features, advantages and benefits to those who specify die casting as a manufacturing process.

Here is a bullet list of die cast advantages and why a designer would want to design his product as a die casting:

  • Die casting provides complex shapes within closer tolerances than many other mass production processes.
  • Die Castings are produced at high rates of production. Little or no machining is required.
  • Die casting provides parts which are durable, dimensionally stable, and have the feel and appearance of quality.
  • Die castings can be produced with thinner walls than those obtainable by other casting methods and much stronger than plastic injection moldings with the same dimensions.
  • Die casting dies can produce thousands of identical castings within specified tolerances before additional tooling may be required.
  • Zinc castings can be easily plated or finished with a minimum of surface preparation.
  • Die castings can be produced with surfaces simulating a wide variety of textures.
  • Die cast surfaces, as cast, are smoother than most other forms of casting such as sand, permanent mold, and investment processes.
  • Holes in die castings can be cored, and made to tap drill sizes.
  • External threads on parts can be readily die cast.
  • Die castings provide integral fastening elements, such as bosses and studs, which can result in assembly  economies.
  • Inserts of other metals and some non-metals can be die cast in place.
  • Corrosion resistance of die casting alloys rates from good to high.
  • Die castings are monolithic.  They combine many functions in one, complex shaped part.  Because die castings do not consist of separate parts, welded or fastened together, the strength is that of the material, not that of threads or welds.

Die casting is an efficient, economical process which, when used to its maximum potential, replaces assemblies of a variety of parts produced by various manufacturing processes at significant savings in cost and labor.

Our last 20″ FCL loaded before our long CNY holiday close.

Thanks for our hard working team,

we work tightly shift and carry on the production,

promise our on time lead time, so even the CNY holiday closely,

we still completed the order shipment successfully,

we will be happy closed and go hometown to celebrate Chinese 2019 new year !

We loaded the Container nearly fully, with max. 1 CBM space left, great job! A big shipment, our client are urgently waiting for this FCL shipment, and we wish can achieve repeat Order after CNY holiday!
We loaded the Container nearly fully, with max. 1 CBM space left, great job! A big shipment, our client are urgently waiting for this FCL shipment, and we wish can achieve repeat Order after CNY holiday!

Welcome HMD team to visit our company in January 2019

James- Sales Director of HMD and the team from London, UK visited our company in 21st January 2019,

we have a good meeting,

and found a solution that works for both our companies to grow the business in 2019 year.

And we have a easy and nice lunch at company cooked by our factory’s kitchen.

James- Sales Director of HMD and the team from London, UK visited our company in 21st January 2019,

Sand Castings Casting

Sand casting is used to make large parts (typically Iron, but also Bronze, Brass, Aluminum). Molten metal is poured into a mold cavity formed out of sand (natural or synthetic). The processes of sand casting are discussed in this section, include patterns, sprues and runners, design considerations, and casting allowance.cast iron casting
patterns
The cavity in the sand is formed by using a pattern (an approximate duplicate of the real part), which are typically made out of wood, sometimes metal. The cavity is contained in an aggregate housed in a box called the flask. Core is a sand shape inserted into the mold to produce the internal features of the part such as holes or internal passages. Cores are placed in the cavity to form holes of the desired shapes. Core print is the region added to the pattern, core, or mold that is used to locate and support the core within the mold. A riser is an extra void created in the mold to contain excessive molten material. The purpose of this is feed the molten metal to the mold cavity as the molten metal solidifies and shrinks, and thereby prevents voids in the main casting. cast iron casting, aluminum sand castings, grey iron casting, ductile iron casting
Typical Components of a Two-part Sand Casting Mold
In a two-part mold, which is typical of sand castings, the upper half, including the top half of the pattern, flask, and core is called cope and the lower half is called drag. The parting line or the parting surface is line or surface that separates the cope and drag. The drag is first filled partially with sand, and the core print, the cores, and the gating system are placed near the parting line. The cope is then assembled to the drag, andthe sand is poured on the cope half, covering the pattern, core and the gating system. The sand is compacted by vibration and mechanical means. Next, the cope is removed from the drag, and the pattern is carefully removed. The object is to remove the pattern without breaking the mold cavity. This is facilitated by designing a draft, a slight angular offset from the vertical to the vertical surfaces of the pattern. This is usually a minimum of 1?or 1.5 mm (0.060 in), whichever is greater. The rougher the surface of the pattern, the more the draft to be provided. cast iron casting
  Sprues and Runners
The molten material is poured in the pouring cup, which is part of the gating system that supplies the molten material to the mold cavity. The vertical part of the gating system connected to the pouring cup is the sprue, and the horizontal portion is called the runners and finally to the multiple points where it is introduced to the mold cavity called the gates. Additionally there are extensions to the gating system called vents that provide the path for the built up gases and the displaced air to vent to the atmosphere. 
The cavity is usually made oversize to allow for the metal contraction as it cools down to room temperature. This is achieved by making the pattern oversize. To account for shrinking, the pattern must be made oversize by these factors, on the average. These are linear factors and apply in each direction. These shrinkage allowance are only approximate, because the exact allowance is determined the shape and size of the casting. In addition, different parts of the casting might require a different shrinkage allowance. See the casting allowance table for the approximate shrinkage allowance expressed as the Pattern Oversize Factor. cast iron castingsSand castings generally have a rough surface sometimes with surface impurities, and surface variations. A machining (finish) allowance is made for this type of defect. See casting allowance table for the finish allowance.

From WEST YORKSHIRE, UK, our VIP Client, friend (AG) visited our company and sub-contractor again in November 2018, warmly welcome !

In order to expand the business range and long standing relationship with our this uk client,

we have been in continued business since 2005 and will continue into 2018 and 2019.

Therefore it is important for the two companies to work together during this period,

Mr ag managing director came to ningbo city to visit our factory again in 2018 year

to check & discuss production and tooling requirements during this period.

Thanks for the visit, it help our two companies move forward, and with face to face discussion,

we solved the problem very quickly, and created new idea shortly,

which will help our tightly cooperation.

Then we have a great rest in the weekend after the tightly schedule meeting and visiting, picture photographed in hyat resort, dongqian lake,

later we have a nice dinner to cerebrate our sucessful deal.

PICTURE PHOTOGRAPHED IN HYAT RESORT, DONGQIAN LAKE, NINGBO CITY, CHINA

PICTURE PHOTOGRAPHED IN HYAT RESORT, DONGQIAN LAKE, NINGBO CITY, CHINA
After the dinner, we drunk a dozen of Tsingtao beer and the Singer in the Pub specially song an English classic song  "Hotel California " to our friend, AG, what a wonderful night!
After the dinner, we drunk a dozen of Tsingtao beer and the Singer in the Pub specially song an English classic song “Hotel California ” to our friend, AG, what a wonderful night!