Why You Need Value Engineering for Casting Aluminum

Looking for aluminum casting solutions at the best value? Make sure that your die casting company is an expert in value engineering. Die casting can be an expensive process, but with the right design and steps, you can have your die cast component manufactured for a great value.

It’s best to go with a die casting company that has been around a while. These companies have worked out kinks in the process and will be able to help you through production with less costly errors and design iterations before you find the best design for your product.  They will be able to find innovative designs and use value analysis techniques to help you create the most cost-efficient design for your needs. From metals selection to draft angle calculation, these more experienced companies will walk you through a seamless and cost efficient product process.

If you are considering another manufacturing method, make sure to first get a die casting quote. Die casting, if done correctly, can have significant cost and other advantages. Die casting alloys are fully recyclable and can be very cost efficient (consider zinc). Die casting also allows for complex parts to be produced without the need for secondary machining, further reducing costs.

Some ideas to consider are:

·        Designing parts to be manufactured using multi-slide die casting

      Consolidating parts and simplifying component function

·         Designing parts to eliminate or reduce assembly operations
 Designing parts to eliminate secondary machining needs

Global Value Engineering – Going international is a big undertaking. If you’re going to sell parts in foreign countries, consider a company that has die casting facilities in those localities. You’ll save on transportation costs of your parts once they go to market. You’ll also save on manufacturing time by splitting up the job between multiple facilities located closer to their end destination, allowing you to meet strict production deadlines. 

Think Zinc

Die casting is the process of engineering metal parts by forcing molten metal under high pressure into reusable molds.  These molds, also referred to as dies, can be designed to produce complex shapes with a very high degree of accuracy.  Zinc is the fourth most common metal used in die casting parts and is behind only iron, aluminum, and copper.  It is one of the easiest alloys to cast because it offers high ductility, high impact strength, and is also easily plated. 

Zinc is an ideal metal for die casting due to its strength and hardiness.  It also has excellent electrical conductivity, high thermal conductivity, low raw material cost, and high dimensional accuracy.  Zinc is also an environmentally responsible choice for die casting because it is fully recyclable.  At the end of their product life, these die castings can be recycled and reused in new products by industries such as steel, rubber, agricultural, and pharmaceutical. 

Zinc die casting is used in tons of familiar objects such as household appliances, hand tools, telecommunication devices, computers, and several types of automotive vehicles.  Zinc die casting uses hot chamber machines because of its low melting point and the fact that it does not erode metal pots, cylinders, and plungers.

There are several metals that can be used in the die casting process.  Zinc is a top choice because of the many benefits it offers for creating metal parts.  

Steps of the Die Casting Process

The die casting process may seem complicated, but it is surprisingly simple!  In fact, there are only four main steps involved in the die casting process: die preparation, filling, ejection, and shakeout.  We will outline each step so you fully understand the die casting process!

Die Preparation

Die preparation begins with misting the mold with a specialized lubricant. This preparation both assists in regulating the temperature of the die in addition to making the cavity easier to remove when the time comes.

Filling

Next, the die is closed before the liquid metal is added to the die amidst extremely high pressure. After the cavity is filled, the amount of pressure is regulated while the casting solidification happens.

Ejection

Ejection begins when the dies open.  At this point, the shot, or a group of several castings, is removed via ejector pins.

Shakeout

The final step in the die casting process is the shakeout.  This step includes detaching the scrap from the shot.  The shakeout is usually executed by utilizing a trimming die with a press.  However, that is not the only method to complete this process.  Another way to execute the shakeout process includes sawing and grinding.  If you are in need of a method that involves less manual labor, then your best option would be to tumble the shots.  

You now know the basic steps involved in the die casting process!  Though there are only four main steps in the process; it is crucial that these steps are done correctly to result in the highest quality possible for the finished product.  For example, utilizing high-pressure injection results in the die being filled as fast as possible.  This step is crucial because it ensures that the whole cavity is full prior to the casting starting to solidify.  Since the die casting process is one of the leading processes is the manufacturing industry, it is important to know the factors involved in the process.

3 FAQs about Die Casting Processes

What is involved the die casting process?

Generally, the die casting process involves inserting metal under extreme pressure inside a mold, or a die. Die casting equipment is generally categorized by tons equal to how much pressure the machine can apply onto the die. Die casting machines come in a wide range of sizes, from 400 tons to 4000 tons.

Despite the wide range of sizes, the main difference between the different die casting machines is the approach used to insert the metal into the die. The two approaches used are hot chamber and cold chamber die casting. A complete die casting process cycle can range from not even a second, when developing small parts, to a couple minutes for the creation of several pounds. The die casting process is the quickest method available for developing specific metal parts.

How does the die casting process compare to other processes?

When choosing between the die casting process and plastic molding there are a few things to consider. Die casting is used for creating tougher parts with high tolerances that have strength and endurance. Components made in the die casting process can withstand extreme temperatures.

Another option companies consider is sand casting compared to die casting. Die casting manufacturing creates components with smooth surfaces, thin walls, and close dimensions. Production using the die casting process is also faster and the cost of labor is lower than sand casting.

How do I choose the proper alloy for the die casting process?

Each metal used for die casting provides a different benefit to the component being created.

For example, zinc is the simplest metal to cast. Zinc provides top quality strength and is simple to plate. This ease of use makes zinc extremely cost effective when creating small product components. On the other hand, aluminum is lightweight, but still possesses stability for intricate shapes and thin sides. This alloy is also resistant to corrosion and high temperatures.

How To Choose An Aluminum Die Casting Manufacturer

Aluminum alloys are commonly used for die casting parts across industries, including consumer electronics, automotive parts, computers & peripherals, healthcare, computers and mobile devices. Companies with a demanding and consistent need for aluminum die cast parts will often build their own die casting factories. However, some companies will need the expertise of a professional die casting manufacturer. Here are some tips if you are currently evaluating different die casting companies to hire to mass produce your die cast part.

Die Casting Manufacturer Strengths to Consider

Before selecting a die casting manufacturer for your aluminum part there are several variables you should consider:

·         At what point in the die casting production process are you currently? If you’re still searching for a die casting manufacturer, chances are you still need help with designing your die casting mold, or die. If you already have a prototype you might only need manufacturing and any finishing services needed.

·         What is the geographical scope for promoting your final product? If you plan on marketing your final product internationally, it can be more cost effective to find a die casting manufacturer that specializes in global engineering, or using a global network of die casting facilities to cut costs.

·         Will you need project management for your die casting part production?  Some manufacturers will request only die casting manufacturing services. Others will require full service project management from prototyping to tooling, to manufacturing.

·         Will your die cast part require secondary machining? Machining is the process by which flash and other excess material produced in the die casting process is removed.

Die Casting Manufacturer Experience to Consider

Certain aluminum die casting manufacturers specialize in industries or verticals. It is best to find a manufacturer with experience in the vertical for which you are producing your aluminum die casting.

It is also important to find a manufacturer with the advanced machinery and proprietary processes that will give you the best result with the least amount of secondary operations needed. Check to see how long your die casting candidate has been using their specific die casting process. Have they had time to perfect it?

Difficulty and complexity of the die are also a consideration in choosing an aluminum die casting manufacturer. Certain companies specialize in intricate component design. These companies will have a deep understanding of die casting design elements, such as fillet radii, ribs, corners and ejector pins.   

Value Engineering

To ensure that you’re getting the most out of your investment, make sure that you find a die casting company that specializes in value engineering. These companies will recommend several options to best fit your goal within your budget, verses giving you only one pricing and process as an option.