The different personnel involved in die casting alloys include the engineer, the die caster, and product designers. They all play a key role in choosing the right alloy, and in the process of designing an alloy. However, it can be a tricky task for an end customer to choose the right die caster. Below are some phases involved in die casting and aspects that influence a consumer’s choice.
Prototype Design Phase
In general, the engineers in a foundry analyze and stimulate plans regarding product prototype. The engineers tend to stimulate the design using tools such as Computer Aided Design software and CNC machines during the design phase of die casting alloy. The design phase is critical for shaping an alloy using thin wall components or thick wall components, or as per the customer requirements. Generally, automotive or even pilot toys have prototypes before the actual project commences in the foundry.
In high-pressure die casting, the parameter of injection curves, mold temperature, etc., can be optimized via a simulation analysis called Computational Fluid Dynamics. At the onset of a product manufacturing process, simulation saves time to cast alloy, complies with client requirement, and avoids material scrap and empirical tests in the foundry. Such phases would pre-empt the issues, which may arise inside the hot chamber and bring about desired product results.
The Automation Aspect
Die casters use statistical tools and automation equipment such as auto ladle and auto spray to cast an alloy and deliver the finished product on time to the customer. Trim unloading equipment aids in the packaging process of cast components, as delivery remains a priority for the end consumer. When the Original Equipment Manufacturer gets the product packaged green and right in time, the die cast product would serve the end consumer in the best possible manner.
Mixing Automation with Manufacturing Cycles
Zinc is an alloy with narrow tolerance in pressure die casting and is a non-ferrous as well. Brass die casting also uses high pressure, and brass remains a non-ferrous metal. Without having to undermine the technical aspects of both alloys, it is quite possible to change the morphology of the end product with proper automation.