The Process Flow of a Die-Casting Machine

1. Brief Introduction to Die Casting

Die Casting is a high-efficiency, high-precision near-net-shape metal forming process. Its core principle is to inject molten metal into a precision mold cavity at high pressure and high speed. After cooling and solidification, high-precision, near-net-shape metal parts are directly obtained.

Compared with ordinary permanent molds, die-casting molds feature higher structural strength and longer service life (up to more than 100,000 cycles). They are especially suitable for mass production of large-quantity, complex-structured and thin-walled components.

2. History of Die Casting

Die casting technology emerged in the mid-19th century, with a history of about 160 years. It originated from type casting in the printing industry and represents a modern upgrade of traditional casting.

In the evolution of equipment, horizontal cold-chamber die casting machines have long dominated the industry due to their advantages in large-scale, integration and automation. They are suitable for non-ferrous metals such as zinc, aluminum, magnesium, copper, as well as ferrous metals.

In terms of material application, die casting of magnesium and copper alloys began around 1930. After the 1940s, aluminum alloys comprehensively replaced zinc alloys and became the mainstream material for die casting thanks to their comprehensive advantages.

3. Brief Introduction to Open Die Forging

Open die forging is a plastic forming process without special molds: the metal blank is placed between upper and lower anvils, and pressure is applied to make the metal flow freely in all directions to achieve the desired shape.

Flexible process: Capable of producing various simple and special-shaped forgings to meet diverse needs.

Suitable for small-batch production: No mold development required, ideal for single-piece and small-batch trial production.

Excellent performance: Forged parts feature dense structure, refined grains and outstanding mechanical properties, widely used in key components with complex stress and high reliability requirements.

4. Brief Introduction to Die Casting and Forging (Squeeze Casting)

Die casting and forging is a composite forming process that combines the advantages of die casting and forging, and must be carried out on special die casting-forging equipment.

The process is as follows: first, the molten metal is filled into the mold by casting; during the cooling and solidification stage, forging pressure is applied through the movable cavity surface of the mold. This not only completely eliminates internal defects such as shrinkage cavities and porosity, but also refines the structure into a forged fine-grained structure, greatly improving the overall mechanical properties of the parts.

This process can achieve a surface roughness of Ra1.6 (Grade 7) on the blank, close to the level of cold extrusion and finish machining, with metallic luster. Therefore, it is known in the industry as an ultimate forming process, representing a higher level of near-net-shape and chipless forming technology.