Die - Casting Process
- Mold Design: Die-casting mold is an integral part. It is developed to fit in shape and size with motor parts. Computer-Aided Design (CAD) is used to design three-dimensional (3D) modeling of the mold. This is later studied by Computer-Aided Engineering (CAE) tools to optimize gating system, channels to cool down, and ejection system. Gating system offers free flow of zinc-alloy melt to the mold cavity while channels to cool down modulate solidification speed in casting.
- Melting and Shotting: Zinc alloy is melted in between temperatures of approximately 415 to 430°C (779 to 806°F) in a furnace. This alloy is injected in die-casting die in required quantity in proportion to required heating in this process. This is done by way of high-pressure in between 10 to 175 MPa. This high-pressure fills die-casting die to capacity and provides die detailing accurate duplication in casting.
- Solidification and Ejection: Solidification is formed in liquid alloy by filling in the mold. Solidification is formed in desired shape by controlling the time to prevent defect formations such as shrinkage or porosity. When solidification is formed in casting, ejection is done by opening the mold by an ejection system.
Post - Processing
- Trimming: After ejection, residue material in the shape of flash or sprues can remain in the casting. This is eliminated by trimming presses or machining methods. This is carried out to achieve exact sizes and smoothness to the casting.
- Surface Treatment: Motor parts can be treated to both be aesthetically pleasing and have increased corrosion resistance through the process of surface treatments. Common treatments used in zinc die-casting products range between chrome plating or plating through an electroplating process to powder coating or passivating. Passivating forms an oxide layer to prevent attack by the surface while making both functional and aesthetically pleasing.
- Machining: Some motor parts can have additional machining steps to achieve desired functionality and tolerance. Procedures such as machining can be used to drill holes, turn threads, or conduct other forms to achieve desired qualities in the casting.
Quality Assurance
- Dimensional Inspection: Motor part die-casting sizes are inspected by accurate equipment in the form of calipers, computerized Coordinate Measuring Machines (CMMs) to validate these sizes to design specifications and can fit appropriately in to the motor.
- Non-Destructive Testing: Internal faults in the shape of pores, cracks, or inclusions in casting can be brought to life by non-destructive testing techniques such as X-ray testing and ultrasonic testing. Defects can affect motor part performance and mechanical characteristics.
- Mechanical Testing: Tension tests, tests to check tests to check hardness tests to check impact tests are done to test zinc die-casting material to check the material's mechanical characteristics. All these tests confirm that the part has strength, hardness, and toughness to withstand working conditions in motor.
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