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Aluminum Die Casting, Zinc Die Casting, CNC Machining, CNC Turning, CNC Milling, Tapping, Drilling, Boring, Stamping

Aluminum Die Casting/ Cold Chamber Die Casting

Aluminum alloys are the most widely used for die cast parts. Aluminum die casting suppliers benefit from the total recyclability of the material and its ease of use. Due to the comparatively higher melting point, aluminum die casting may require a cold chamber casting process. Metal is melted in a separate furnace and deposited into the shot chamber through a pouring hole by hand with a ladle. In cold chamber die casting, the mold is connected directly to the shot chamber and does not utilize a plunger system. Instead, a ram forces molten metal into the mold and held under high pressure while the metal solidifies.

Aluminum Alloy Characteristics

Aluminum Die Casting Applications

High operating temperatures

Outstanding corrosion resistance

Lightweight

Very good strength and hardness

Good stiffness and strength-to-weight ratio

Excellent EMI and RFI shielding properties

Excellent thermal conductivity

High electrical conductivity

Good finishing characteristics

Full recyclability

Aluminum’s strength, corrosion resistance, and heat dissipating properties offer mechanical designers significant advantages. And our proprietary Thin Wall Aluminum Technology has made aluminum die casting an option for even more applications.

Aluminum castings improve automotive fuel efficiency by contributing to weight saving requirements

Aluminum is used in a broad range of networking and infrastructure equipment in the telecom and computing industries because RF filter boxes and housings require heat dissipation

In handheld devices, aluminum castings provide EMI/RFI shielding, rigidity, and durability with minimal weight

Because of aluminum’s excellent electrical performance and shielding properties, even in high-temperature environments, die cast aluminum is ideal for electronic connectors and housings

Zinc Die Casting/ Hot Chamber Die Casting

Also known as gooseneck casting, It is optimal for working with lower melting point alloys such as zinc, magnesium, and lead. A holding pot is filled with metal and heated with hot chamber die casting until molten by an attached or built-in furnace. A feature of the hot chamber system referred to as the gooseneck forms a holding chamber within the pot and a nozzle-like pathway that connects to the injection cavity of the fixed half of the die. A plunger that sits above the chamber allows it to fill with molten metal from the holding pot. When the chamber is loaded, the plunger lowers and forces molten material up the gooseneck into the die cavity. The mold is held together under pressure while the metal cools and solidifies in the mold. Once the metal is cool enough, the dies open, and the casted piece ejects via ejector pins.

Zinc is the easiest to cast material among the die casting metals and is typically used in hot chamber processes. Molten zinc has exceptional casting fluidity and a lower melting point. Its strength and stiffness allow it to produce parts with thinner walls and highly detailed features and maintain tight tolerances. The low melting point of die casting zinc alloys means the die casted parts cool off and solidify more quickly, which results in the fastest production rates of the die casting materials.

Zinc is an all-around well-performing material due to its balance of mechanical and physical

characteristics, which include

Impact strength

High hardness

Great stability

High-quality surface finish and easily plated

Low melting point

ZH offers the most popular types of Zamak and ZA die casting zinc alloys. More specifically, those alloys include:

Zamak 2 (ZA-2)

Zamak 3 (ZA-3)

Zamak 5 (ZA-5)

CNC Machining

CNC, or computer numerical control machining, is a widely used manufacturing process that uses automated, high-speed cutting tools to form designs from metal. Standard CNC machines include 3-axis, 4-axis, and 5-axis milling machines, lathes, and routers. Machines may vary in how CNC parts are cut—the workpiece may remain in place while the tool moves, the tool may remain in place while the workpiece is rotated and moved, or both the cutting tool and workpiece may move together. Skilled machinists operate a CNC machine by programming tool paths based on the geometry of the final machined parts. The part geometry information is provided by a CAD (computer-aided design) model. CNC machines can cut almost any metal alloy with high precision and repeatability, making custom machined parts suitable for nearly every industry, including aerospace, medical, robotics, electronics, and industrial.

CNC Machining Tolerances

Maximum Part Size：

Milled parts up to 31.49” x 19.68” x 20.47” (800 x 500 x 520 mm).

General Tolerances：Tolerances on metals will be held to +/- 0.005" (+/- 0.127 mm)

Precision Tolerances：+/- 0.01 mm

Minimum Feature Size

0.020” (0.50 mm). This may vary depending on part geometry and chosen material.

CNC Turning

Overview: What is CNC Turning?

The Basics Of CNC Lathes

A CNC lathe machine, also called live tooling lathes, is ideal for cutting any symmetrical cylindrical or spherical parts. Characteristically, a lathe spins a workpiece on a vertical or horizontal axis, while a fixed shaping instrument moves around it on a more or less linear path. The act of cutting a workpiece on a CNC lathe is called turning.

How CNC Turning Works

Benefits Of CNC Turning

CNC lathes use a subtractive method to create the desired shape. With the G-Code created, a blank bar of stock material is loaded into the chuck of the lathe's spindle. The chuck holds the workpiece in place while the spindle spins. When the spindle is up to speed, a stationary cutting tool is brought into contact with the workpiece to remove material until the desired geometry is achieved.

Like CNC mills, CNC lathes can be easily set up for high repeatability, which makes them great for everything from rapid prototyping to low and high-volume production. Multi-axis CNC turning centers and Swiss-type lathes allow for multiple machining operations in one machine. making them a cost-effective option for complex geometries that would otherwise require multiple machines or tool changes in a traditional CNC mill.

CNC Milling

The milling process uses rotating cutters for removing the material from the workpiece. A milling machine has a movable table, upon which it is mounted. The cutting tools are fixed and the table of the machine moves the material, whereby the preferred cuts can be created. This is how it works in most milling equipment units. Other such units have both cutting tools and table as movable implements.

A milling machine can perform operations such as planning, rebating, cutting, die-sinking, routing, and other intricate tool-paths, which make it a flexible equipment unit in a machine shop. Milling machines provide flexible operations and require low maintenance cost; as they usually have a glitch-free and long life, the return on investment is high.

Milling is applied ideally as a secondary process to a workpiece that is already machined. It helps in defining features and works as a ‘finishing coat’. Use it as a secondary process in order to add features like holes, pockets, slots, and contours.

Tapping

The process of cutting a thread within a hole, so that a bolt or capscrew can be threaded into it, is called tapping. It is also used for making thread upon nuts. It can be performed on the lathe either by hand or power feed. Irrespective of the process, the hole has to be drilled with the appropriate size tap drill as well as chamfered at the end.

Tapping offers economical and productive threading, particularly for smaller threads, via reduced machine downtime, superior cutting speeds as well as longer tool life. It is an easy, popular and very efficient manufacturing process, covering the most common thread profiles as well as suitable for all types of machine types with non-rotating and rotating components.

Drilling

Drilling is the process of creating or refining the holes by bringing a single rotating cutting instrument into contact with the solid piece. Milling machine or lathe is also used to perform drilling. It occurs as cylindrical holes are made in a solid piece of material with a drill bit. It is often used to make sure stability and accuracy. Drilling is one of the significant machining techniques since the holes being made are often meant to aid in assembly.

The drill bits feature a couple of spiral channels, which run up the bit’s shaft. Called the ‘fluting’, it carries the swarf or chips out of the hole when the bit progresses into the piece being worked on.

Boring

Also known as internal turning, boring is used to increase an existing hole’s inside diameter. The hole is usually drilled, or it may be cored in a metal casting. The boring process achieves three things, and they are as follows.

Sizing: The process makes the size and finish of the hole appropriate.

Straightness: It will straighten the initially cast or drilled hole.

Concentricity: The process will make it concentric, with its outside diameter inside the accuracy limits of the holding or chuck device. For the best concentricity, the outside diameter’s turning and inside diameter’s boring is performed in a set-up, that is, sans moving the work amid operations.

Stamping

Aluminum Stampings – cost-efficient with lightweight properties and a high strength-to-weight ratio. Its usage includes building components, aircraft and aerospace components, marine hardware, electronic chassis, and countless other uses.

Stainless Steel Stampings – high corrosion resistance and high strength. Due to its hygienic properties, it is used for food-grade, pharmaceutical, also aerospace, transportation, and medical applications.

Steel Stampings – versatile due to its exceptional malleability and ductility. It is beneficial for automotive applications, various structural components, and building components.

Industrial Applications of Metal Stamping:

Common applications include:

Automotive Stampings

Building Products

Solar BOS (balance of system) Components