When we need producing zinc die casting parts to meet the demands of some specifications in many fields, zinc die casting is ideal for medium and small sizes parts. Complying with the guideline, company can design high effective, cost-effective, and reliable zinc die-cast part. Here is step-by-step zinc die casting design guide to design good quality zinc die casting parts to meet the demands of many fields.
Zinc die casting design, which is care and complex procedure. With cutting-edge computerial design tools, Our well-experienced engineers design 3d model of the cast part and high precision steel mold at high volume production under fast cast cycle. Considering of using Hot Chamber Die Casting Produces Zinc Cast Parts .We can comply with the below steps to proceed.
No.1 CAD Part Model Design
At the begining for zinc die casting design, according to the functional requirements of the zinc cast part, Engineers often design the model of cast part firstly. Using tools like SolidWorks, Autodesk Fusion 360, or Siemens NX.
From the below key attentions for zinc die casting design, our engineering team can collaborate with client and finish any OEM and ODM project perfectly. The process belongs to hot chamber die casting, which cast consistent high quality zinc cast parts. The follow 8 critical factors for zinc die casting part structure design.
- Wall Thickness: between 0.5mm to 5mm throughout the component
- Draft Angles: draft angle between 1° and 3°
- Undercuts: Die Slide And Lifter Design
- Fillet Radii: Radii (R ≥ 0.5 mm), minimum 0.3 mm radius
- Parting Line & Ejection
- Ribs & Bosses: Reinforce the structural integrity of the part
- Surface Finish & Textures: Texture treatment
- Post-Casting Considerations
No.2 DFM (Design for Manufacturing) Optimization
The step involves of high precision cast die design, achieve a high effective mass production at high volume. It includes the selection of the material of tooling steel, the detailed core and cavity of the die design, the workflow of the die and other additional functions. Considering that the cast parts may accept secondary processes. The cast die design will have initial draft output. The design of cast die is the center of zinc die casting design.
No.3 Mold Flow Simulation
Some inevitable troubles may be arised during casting die manufacturing process when there are the divergence between the desired design and real physical operation. These addational troubles can exhaust more labor cost and time for repairing and improving the die. So simulation metal flow tools provides more supports for zinc die casting design, zinc die casting prototyping design:flow simulation tools, which can predict some fore troubles and reminder engineering clerk to have a proper adjustment and modification of the design cast die in advance.
No.4 Optimization for Detail Improvement Of Design
Optimization for detail improvement of cast part design is one vital step for zinc die casting part design. Our engineers can access the aesthetic and functional needs of the die casting part, position the part line location and minimize impacting the part appearance. Place ejection pins in non-visible or non-functional areas to avoid marks on critical surfaces. Meanwhile control ejection pin push power avoid over push power to deform the part. Optimizing these optimal gates and vents to ensure efficient material flow and minimal air entrapment. and ensure the as-cast part high qulity.
No.5 Zinc Cast Die Manufacturing
Zinc cast die manufacturing is careful and precision process procedure. Our engineers convert 3d file of the cast die into 2d drawing and hand to mold technicians. Our mold technicians make the precision cast die depends on the requirements of the drawings. Considering of the manufacturability of the die, they choose the proper tooling steel, through some precision machining processes, such as cnc machining, milling, grinding and EDM etc. Zinc die casting design must ensure precision geometries, tight-tolerance dimension and longer tooling life. All components for the die are finished, technician assemblies these component and aligning with the halves of the die, finish the zinc cast die manufaturing.
No.6 Material Selection For Zinc Die Casting
Undergoing zinc die casting design, including cast part structural, aesthetic, or functions. Choose the zinc alloy that best suits the component’s function and applications. Focusing on the common zinc alloys, which are Zamak and ZA serial.
Zamak Serial
| Zinc Alloy Type | Composition | Tensile Strength(MPa) | Yield Strength(MPa) | Elongation Content | Hardness(Brinell) | Impact Strength |
|---|---|---|---|---|---|---|
| Zamak 2 | ~95.5%,Zn,3.5-4.3%,Al, 2.5–3.5%,Cu, 0.02–0.06%, Mg, Other,<0.1 Fe, <0.007 Pb | 328–359 | 208–240 | 7-10% | 82-100 | 53–58 |
| Zamak 3 | ~95.5%,Zn,3.5-4.3%,Al, 2.5–3.5%,Cu, <0.1%, Mg, | 283–328 | 208–240 | 10–15% | 80–90 | 48-53 |
| Zamak 5 | ~95.5%,Zn,3.5-4.3%,Al, 2.5–3.5%,Cu, 0.75–1.25%, Mg | 317–359 | 228–262 | 7-10% | 91-100 | 41-48 |
ZA(Zin-Aluminum Alloys) Serial
| Zinc Alloys | Composition | Tensile Strength (MPa) | Yield Strength (MPa) | Elongation Content | Hardness (Brinell) | Impact Strength | Typical Applications |
|---|---|---|---|---|---|---|---|
| ZA-8 | ~91.1%,Zn,8.0-8.8%,Al, 0.8–1.3%,Cu, 0.015–0.03.3%, Mg, | 374–386 | 283–317 | 6-10% | 100–110 | 35–41 | Small precision parts (connectors) |
| ZA-12 | ~86.5%,Zn,10.5-11.5%,Al, 0.5–1.2%,Cu, 0.015–0.03%, Mg, | 400–414 | 317–345 | 3-6 | 110-120 | 25-30 | Industrial components (gears, housings) |
| ZA-27 | ~70%,Zn,25-28%,Al, 2.0–2.5%,Cu, 0.01–0.02%, Mg, | 400–440 | 345–386 | 1-3 | 115-130 | 15-20 | High-strength applications (aerospace) |
Depends on the function requirements of the zinc die casting design, we should choose the best zinc alloy to cast component that client reqirements is achieved.
No.7 Rapid Prototyping Test
Create a prototype to test the die functionality, fit, and performance before mass production. Prototypes can be produced by precise casting die in further post-process. Like CNC machining, grinding, polishing or coating treatments to realize the functionalities of the die. The prototype should be tested for its assembly and fit other components smoothly and identify its performance. The rapid prototyping services should be addressed before moving to high volume quantity production.
No.8 Tooling Adjustments & Optimization
Engineer can have proper adjustments based on testing results, improve tooling aspects like wall thickness, rib locations, or gate and vent places, Implement guide to troubleshooting zinc castings until the qualified prototype is confirmed. Once the design is validated, finalize the die design and manufacturing parameters. Record these test result and part parameters, include of the part material, cast cycle time, cooling and solidification temperature and the pluger force power.
No.9 Secondary Operations
The as-cast part can be deburred through some post-processing methods, involves of cnc machining, tapping, drilling, trimming, sand-blastering and polishing. Zinc die casting part is required to machined precisely, and remove the excess material or burrs on the part, achieve superior surface finish so that allows further finishes.
No.10 Surface Finishing
These superior surface finish cast parts can accept some coating finishings for improving its appearance,enhancement of durability. Like the below common surface finishing approches.
- Electroplating (nickel, chrome)
- Powder coating
- Painting
For zinc die casting design, surface finishing for the cast parts is considerable available.
No.11 Quality Inspection
From selection for the material of zinc alloys, random check in-process to final products inspection and testing, implement strict quality management regulations, handle every link joint, use right instrument to measure the zinc cast part, rigidly excute incoming testing and monitoring with X-ray scanner, Cast part measurement in process with micrometer and Final product dimension inspection with CMM.
No.12 Mass Production Setup
Mass production requires machine technician these setup, such as cycle time, injection temperatue, cooling temperature, pressure parameter and scrap reuse. The low temperature die casting is high effective and fast cycle time manufaturing process. With advanced die casting machines, automation production lines and robotic hands, our workers follow the standard production procedure, Under strict quality control system, finish the mass production at high volume in cost-efficiency.
By the above steps, we can handle zinc die casting design in accuracy. Zinc die casting design guide is execution documents before making samples for mass production. In another one, using metal flow simulition tools to simulite running casting die process to check some predicted defects and trouble before die fabrication.
Conclusion
In summary, A sound zinc die casting design guide should be made before proceeding design a zinc custom die casting component. we can have a concise summary for zinc die casting design. As guidance for design high quality zinc die casting part, which can guide us to select the best zinc alloy, design precise steel casting die, optimization for detail design and the die improvement , prototype testing and modification and adjustion for the die, until produce high quality zinc die casting parts.
FAQ
What Property Of Zinc Alloys Most Suitable For Casting Components?
The most zinc alloys : Zamak serial is most suitable for casting components, because the material is low melting points, easy to cast and has excellent mechanical property and a long life. They can bring durablity to end users, and create lower cost and easy to cast property to die casting manufacturers. As professional die casting manufacturer, we adopt zamak to produce high qualtiy zinc die casting components.
How To Design A part For Casting?
As Die casting design for a part, engineer should ensure the surface of the cavity and core is smooth, avoid residue stick on the surface of the die during casting process. Maintain the uniformly cooling when the casting part is solidified and minimizing cold shut, warp and shrinkage ocurred. Ensuring gate and vent channels is unobstructed, make metal flow fill the die fully in short time.
How to Reduce Porosity on Zinc Die Casting ?
These effective methods can reduce porosity on zinc die casting when visable porosity on zinc die casting parts. As expertise engineer, I recommand die casting manufacturers to do the below measures and ensure cast high quality zinc die casting parts. Optimize Die Design, Improve Zinc Alloy Quality, Control Process Parameters, Introduced Advanced Technologies and Implement Rigid Quality Control Rules.
