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3 Factors to Consider in Alloy Die Casting Cost

1. Die Casting Material Cost

The cost of die casting materials is determined by the weight of the material and the unit price of the material. The weight of a material is the result of volume and material density. However, the maximum wall thickness of the die casting parts can also play a role. The weight of the required material includes the material filling the die casting mold channels. The thinner part of the wall requires a larger runner system to ensure that the entire part is filled quickly and evenly, thereby increasing the amount of material required. However, this additional material is usually less than the material that reduces the volume of the casting parts, which is caused by the thinning of the wall. Therefore, despite the larger passages, the use of thinner walls generally reduces material costs.

2. Die Casting Production Cost

The production cost of die casting is mainly calculated by hour and cycle. The hourly frequency is proportional to the size of the molding machine used, so it is important to understand how the die casting design affects the choice of machine. Molding machines usually refer to the tonnage of the clamping force they provide. The required clamping force is determined by the projected area of the part and the pressure of molten metal injection. Therefore, larger parts require greater clamping force and therefore more expensive machines. Besides, certain materials that require high injection pressure may require higher tonnage machines. The size of the parts must also comply with other machine specifications, such as pinching, platen size and shooting ability. In addition to the size of the machine, the type of die casting machine (hot room and cold room) also affects the cost. Materials using high melting point materials, such as aluminum alloy die casting, will require cold room machines, which are usually more expensive.

The production cycle time can be broken down into injection time, cooling time and reset time. By reducing these times, production costs will be reduced. By reducing the maximum wall thickness of the part, the injection time can be reduced. Besides, the injection speed of some materials is faster than other materials, but the injection time is short, and the cost savings are negligible. Using a hot chamber machine can save a lot of time, because in a cold chamber machine, the molten metal must be scooped into the machine. The time of this scoop depends on the weight of the shot. The cooling time is also reduced because they need less time to cool down the entire process. Several thermodynamic properties of the material also affect the cooling time.

Finally, the reset time depends on the size of the die casting machine and the size of the components. Larger die casting parts will require greater actions from the machine to open, close, and eject this part, while larger machines require more time to perform these operations. Besides, the use of any side core will delay this process.

3. Die Casting Mold Cost

There are two main components of mold cost: module and cavity processing. The cost of the die casting mold is mainly controlled by the size of the part. Larger parts require a larger and more expensive module, and the cost of processing the cavity is affected by almost all aspects of the part geometry. The main cost is the size of the cavity that must be processed, which is measured by the projected area of the cavity (equal to the projected area of the part and the projected hole) and its depth.

The number of parts and materials will affect the service life of the casting mold, thereby affecting the cost. Materials with high casting temperatures, such as copper alloy die casting, will cause short processing life. Zinc alloy can be cast at a lower temperature, which can extend its service life. As the number of production increases, the cost of molds also increases.

ACE BEST provides industrial fluid temperature control solutions for the die casting industry. Die casting mold temperature controllers can improve production efficiency, reduce production costs, and extend mold life. Besides, we also provide precision investment casting and custom forging services.

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If you would like to have a question then get in touch today, we are ready to assist 24/7.
We welcome your cooperation and we will develop with you.

 Factory-direct Connectivity Solutions.
 High quality, Competitive Price.
 Custom-tailored solutions.
 Problem-solving approach.