In the world of manufacturing, casting and machining are two of the most basic and widely used part forming technologies. How do you make an informed choice between the two when faced with a specific part requirement? This is directly related to the quality, cost and lead time of the product. In this article, we will analyze the core principles of casting and machining, advantages and disadvantages, key differences and applicable scenarios, to help you make a precise decision. What is casting? Casting is a time-honored manufacturing process that centers on pouring molten metal (or alloy) into a pre-prepared cavity (mold). The metal cools in the mold, solidifies and eventually forms a solid part with the shape of the mold cavity. The resulting part is called a "casting". How does casting work? Aluminum Casting High Pressure Die Casting Production Casting Process ...

In the grand picture of machine building, metal cutting processing occupies a central position. As the key means to achieve precise shapes and sizes of parts, a variety of machine tools have come into being, and together they have driven the progress of industrial civilization. Among them, milling machine and planer as two types of long history and very strong basic machine tools, in the early stage of shaping the foundation of modern industry played an indelible role. Although they belong to the same category of removing the processing of materials, but its core working principle, applicable processing objects and the embodiment of the characteristics of the process, but there are essential differences. Milling machine, with its rotating multi-flute cutter (milling cutter) as the main feature, through the tool's high-speed rotation and multi-directional feed movement of the workpiece, can be efficiently processed out of the plane, grooves, gear teeth, helical surfaces, and a variety of complex curved surfaces of the wheels ...

Aims and objectives CNC machining technology and machining process has a holistic and general understanding of CNC CNC machining history and development trends Introduction 1. Background 1. The shortcomings of traditional machine tools - manual operation, labor-intensive, - difficult to improve productivity - human error, difficult to ensure quality Difficult to process complex shaped parts - not conducive to the modernization of production management 2. The development needs of the manufacturing industry products are becoming increasingly sophisticated, complex, frequent modifications, put forward high-performance, high-precision and high-automation requirements 2. The emergence and development of the course of 1. Overseas 1930, CNC patents 1948, the budding production of CNC machine tools 1952, the first CNC milling machine, the first CNC milling machine. In 1952, the first CNC milling machine (Parsons and the Massachusetts Institute of Technology) in 1958, the first machining center in 1968, flexible manufacturing system in 1974, the use of microprocessors (CNC) 1...

Drilling The method of processing holes in solid material with a twist drill is called drilling. General processing can be up to the size tolerance grade IT14 ~ IT11, surface roughness Ra value of 50 ~ 12.5μm. Commonly used drilling machines are: desktop drilling machine, vertical drilling machine and rocker arm drilling machines. 1, drilling machine 1) desktop drilling machine referred to as table drill (Figure 1), is a small machine tool, placed in the clamping table to use. Its drilling diameter is generally below 12mm. Mainly used for processing small workpieces on a variety of holes, clamping in the most used. Fig. 1 Benchtop drilling machine 1-Table 2-Feeding handle 3-Spindle 4-Belt cover 5-Motor 6-Spindle holder 7-Column 8 (2) Vertical drilling machine, referred to as vertical drill (Figure 2), is generally used to drill holes in medium-sized workpieces, and its specifications are expressed in terms of the maximum drilling diameter. Commonly used are 25mm, 35mm, 40mm, 50mm, etc...

Aluminum alloys are widely used in aerospace, automotive, electronics and other fields due to their light weight, high strength and corrosion resistance. However, the traditional chromate passivation process has been strictly limited by international environmental regulations due to the high toxicity and serious pollution of hexavalent chromium. In this paper, the research on chromium-free passivation technology is carried out to explore the film-forming mechanism of silane/rare earth salt composite system, to improve the corrosion resistance of passivation film by optimizing the process parameters, and to analyze its environmental protection and economic value, so as to provide theoretical and technical references for the alternative chromate process. From this paper, we can learn: The application of aluminum is the highest production of non-ferrous metals, the most widely used metal materials. In the metal structural materials, its production is second only to steel. All-Aluminum Engines The advantage of a cast aluminum block is that it is lightweight,...

Challenges and Importance of Welding Aluminum Alloys Aluminum alloys are widely used in automotive, aerospace and shipbuilding applications due to their light weight, high strength and corrosion resistance. However, its high thermal conductivity, oxidizability and susceptibility to thermal cracking make the welding process a serious challenge. Take the battery tray of new energy vehicles as an example, the weld needs to be both high strength and airtight, which is difficult to meet the needs of traditional processes, and TIG and MIG welding technology provides an efficient solution for this. Aluminum alloy features: low density: the density of aluminum alloy is smaller than that of steel and copper, about 2.7 g/cm3, so aluminum alloy products are lighter than steel products of the same volume. High strength: Aluminum alloy has high strength and hardness, and its strength and hardness can be significantly improved after heat treatment. Good electrical conductivity: the electrical conductivity of aluminum alloy is better than pure copper and steel...

Types of Aluminum Corrosion 1. Atmospheric Corrosion The most common form of aluminum corrosion. Atmospheric corrosion of aluminum occurs due to exposure to natural elements. Because of its likelihood of occurring in most places, atmospheric corrosion accounts for the largest share of the total damage to aluminum caused by all types of corrosion combined in the world. Atmospheric corrosion can be categorized into three subcategories. They are dry, wet and moist, depending on the level of moisture in the service environment. Since moisture levels can vary greatly depending on your geographic location, certain areas will experience greater corrosion than others. Other environmental factors that affect the level of atmospheric corrosion are changes in wind direction, temperature and precipitation. The concentration and type of pollutants in the air and proximity to large bodies of water also play an important role. 2.Galvanic Coupling Corrosion When aluminum is physically or through...

As a highly efficient solution for die casting, A380 is the most popular die casting aluminum because it combines the properties of easy casting, ease of machining, and good thermal conductivity. It has a high degree of variability, load-bearing capacity, and resistance to high-temperature splitting. Although Type A380 has always been considered easy to machine, it is slightly rough due to its high silicon content. It is utilized in a wide variety of products including motor equipment chassis, engine mounts, gearboxes, furniture, generators, and hand tools. The following is a visual presentation of its core technical parameters through a comparison of professional data: A380 Aluminum Alloy Composition Table Element Content Range (wt%) Function Aluminum (Al) 85.0-89.5 Matrix material to ensure a lightweight base Silicon (Si) 7.5-9.5 Enhances mobility and wear resistance Copper (Cu) 3.0-4.0 Enhances high...

The most widely used material for modern automotive cast aluminum alloys is the American Society for Testing and Materials (ASTM) grade A356 alloy, which is equivalent to China's ZL101A, Japan's AC4CH, Germany's AlSi7Mg, France's A-S7G03, and Russia's Aл9-1. In addition to the A356 alloy, Germany uses AlSi9Mg, AlSi10Mg, AlSi11Mg, and France uses A-S11G and A-S12.5. France also uses A-S11G, A-S12.5 . These high Si alloys are not heat-treated, they have good liquid mobility, strong shrinkage capacity, good casting performance, casting defects. But the mechanical properties and machining process performance is not as good as A356 alloy. Chemical Composition Element Symbol Component Range (Mass %, %) Remarks (Maximum Allowable or Other Requirements) Si 6.5 - 7.5 Primary alloying element, improves fluidity Mg 0.25 - 0.45 Enhances strength and response to heat treatment Fe ≤ 0.20 Miscellaneous...

In the field of industrial manufacturing, aluminum has become the material of choice in the automotive, electronics, and construction industries due to its lightweight, corrosion-resistant, and high-strength characteristics. However, the core difference between the two processes of aluminum extrusion (Aluminum Extrusion) and aluminum die casting (Aluminum Die Casting) directly affects the production cost, structural accuracy and mass production efficiency. As a deep ploughing aluminum die casting field 20 years of technical experts, ningbo he Xin die casting factory through this paper analysis of the engineering logic of the two processes, and share how to through the precision die casting technology for customers to reduce costs and increase efficiency. Forming principle of the essence of the contrast (the fundamental difference between the way the material flow) aluminum extrusion process through up to 15000 tons of hydraulic pressure, forcing the ingot heated to 400-500 ℃ through the hole of the special mold, this continuous plastic deformation process similar to the "toothpaste squeeze"...

ADC12 (Japan JIS standard 12 aluminum) is a high-performance Al-Si-Cu die-cast aluminum alloy, which implements the JIS H 5302-2000 standard. The alloy is known for its excellent casting fluidity, good machinability and high dimensional stability, and is particularly suitable for the production of complex thin-walled components. Its typical composition (Si 9.6-12.0%, Cu 1.5-3.5%) ensures that the material combines good strength, heat and corrosion resistance while keeping production costs low. In the automotive industry, ADC12 is widely used in the manufacture of key components, including cylinder head covers, various types of sensor housings, engine mounts, transmission components and motor housings and other structural parts. It is one of the most common materials used in the die casting industry. Material Composition JIS Standard Copper Silicon mg Zinc Iron Manganese Ni Sn Aluminum ADC...

This article systematically analyzes the correlation between the material properties of die-casting aluminum alloy ADC12 and shot blasting process, and puts forward a multi-dimensional solution for the frequent shot blasting peeling problem in the industry. The article firstly elucidates the direct influence of ADC12 chemical composition on material properties, revealing the intrinsic correlation between fluctuations in the content of silicon, copper, magnesium and other elements and the fluidity, strength and corrosion resistance of the alloy. Based on the principle of shot peening process, the article analyzes the quantitative role of core variables such as shot parameters and ejection speed on the surface treatment effect, and points out that there is a common shortcoming in the current industry that only focuses on adhesion but ignores the standardization of surface quality. Through mold flow analysis, process parameter optimization and experimental verification, we innovatively constructed a whole chain improvement system from material source control to mold design and equipment maintenance, and combined with the case of electric motor shell, we demonstrated the optimization of exhaust channel, storage...

Applications of Aluminum Aluminum is the most productive and widely used metallic material among non-ferrous metals. It is second only to steel in terms of production of structural metallic materials. All-aluminum engines The advantage of cast aluminum blocks in die-casting production is their light weight, which enables fuel savings through weight reduction. In an engine of the same displacement, the use of an aluminum block engine reduces weight by about 20 kilograms. For every 10% reduction in the car's own weight, fuel consumption can be reduced by 6% to 8%. Disadvantages of chromate surface treatment The waste tank liquid of chromate treatment method contains a large amount of hexavalent chromium ions, and according to GB 8978--1996 Comprehensive Sewage Discharge Standard, the concentration of hexavalent chromium in the waste tank liquid is not more than 0.5mg/L. However, hexavalent chromium ions have carcinogenic effect on human body. Long-term exposure to hexavalent chromium compounds can lead to...

As a core member of Ningbo Hersin's casting technology team, I have been working in the field of high pressure casting, low pressure casting, gravity casting and aluminum materials for more than 20 years, and have led the process development of hundreds of industrial projects. Whenever a customer raises the question of "how to choose between casting and machining", my answer is always: "There is no absolute advantage or disadvantage, only the most suitable combination of technologies for the scene." The following technical principles, practical experience and industry trends in three dimensions, in-depth analysis of the core differences between the two and the logic of choice. What is casting? Casting is melting metal, manufacturing casting, and pouring molten metal into the casting, solidification to obtain a certain shape and performance of the casting molding method. Casting and other parts molding process, compared with low production costs, process flexibility, almost independent of the size and shape of the part...

The process principle of plastic spraying Electrostatic powder coating technology through high-voltage electrostatic adsorption to achieve high efficiency coating. The core process is: compressed air will be powder coating conveyed to the electrostatic spray gun, the muzzle of the high-voltage generator produces 80-100kV static field triggered corona discharge, so that the atomized powder charged; charged particles in the electric field under the action of directional adsorption on the surface of the grounded workpiece, along with the thickening of the coating to form a charge buildup, the uniformity of the film through the homogeneous static repulsive autonomy control; and ultimately, the formation of dense film by the high-temperature curing to complete the whole process of industrialized application from powder adsorption to coating formation. The whole process from powder adsorption to coating molding is completed. Workflow Process Name Purpose of Process and Detailed Steps Related Equipment Related Materials 1. Pre-treatment Purpose: To remove the pollutants on the surface of the workpiece and form a phosphate layer that prevents rust and enhances adhesion Detailed Steps: ① Degreasing: Acid...

Friction welding definition Friction welding is the use of relative friction movement of the weldment to produce heat to achieve a reliable connection between the materials of a pressure welding method. The welding process is under the action of pressure, the relative movement of the material to be welded between the friction, so that the interface and its nearby temperature rises and reaches a thermoplastic state, with the role of the top forging force interfacial oxide film broken, the material undergoes plastic deformation and flow, through the interface element diffusion and recrystallization of the metallurgical reaction and the formation of joints. Friction welding principle Two round section of the metal workpiece in the friction welding before, respectively, can be clamped in the rotating chuck and can move forward to pressurize the chuck. At the beginning of welding, the workpiece 1 rotates at high speed, the workpiece 2 moves in the direction of the workpiece 1 and contacts, and a large enough friction pressure is applied to start the friction heating process. After a period of friction, the joint...

Author: Senior Engineer of Ningbo Hexin Molding Co., Ltd (20 years of experience in casting industry) 1. Strategic Value of Aluminum Alloy Materials With the deepening of global carbon emission reduction policy, the automotive industry is experiencing a structural transformation from "steel-based" to "multi-material synergy". Aluminum alloy materials have become the core breakthrough in realizing vehicle lightweighting by virtue of their low-density characteristics and recyclable advantages. In the architecture of new energy models, aluminum alloy die castings have penetrated into the body frame, three electric systems, chassis structure and other key areas, forming a lightweight solution covering the whole body. Current industrial practice shows that the use of modular die casting technology can significantly reduce the number of parts and assembly complexity. Typical cases show that through the structural integration and process innovation, a model of body-in-white successfully realized material weight reduction and production...

Machining Machining as the core technology of modern manufacturing industry, through lathe, milling machine, grinder and other professional equipment on metal, plastic and other workpieces for cutting, grinding, drilling and other processes, precise control of the geometry of the parts, the structure of the dimensions and surface finish, to ensure that from the automotive engine components to the aerospace precision parts of the whole field of manufacturing needs. With the deep integration of CNC technology and automated production lines, the machining process has realized the transformation and upgrading from traditional manual operation to intelligent programming control, which improves machining efficiency while effectively controlling production costs. The quality control system that strictly follows international standards ensures process stability in mass production through real-time monitoring of tool wear status and optimization of machining parameters. Under the current trend of Industry 4.0, machining is moving towards flexible...

In today's era of rapid development of manufacturing industry, low pressure casting technology has become one of the core processes for the production of high-end metal parts. The excellent performance of the equipment is inseparable from the standardized operation and refined management. This operation specification to improve the yield rate, to ensure production safety as the core objective, combined with many years of practical experience and the latest technology standards, systematized from the daily start-up, production process to the maintenance of the equipment of the whole chain of operating points. Whether you are new to this equipment or a technician who wants to optimize the production process, this guide provides you with a clear and practical reference basis. Daily start-up and production Routine operations during production Daily shutdown Key operations and parameters to maintain casting yields Daily polishing experiments to confirm material goodness. Effective cleaning: there...

Low-pressure casting is a casting method in which molten metal is injected into a mold cavity by gas pressure. Compared with high-pressure casting, low-pressure casting can improve the surface quality of castings, reduce porosity, and suitable for casting more complex shapes. In the process of low-pressure casting, the composition and design of the mold is critical, which directly affects the quality of castings, production efficiency and mold life. In this paper, we will discuss the main components of the low-pressure casting mold and their impact on the casting quality. The main components of low-pressure casting mold Low-pressure casting mold by the six core components of the synergistic effect: mold cavity as the core of the molding, the use of H13 hot work die steel precision machining, to ensure that the ± 0.15mm dimensional tolerances and Ra ≤ 0.8μm surface finish; injection port through the 60 ° tapered tangent design to achieve the laminar flow of the filling, the flow of the...

As an engineer deeply involved in aluminum alloy forming for more than 20 years, I am often asked about the core differences between aluminum extrusion and aluminum die casting. In this article, I will combine the high-pressure/low-pressure/gravity casting practical experience to make a systematic comparison from material science, process principle to business decision. What is aluminum extrusion? Aluminum extrusion is a solid-state process of extruding through a die, belonging to solid-state plastic forming, commonly used in the production of assembly line aluminum profiles, heat dissipation aluminum parts and so on. At its core, aluminum rods heated to a plastic state (400-500°C) are fed into an extruder and forced through a die of a specific cross-sectional shape to form a continuous profile, which can be used to manufacture long-sized products such as door and window frames, rails, and other long products (longitudinal lengths of up to 10 meters or more). Advantages of Aluminum Extrusion Aluminum extrusion products are lightweight, corrosion-resistant, and have low die investment costs (about 30,000...

As a living fossil of industrial civilization, the evolution of CNC lathe maps the eternal pursuit of human precision manufacturing. From 1300 BC Egyptian craftsmen with rope-driven wooden rotary bed, to the 21st century equipped with AI algorithms five-axis intelligent machine tools, the technology has always been in the redefinition of the "precision" of the boundaries of the industrial revolution period of steam-powered lathe will be compressed to 0.1mm processing error, while the modern CNC system through the scale closed-loop control has achieved 0.0000mm. During the industrial revolution, steam-powered lathes compressed machining errors to 0.1mm, while modern CNC systems have realized microscopic control of 0.001mm through closed-loop scale control. Especially in the field of high-performance aluminum alloy parts manufacturing, the multi-axis synergy of CNC lathe has completely changed the traditional process: Take the new energy vehicle motor shell as an example, the composite machining of its heat dissipation tooth piece and bearing bit can be completed at one time in the integrated Y-axis power turret of the CNC system, which can improve the efficiency of 400% compared with the traditional processing efficiency in sequence, and the same ...

Die casting machine is the market is more widely used mechanical products, in many industries need to use, then you know what are the top ten die casting machine brand list? The following by more than 20 years of aluminum die casting experience ningbo he Xin company for you to introduce the world's top ten brands of die casting machine. 1, Lijin / L.K Lijin Technology Group (founded in 1979 in Hong Kong) as a global die casting equipment leader, the first to realize the cold / hot room die casting machine and five-axis CNC machining centers integrated production. 2008 strategic merger and acquisition of Italy IDRA, the global market share exceeded 32%, of which more than 2800T large-scale die casting unit of the domestic market share for 15 consecutive years over 65%. 65%. The DCC series of real-time closed-loop control system developed by the company has improved the precision of die casting to ± 0.01mm (ISO international standard certification). 2, Izumi Guangdong Izumi (stock code ...

What is centrifugal casting? Centrifugal casting is a liquid forming process in which liquid metal is poured into a rotating mold by the centrifugal force generated by the rotating mold (up to 150 times the force of gravity) and rotated at high speeds (usually 250 to 1500 r/min) so that it fills the mold and solidifies under the action of centrifugal force to form a casting. The process is particularly suitable for the manufacture of marine engine cylinder liner, aerospace and high temperature parts and other harsh working conditions products - more measured data show that the centrifugal casting aluminum alloy pieces of tensile strength than the traditional sand casting to enhance the 25% or more. How Centrifugal Casting Works The centrifugal casting process begins with the injection of liquid metal into a rotating, high-temperature mold. Depending on the specific requirements of the design, the mold can rotate vertically or horizontally. During this process, centrifugal force evenly distributes the liquid metal at a pressure close to several times the force of gravity...