Die Casting Solution Profiles
Household appliances - material waste is eliminated and high strength, creep resistant zinc alloy meets operating specifications.
Die casting a shaft configuration used in a clothes dryer
increases productivity and eliminates the waste of a screw machining
operation. Finite Element Analysis (FEA) was used to
prove the viability of a staking operation between the shaft and
its mating part. ZAMAK 3 and 5 zinc alloys creeped in the
shaft's operating environment, so FisherCast Global
recommended ACuZinc. With the highest structural strength
and creep resistance of all zinc alloys, ACuZinc meets the
required specifications. A tool insert reduces tooling cost for a
second shaft configuration.
Flash-free, net shape components with tight tolerances have:
A manual override shaft used in heating system damper controls is die cast in ZAMAK 2 alloy. Slides in the tool produce a blind hole at each end of the component as well as the gear produced to an AGMA Quality Class 6 specification. Dimensional tolerances are typically ±0.1 mm (±.004").
Automotive - circular runout critical for performance/ part-to-part consistency.
To ensure uniform fill of the tooth form
in a front end plate of a windshield
wiper motor, FisherCast Global's unique
center (through-hole) gating process
injects molten alloy from the inside to
the outer most edges of the
component. Three slides produce the
three blind holes which are
perpendicular to the tooth form.
Industrial controls - unique gating technique ensures quality of complex internal splines/no secondary operations.
A hub used in as a control mechanism for gas valves requires
four side cores in the die cast tool to produce the undercuts.
FisherCast Global's unique center gating provides uniform alloy
distribution to form the internal splines and castellated end.
Hardware - high strength ACuZinc alloy meets performance specifications.
The ZAMAK range of alloys could not meet the strength
performance requirements of a rack used in a door lock
assembly. With long experience in die casting ACuZinc,
FisherCast Global recommended the use of this higher
copper content alloy which provides enhanced tensile
strength. The tolerances held on the tooth forms were
critical.
Hand and edge tools - die casting improves quality/reduces manufacturing costs.
Costs are reduced and quality improved by casting a shift cap for a racheting socket wrench. A slide is used to keep the head of the cap free of parting line witness marks.
Electronics / Telecom - Complex geometry is cast flash-free, zinc alloy provides EMI/RFI shielding properties.
The complex geometry of an electronic
connector for audio systems needed a
very complex tool configuration to
produce features on five sides of the
component. Normally this would be
accomplished with a single cavity tool,
which increases production cost.
FisherCast Global's tooling technology
allows all features to be cast in a two cavity tool with cores pulled on five of the
components six planes.
Stronger Gears at Lower Cost
Die casting is well known for reducing manufacturing
costs in external, internal, face, helical, spur, and worm
gears -- casting them to AGMA 6 to 8 specification.
Most tooth forms can be cast, including teeth with helix
angles as great 20°. Up to 50 external threads/inch are
cast flash-free to Class 2A tolerance without cleaning or
chasing, as are multi-start threads.
Gating through the center bore of
this horizontal gear drive ensures
uniform alloy distribution for
consistent fill of the thread and
gear tooth forms. The walls of the
center hole are held parallel within
+/-0.0005 in. The drive gear, used
in an automobile seat, is cast
ready to use with no finishing or
deburring operations required.
The potential for piece price reduction is the usual motivation for high-volume die
casting. Economies of scale start at 50,000 pieces annually. Numerous factors can affect
production economics. These include component complexity, alloy properties, die-casting
technology used, precision of the die-cast tool, and cycle rate. One reason die casting
can be thrifty is that a single cast part often replaces multiple components. And it is
frequently possible to incorporate features in the casting that eliminate secondary milling,
boring, reaming, and grinding operations. Convert with FisherCast Global and Save up to 70%!
Our leading-edge technology can deliver better components at
lower cost. You could save up to 70% by switching to
FisherCast Global's unique die casting process from your
current small component production method.
For example, if you are using the powdered metal process, you
could be paying for more strength than you really need. Or, if
you are using the screw machine process, you may be paying
for wasted material.
Switching to FisherCast Global gives you three immediate
benefits:
High precision, flash-free tooling, combined with our
proprietary die casting systems, enables FisherCast Global to
produce your components to the tightest tolerances over long
production runs, and the net shape components are ready-to-use
with no secondary trimming or deburring required.
In fact, cross-holes and other complex features can be made as part of the die casting process. You can even die cast logos, part numbers and other coding information. ACuZinc and other higher copper content zinc alloys can also be used for applications that require special mechanical properties.
So you get more complex shapes with tighter tolerances and better part-to-part consistency for less than you are paying now - often a lot less. Our experienced Application Engineers will work with you to deliver components with the characteristics and performance you require.
Household appliances - material waste is eliminated and high strength, creep resistant zinc alloy meets operating specifications.
Die casting a shaft configuration used in a clothes dryer
increases productivity and eliminates the waste of a screw machining
operation. Finite Element Analysis (FEA) was used to
prove the viability of a staking operation between the shaft and
its mating part. ZAMAK 3 and 5 zinc alloys creeped in the
shaft's operating environment, so FisherCast Global
recommended ACuZinc. With the highest structural strength
and creep resistance of all zinc alloys, ACuZinc meets the
required specifications. A tool insert reduces tooling cost for a
second shaft configuration. Flash-free, net shape components with tight tolerances have:
- overall diameter held within ±0.025 mm (±.001")
- dimensional tolerances of ±0.05 mm (±.002")
A manual override shaft used in heating system damper controls is die cast in ZAMAK 2 alloy. Slides in the tool produce a blind hole at each end of the component as well as the gear produced to an AGMA Quality Class 6 specification. Dimensional tolerances are typically ±0.1 mm (±.004").
- unique internal shape is formed without machining
- flash-free net shape - no secondary finishing
- part-to-part consistency.
Automotive - circular runout critical for performance/ part-to-part consistency.
To ensure uniform fill of the tooth form
in a front end plate of a windshield
wiper motor, FisherCast Global's unique
center (through-hole) gating process
injects molten alloy from the inside to
the outer most edges of the
component. Three slides produce the
three blind holes which are
perpendicular to the tooth form. - Critical to the front end plate's performance is the circular runout of the tooth form which is held to within 0.08 mm (.003") relative to its datum surfaces
- Dimensional tolerances are typically ±0.13 mm (±.005").
Industrial controls - unique gating technique ensures quality of complex internal splines/no secondary operations.
A hub used in as a control mechanism for gas valves requires
four side cores in the die cast tool to produce the undercuts.
FisherCast Global's unique center gating provides uniform alloy
distribution to form the internal splines and castellated end. - Circular runout of the outside diameters is held within 0.076 mm (.003").
- Complex geometry is cast net shape - no secondary operations are needed.
Hardware - high strength ACuZinc alloy meets performance specifications.
The ZAMAK range of alloys could not meet the strength
performance requirements of a rack used in a door lock
assembly. With long experience in die casting ACuZinc,
FisherCast Global recommended the use of this higher
copper content alloy which provides enhanced tensile
strength. The tolerances held on the tooth forms were
critical. - The height and the depth of the tooth forms are held within ±0.025 mm (±.001") relative to the pitch line.
- The tooth crest radii are held within ±0.051 mm (±.002")
Hand and edge tools - die casting improves quality/reduces manufacturing costs.
Costs are reduced and quality improved by casting a shift cap for a racheting socket wrench. A slide is used to keep the head of the cap free of parting line witness marks.
- Part-to-part consistency over long production runs
- Net shape - no secondary operations
- Inserts reduce the cost of casting different size shift caps
Electronics / Telecom - Complex geometry is cast flash-free, zinc alloy provides EMI/RFI shielding properties.
The complex geometry of an electronic
connector for audio systems needed a
very complex tool configuration to
produce features on five sides of the
component. Normally this would be
accomplished with a single cavity tool,
which increases production cost.
FisherCast Global's tooling technology
allows all features to be cast in a two cavity tool with cores pulled on five of the
components six planes. - Cores forming the holes seal tightly, producing a flash-free component
- Zinc alloy's inherent EMI/RFI shielding properties reduce manufacturing cost
- Dimensional tolerances typically ±0.05 mm (±.002").
Stronger Gears at Lower Cost
Die casting is well known for reducing manufacturing
costs in external, internal, face, helical, spur, and worm
gears -- casting them to AGMA 6 to 8 specification.
Most tooth forms can be cast, including teeth with helix
angles as great 20°. Up to 50 external threads/inch are
cast flash-free to Class 2A tolerance without cleaning or
chasing, as are multi-start threads. Gating through the center bore of
this horizontal gear drive ensures
uniform alloy distribution for
consistent fill of the thread and
gear tooth forms. The walls of the
center hole are held parallel within
+/-0.0005 in. The drive gear, used
in an automobile seat, is cast
ready to use with no finishing or
deburring operations required. The potential for piece price reduction is the usual motivation for high-volume die
casting. Economies of scale start at 50,000 pieces annually. Numerous factors can affect
production economics. These include component complexity, alloy properties, die-casting
technology used, precision of the die-cast tool, and cycle rate. One reason die casting
can be thrifty is that a single cast part often replaces multiple components. And it is
frequently possible to incorporate features in the casting that eliminate secondary milling,
boring, reaming, and grinding operations. Convert with FisherCast Global and Save up to 70%! Our leading-edge technology can deliver better components at
lower cost. You could save up to 70% by switching to
FisherCast Global's unique die casting process from your
current small component production method.
For example, if you are using the powdered metal process, you
could be paying for more strength than you really need. Or, if
you are using the screw machine process, you may be paying
for wasted material. Switching to FisherCast Global gives you three immediate
benefits: - Multiple features and complex geometries
- Superior part-to-part consistency
- Elimination of secondary operations
High precision, flash-free tooling, combined with our
proprietary die casting systems, enables FisherCast Global to
produce your components to the tightest tolerances over long
production runs, and the net shape components are ready-to-use
with no secondary trimming or deburring required. In fact, cross-holes and other complex features can be made as part of the die casting process. You can even die cast logos, part numbers and other coding information. ACuZinc and other higher copper content zinc alloys can also be used for applications that require special mechanical properties.
So you get more complex shapes with tighter tolerances and better part-to-part consistency for less than you are paying now - often a lot less. Our experienced Application Engineers will work with you to deliver components with the characteristics and performance you require.
