What Are The Rules For Creating Good Designs For General Die Castings?

2024-09-13 11:09:54

Techniques that ensure good designs for general die casting parts to abide by strict standards, including but not limited to the following rules:

There should be no undercuts.

The walls of the die casted part should have a uniform thickness.

Parts should have curved surfaces in order to avoid any faults due to sudden changes in direction of flow.

Bosses should be added to the general die parts in order to avoid additional machining.

Adequate draft angles and fillets should be added.

There should be openings for any additions post-production.

Proper identification of the general die cast part should be observed.

CNC workpiece surface treatment process:

We support one-stop surface finishing to meet the visual and functional requirements of any design. Including brushing ,sanding, sand blasting, mirror polishing, painting, printing, laser etching, anodizing, electroplating, chroming, powder coating, etc.

BRUSHING

Brushing is a surface treatment process in which abrasive belts are used to draw traces on the surface of a material, usually for aesthetic purposes. Most commonly applied to aluminum. According to the brushed pattern, brushed aluminum sheets are mainly divided into straight wire brushing, chaotic brushing, corrugated brushing, rotary brushing, thread brushing, etc.

Although suitable for a handful of metals, brushing is most commonly applied to aluminum.

Design Considerations: Brushing is not recommended for parts needing a high level of corrosion resistance.

PAINTING Painting involves spraying a layer of paint onto the surface of the part. Colors can be matched to a Pantone color number of the customer’s choosing, while finishes range from matte to gloss to metallic. IDEAL can achieve painting effect like  Gloss, semi-gloss, flat, metallic, textured. 

We can also simulate a specific Mold-Tech texture or soft touch to achieve a feel similar to the texture or over-molding of injection molded parts.   Functional Coatings: UV coating is able to resist ultraviolet radiation and protect the underlying material to enhance the durability and wear or scratch resistance. 

With EMI, the coating is used to shield or contain electronic equipment from magnetic fields or interference.   Design Considerations: POM and PP materials do not have the required adhesiveness for painting, and Sanding should take place before painting.

Smooth sandpaper polishing can remove machining marks, burrs, machine lines, and adhesive marks on the surface of the parts. The flatness of the part will be improved and roughness will be reduced to create a smooth and uniform look.

Each grits of the sandpaper are : 120/220/320/400/600/800/1000/1200/1500/2000/2500/

Sanded to 600 grit sandpaper surface finish is Ra 0.8 μm;

Sanded to 1000 grit sandpaper surface finish is Ra 0.4 μm;

Mirror polished and clear polished surface finish is Ra 0.1-0.05 μm.

 Precision requirements cannot be too high when using sand polishing. Parts with very complicated feature structures are not suitable for the process.

BEAD BLASTING

Bead blasting adds a uniform matte surface finish on a machined part, removing the marks of tool and sandpaper. It is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, or remove surface contaminants. The size of the air pressure and the size of the glass beads are the main process parameters. Glass beads come in different sizes from #80 to #220.

Due to the impact and cutting effect of the abrasive material on the surface of the workpiece, the properties of the workpiece surface — such as its roughness and uniformity — are altered and improved

 Masking or plugging is available for areas with tight tolerances. Complex, fine and intricate geometries may be difficult to blast evenly. Thin walls should not be blasted, for risk of deformation.