What is the best way to transition from die casting to CNC mach

• Posted by vincenttomei laz December 23, 2021 - Filed in Technology - #Precision Parts  - 585 views

  Making a decision on which manufacturing process to use can be difficult because there are so many different factors to take into consideration. You should begin with the die casting process because it can produce the quantities you require while maintaining the tolerances you require. However, it is possible that you will need to switch to a different manufacturing process in the future. In the event that the demand for parts changes, your production lead time and quality requirements must be adjusted, this may occur.
  
  In which cases should CNC Machining Nylon machining be preferred over casting?
  
  Why would you choose to redesign your parts and use CNC machining instead of die casting if you start with die casting? Despite the fact that casting is more cost-effective for high-volume parts, CNC machining is the most cost-effective option for low- to mid-volume components.
  
  

   

  In addition, CNC machining can better meet the tight delivery cycle because it eliminates the need to fabricate molds and saves time and money by doing so in real time during the machining process. Furthermore, machining is usually required as an auxiliary operation in the case of die casting in any case. Post-processing is used to achieve specific surface finishes, drill and tap holes, and to ensure that cast parts that are matched with other machining service in the assembly meet the strict tolerances required by the manufacturer. Furthermore, post-processing necessitates the creation of custom fixtures, which is a time-consuming and difficult process in and of itself.
  
  CNC Medical Machining machining can also result in higher-quality parts being produced. With increased confidence, you can rest assured that each part will be manufactured consistently and within your tolerance requirements, as specified. Inherently more precise manufacturing processes such as CNC Swiss Machining machining and casting eliminate the possibility of casting defects such as pores, dents, and improper filling that can occur during the casting process.
  
  Furthermore, casting complex geometries necessitates the use of more complex molds as well as the addition of additional components such as cores, sliders, and inserts. All of these factors add up, and even prior to the start of production, a significant amount of money was spent on costs and time. Not only are complex parts more valuable for  machining, but so are small parts. For example, CNC machine tools can quickly and easily manufacture flat plates by cutting stock materials to the desired size and thickness and then assembling them together. Casting the same metal plate, on the other hand, can easily result in filling, warping, or sinking issues.
  
  What is the best way to convert a casting design into a CNC machining design?
  
  If you decide to redesign the part in order to make it more suitable for machining, you will need to make a number of important modifications. Consider the draft angle, grooves and cavities, wall thicknesses, critical dimensions and tolerances, and material selection when designing a draft angle drafter.
  
  Remove the draft angle from the equation.
  
  If you had originally considered casting when designing the part, you should have taken the draft angle into consideration. As is the case with injection molding, the draft angle is critical in order for the part to be removed from the mold after it has completely cooled. It is not necessary to use the draft angle when machining and it should be avoided. The use of a ball-end milling cutter is required for designs that include draft angles, which increases the processing time overall. Extra machine time, additional tools, and additional tool change operations all result in increased costs; therefore, save some money by foregoing the draft angle design.
  
  Keep large and deep grooves and hollow cavities to a minimum.
  
  It is common practice in casting to avoid shrinkage and hollow cavities because thicker areas are frequently not adequately filled, which can result in defects such as denting. These same functions take a long time to complete, resulting in a significant amount of waste material. Furthermore, because all of the forces are concentrated on one side of the part, once the part is removed from the fixture, the stress in the deep cavity may cause it to warp. It is possible to fill grooves to prevent warping or deformation, if they are not a critical design feature and if you are willing to accept the additional weight.

   

  

  
  The appointment is made the thicker the wall is.
  
  In the same way, you must consider the thickness of the walls. Depending on the structure, function, and material of a given casting, the recommended wall thickness is usually quite thin, ranging between 2.0 and 3.5 millimeters in thickness. The wall thickness of very small parts can be even smaller, but the casting process must be fine-tuned in order to achieve this. cnc mill machining, on the other hand, has no upper limit on the thickness of the walls. In fact, thicker is usually preferable because it requires less processing and results in less waste of raw materials. A further advantage is that warping or deflection risks associated with thin-walled parts are eliminated during the manufacturing process.
  
  Tolerance is extremely strict.
  
  Casting, unlike CNC machining, cannot typically maintain tight tolerances, so you may have had to make concessions or compromises in the casting design. By eliminating these compromises and implementing tighter tolerances, CNC machining allows you to fully realize your design intent and produce more precise parts than you could previously.
  
  Consider utilizing a greater variety of materials.
  
  Last but not least, when compared to casting, CNC machining allows for a greater variety of materials to be used. Aluminum is a very common die casting material that is used in a variety of applications. Die casting also involves the use of zinc and magnesium, which are both common metals. To manufacture high-quality parts from other metals, such as brass, copper, and lead, more specialized processing is required. Carbon steel, alloy steel, and stainless steel are rarely die cast because they are prone to rusting in the process of production.
  
  Precision Parts machining, on the other hand, has a greater variety of metals that are suitable for machining. For your parts, you could even try to make them out of plastic, because there are many different types of plastics available that are both easy to process and have useful material properties. Despite the fact that casting is a fantastic process in some instances, CNC machining is sometimes a better fit for the function or manufacturing requirements of the part. If this is the case, ensure that your parts are redesigned in order to achieve the most efficient and cost-effective CNC machining process possible.