(KYLT provides plastic injection molds design and making, plastic molding parts manufacturing service. Especially in the manufacturing of medical device precision spare parts injection molds and parts.)

Which metal material is suitable for the knob?

As the original design of this knob adopts plastic material, its requiement as follows:

– Plastic Knob Mold Design Requirements:

1. One mold 3cavities, each cavity indicated with a number
2. Hot runner system
3. Gating allowed to any surface
4. Upon ejection, the part must automatically separate from the sprue
5. Sprue remnants shall not affect the part size
6. Central ejector pin on the required area
7. Mold design should enable molding cycle within required seconds
8. Mold lifetime：500,000 ~1,000,000 shots
9. Core and cavity material: 1.2344ESR or equivalent standard mold steel (e.g., H13 or 4Cr5MoVSi)
10. Hardened cavity surface
11. Insulation protection for mold thermal management (insulation boards required)

– Plastic Knob Molding Requirements:

1. PA66+30%GF, Black color
2. Must use new material with quality certification

Die-cast Engineer’s Analysis for this Project:

Which metal material is suitable for this part?

Aluminum and zinc alloys are widely used to produce various designed parts through molds. Therefore, in this project, both materials are suitable.

However, considering the material properties, aluminum die casting requires a larger mold release angle than zinc die casting. Additionally, the injection mold cost for zinc alloy is cheaper than that for aluminum. Based on these factors, our engineer believes that zinc alloy is more suitable for this knob project.

KYLT Zamak die casting service:

Zamak (Zinc) alloy die casting molds design and making

KYLT provides free instant quote when we received customers drawing or samples. If you have a Zinc alloy project or samples, we provide OEM & ODM service. Just send your details to us: cnkylt@aliyun.com

Zamak 3, Zamak 5 Die casting parts manufacturing service:

We have 88T – 150T full auto hot chamber die casting machines to provide 24hrs zamak die casting services. Zinc alloy types: Zamak 3, Zamak 5 or others. Various kind of surface treatment is allowed.

If you have any questions about Zinc/Zamak die casting or aluminum die casting, please feel free to contact us at cnkylt@aliyun.com

Zamak Alloy to instand plastic in the manufacturing of turning knobs最先出现在CNC Machining|CNC Milling & Turning Services|CNC turned parts|。

Introduction

Electric vehicles have revolutionized the automotive industry with their eco-friendly technology. These vehicles are powered by electricity stored in rechargeable batteries, eliminating the need for fossil fuels. The popularity of electric vehicles has led to an increase in demand for die casting aluminum or zinc alloy parts used in electric vehicles. These parts are used in various components of electric vehicles such as the motor, battery casing, and powertrain.

What is Die Casting?

Die casting is a manufacturing process used to produce metal parts with high precision and accuracy. The process involves injecting molten metal into a mold cavity, which is then cooled and solidified. The mold is then opened, and the part is ejected. The die casting process is widely used to produce complex shapes and parts with high dimensional accuracy.

Die Casting Aluminum or Zinc Alloy Parts Used in Electric Vehicle

The die casting process is commonly used to produce aluminum die casting parts or Zamak/Zinc alloy die-cast parts used in electric vehicles. These parts are used in various components of electric vehicles such as:

Battery Casing

The battery casing is an essential component of an electric vehicle. It houses the rechargeable battery that powers the vehicle. Die casting is used to produce lightweight and durable aluminum or zinc alloy battery casings that provide protection to the battery.

Motor Housing

The electric motor is the heart of an electric vehicle. It converts electrical energy into mechanical energy that drives the wheels of the vehicle. Die casting is used to produce lightweight and strong aluminum or zinc alloy motor housings that protect the motor and provide efficient heat dissipation.

Powertrain Components

The powertrain is a critical component of an electric vehicle. It includes the motor, transmission, and drivetrain. Die casting is used to produce lightweight and high-strength aluminum or zinc alloy components for the powertrain, such as transmission cases and differential housings.

Other Components

Apart from battery casing, motor housing, and powertrain components, die casting is used to produce several other components used in electric vehicles, such as suspension parts, steering components, and brake components.

Advantages of Using Die Casting Aluminum or Zinc Alloy Parts in Electric Vehicles

Die casting aluminum or zinc alloy parts used in electric vehicles offer several advantages, such as:

Lightweight

Die casting produces lightweight parts that help reduce the overall weight of the vehicle, improving its energy efficiency and range.

High Strength

Aluminum and zinc alloy parts produced by die casting are strong and durable, providing superior performance and reliability.

High Precision

Die casting produces parts with high dimensional accuracy and precision, ensuring tight tolerances and excellent fit and function.

Cost-Effective

Die casting is a cost-effective manufacturing process that produces high-quality parts at a lower cost compared to other manufacturing processes.

Conclusion

The demand for electric vehicles is growing rapidly, and so is the demand for die casting aluminum or zinc alloy parts used in electric vehicles. These parts offer several advantages, such as lightweight, high strength, high precision, and cost-effectiveness. Die casting is a sustainable manufacturing process that produces high-quality parts at a lower cost compared to other manufacturing processes. As the world moves towards sustainable transportation, die casting aluminum or zinc alloy parts will play a crucial role in the development of electric vehicles.

In conclusion, die casting aluminum or zinc alloy parts used in electric vehicles are essential components that contribute to the performance, efficiency, and safety of electric vehicles. As the demand for electric vehicles continues to rise, the demand for die casting aluminum or zinc alloy parts will also increase. The future of sustainable transportation is bright, and die casting is at the forefront of this revolution.

Get a FREE quotation of your Electric Vehicle Aluminum Zinc (ZAMAK) die casting parts price, Aluminum ZAMAK Zinc die casting mould/mold/die price, please email: cnkylt@aliyun.com

Frequently Asked Questions

Q1. What is the difference between aluminum and zinc alloy die casting?

A1. Aluminum and zinc alloy die casting processes use different types of metals. Aluminum is lightweight and offers excellent corrosion resistance, while zinc is less expensive and offers excellent castability.

Q2. What are the advantages of using aluminum over zinc for die casting electric vehicle parts?

A2. Aluminum is lighter than zinc, providing better energy efficiency and range. It also offers superior corrosion resistance, making it ideal for parts exposed to harsh environmental conditions.

Q3. How does the use of die casting aluminum or zinc alloy parts affect the performance of an electric vehicle?

A3. Die casting aluminum or zinc alloy parts offer superior performance and reliability, as they are strong and durable, and have excellent dimensional accuracy and precision.

Q4. Can die casting be used to produce parts for hybrid vehicles as well?

A4. Yes, die casting can be used to produce parts for hybrid vehicles as well. Hybrid vehicles use a combination of an internal combustion engine and an electric motor, and die casting can be used to produce parts for both.

Q5. Is die casting a sustainable manufacturing process?

A5. Yes, die casting is a sustainable manufacturing process. It produces very little waste and can be recycled, making it an eco-friendly and sustainable manufacturing process.

Q6. Are die casting aluminum or zinc alloy parts used only in electric vehicles, or are they used in other applications as well?

A6. Die casting aluminum or zinc alloy parts are used in various applications other than electric vehicles, such as aerospace, consumer electronics, medical devices, and more. Die casting is a versatile manufacturing process that can be used to produce parts for a wide range of applications.

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Pneumatic hand tool and electric hand tool most use aluminum die casting spare part as the aluminum have good mechanical function and low cost.

What are the advantages of Die Casting method:

Pressure aluminum injection suitable for a range of metal alloys, die casting has the following advantages:

• Saving cost, not only in the part price itself but also in the overall cost of production.
• Produces complex parts to net shape, reducing secondary machining
• High-speed production compared to other manufacturing processes
• Die cast parts are durable and have a long service life
• Produces components with attractive, high-quality surface finishes
• Produces a broad range of shapes and surface textures
• Variable wall thicknesses
• Simplifies the assembly process by integrating fastening elements
• Fewer steps from raw material to finished part
• Tighter tolerances

KYLT Precision CNC machining services (milling & turning service), Fast prototyping, Fixture/Jig/Tooling making, Aluminum die casting & plastic injection parts. Email:cnkylt@aliyun.com +008615195010186

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KYLT Aluminum alloy die casting services:

OEM & ODM products range:

Auto parts, Engine parts, Agriculture equipment parts, Lighting parts, Train parts, etc.

Die Casting Mold material:

H13

Die casting equipment capability: 

Cold chamber die casting machine: 180T, 280T, 500T

Machining equipment:

CNC, Lathe machine, Milling machine, Drilling machine, and so on

Surface treatment:

Powder coating, Anodizing, Chrome plating, Painting, Sand blasting

Aluminum Alloy type:

ADC12, A380, ZL102 aluminum alloy material

What are the Die Casting advantages?

Suitable for a range of metal alloys, die casting has the following advantages:

1. Saving cost, not only in the part price itself but also in the overall cost of production.
2. Produces complex parts to net shape, reducing secondary machining
3. High-speed production compared to other manufacturing processes
4. Die cast parts are durable and have a long service life
5. Produces components with attractive, high-quality surface finishes
6. Produces a broad range of shapes and surface textures
7. Variable wall thicknesses
8. Simplifies the assembly process by integrating fastening elements
9. Fewer steps from raw material to finished part
10. Tighter tolerances

ALUMINUM DIE CASTING PARTS, MADE BY 200-500T COLD CHAMBER DIE CASTING MACHINES:

ZINC / ZAMAK DIE CASTING PARTS, SMALL SIZES PARTS MADE BY HOT CHAMBER DIE CASTING MACHINES, MIDDLE & BIG SIZES PARTS MADE BY COLD CHAMBER DIE CASTING MACHINES:

MAGNESIUM DIE CASTING PARTS, MADE BY MAGNESIUM COLD CHAMBER DIE CASTING MACHINES:

Surface treatment or finishes of Die Casting Part:

1. Only die cast surface
2. Polishing finish
3. Shot blasting finish
4. Painting surface
5. Powder coating

Machining services for Die Casting part:

1. CNC milling
2. Drilling
3. Tapping

Die casting part price:

The calculation of a die casting part price involves：material cost, injection cost, trimming cost, machining cost, surface finish cost, packing cost etc.

Send your die casting project 2D/3D drawing to: cnkylt@aliyun.com , to got a free quotation now.

KYLT Precision CNC machining services (milling & turning service), Fast prototyping, Fixture/Jig/Tooling making, Aluminum die casting & plastic injection parts. Email:cnkylt@aliyun.com +008615195010186

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KYLT Precision Aluminum Alloy Die casting Power, Electric, Hand tools parts manufacturing. cnkylt@aliyun.com +8615195010186

Aluminum die casting Product Description:

1. OEM and ODM 100% 
2. High quality 
3. Best service and best products 
4. Advanced technology and equipment. 

ALUMINUM DIE CASTING PART FEATURES:

1. Application: Auto parts, Engine parts, Agriculture equipment parts, LED Lighting parts, Train parts and so on.
2. Material: 6061,8407, SKD11 or as per customer’s requirements.
3. Die casting equipment: 180T/280T/500T;
4. Mold material: H13
5. Mold life: 30,000-50, 000 shots;
6. Main process:  1> Die casting;
                               2> Deburring;
                               3> Shot blasting;
                               4> Machining;
                               5>Surface treatment

Quick introduction about KYLT die casting capability:

KYLT Aluminum Die Casting Injection Parts. ADC12, A380, ZL102 aluminum alloy material used for die casting workpieces. Precision Machining, Surface treatment is allowed.

KYLT Precision CNC machining services (milling & turning service), Fast prototyping, Fixture/Jig/Tooling making, Aluminum die casting & plastic injection parts. Email:cnkylt@aliyun.com +008615195010186

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Precision Aluminum Alloy Die casting Electrical Appliance spare parts最先出现在CNC Machining|CNC Milling & Turning Services|CNC turned parts|。

Today, we will to introduce the processing methods of aluminum product.

The advantages and characteristics of aluminum are as follows:

1. Low density. The density of aluminum is about 2.7g/cm3. Its density is only 1/3 of iron or copper.
2. High plasticity. Aluminum is malleable and can be made into a variety of supplies by squeezing, stretching and other pressure processing means.
3. Corrosion resistance. Aluminum is a highly charged metal that produces a protective oxide film on the surface of natural conditions or anodization, with much better corrosion resistance than steel.
4. Easy to strengthen. The strength of pure aluminum is not high, but it can be increased by anode oxidation.
5. Easy surface treatment. Surface treatment can further improve or change the surface performance of aluminum. Aluminum anode oxidation process is quite mature, stable operation, in the process of aluminum products has been widely used.
6. Conductelectricity is good, easy to recycle.

PUNCHING OF ALUMINIUM PRODUCT

Cold stamping ALUMINIUM PRODUCT

Use aluminium particles. The extruder table and die are used for one-time forming, which is suitable for cylindrical products or product shapes that are difficult to achieve in drawing process, such as ellipse, square and rectangular products. (Fig. 1 machine, Fig. 2 aluminium particles, Fig. 3 products)

The tonnage of the machine is related to the cross section area of the product. The gap between the upper die punch and the lower die tungsten steel is the wall thickness of the product. The vertical gap between the upper die punch and the lower die tungsten steel is the top thickness of the product when the pressing is completed. (Fig. 4)

Aluminum Cold Stamping Advantages:

Shorter mold making cycle and lower development cost compared with drawing die.

ALUMINUM COLD STAMPING Disadvantage:

The production process is long, the product size fluctuates greatly in the process, and the labor cost is high.

Tensile/DRAWING process for ALUMINIUM PRODUCT

Use aluminium sheet. The continuous punching machine and die are used to deform many times to meet the requirement of shape, which is suitable for non-cylindrical products (aluminium products with bending). (Fig. 5, Fig. 6, Mould, Fig. 7, Fig. 7)

Aluminum tensile or drawing process advantages:

Complicated and multi-deformation products have stable size control and smooth surface in the production process.

ALUMINUM TENSILE OR DRAWING PROCESS Disadvantage:

Die cost is high, development cycle is relatively long, and the selection and precision of machine platform is high.

CNC machining Aluminum product

Aluminum CNC turning and CNC milling is widely used to making aluminum products.

Aluminum CNC turned part, by CNC LATHE can mass making turned parts with low cost, and machined parts have bright and smooth surface.

Aluminum CNC milled part, by CNC machine center or CNC router to making rapid prototype, fixuture, mold and other aluminum products. The cost is expensive, but can got finised parts quickly from design to product.

Aluminum DIe casting

Aluminum die casting product is producing engineered metal parts by forcing molten Aluminum metal under high pressure into reusable steel molds.
Die castings are among the highest volume, mass-produced items manufactured by the metalworking industry, and they can be found in thousands of consumer, commercial, and industrial products. Die cast parts are important components of products ranging from automobiles to toys. Parts can be as simple as a sink faucet or as complex as a connector housing.

aluminium product SURFACE TREATMENT

Sandblasting (shot blasting)

The process of cleaning and roughening metal surface by the impact of high-speed sand flow.

The surface treatment of aluminium parts by this method can obtain a certain degree of cleanliness and different roughness, and improve the mechanical properties of the workpiece surface. Therefore, the fatigue resistance of the workpiece is improved, the adhesion between the workpiece and the coating is increased, the durability of the coating is prolonged, and it is also conducive to the leveling and decoration of the coating. 。 This process is often seen in various products of Apple.

Polishing

The surface roughness of workpiece is reduced by mechanical, chemical or electrochemical action to obtain a bright and smooth surface processing method. Polishing technology is mainly divided into: mechanical polishing, chemical polishing, electrolytic polishing. Aluminum parts can approach mirror effect of stainless steel after mechanical polishing and electrolytic polishing. This process gives people a feeling of high-grade, simple and fashionable future.

Wire drawing

Metal wire drawing is a process of repeatedly scraping aluminium sheet out of line with sandpaper. Drawing can be divided into straight wire drawing, screwed wire drawing, screwed wire drawing, screwed wire drawing. Metal wire drawing process can clearly show each fine trace, so that the metal matte gloss in the exudation of fine silk luster, products both fashionable and technological sense.

High-light cutting/Machining

The diamond knife is strengthened on the spindle of the high-speed CNC router to cut the parts, and a local bright area is generated on the surface of the product. It also named: CNC machining. The brightness of cutting highlight is affected by the speed of the milling bit. The faster the bit speed is, the brighter the cutting highlight is. On the contrary, the darker the cutting highlight is and the easier the cutter grain is. In recent years, high-light CNC milling technology has been used in some metal frames of high-end TV sets. In addition, the anodic oxidation and wire drawing technology make TV sets full of fashion sense and sharp sense of science and technology.

Anodic oxidation

Anodic oxidation refers to the electrochemical oxidation of metals or alloys. Under the corresponding electrolyte and specific technological conditions, aluminum and its alloys form an oxide film on the aluminium products (anodes) due to the action of applied current. Anodic oxidation can not only solve the defects of surface hardness and wear resistance of aluminium, but also prolong the service life of aluminium and enhance its beauty. It has become an indispensable part of surface treatment of aluminium. It is the most widely used and very successful technology at present.

Two-color anode

Dual-color anode refers to the process of anodizing a product and giving different colors to a specific area. Dual-color anodizing process is seldom used in TV industry because of its complex process and high cost, but through the contrast between the two colors, it can better reflect the high-end and unique appearance of the product.

More information about Machined parts surface treatment, please kindly visit: KYLT MACHINED PARTS

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