Die Casting News

Although die casting lubricant is continuously exposed to changing pressures and velocities and differing degrees of wear, a dynamic equilibrium – and, therefore, realistic data – may be attained through careful control.

Excerpt from the May 2018 Issue of Gear Solutions by K.D. Clarke and C.J. Van Tyne

Both hot- and cold-chamber die casting are batch-type processes in which steady-state conditions are never fully achieved and the initial lubricant supply must perform adequately for the duration of the operation. The lubricant is continuously exposed to changing pressures and velocities, and wear or pickup products in the lubricant also continuously vary, although a dynamic equilibrium may be attained through careful control. The absence of steady-state conditions creates challenges for the systematic analysis of lubrication and wear in forging processes.

In many ways, various forging processes are competitive with one another, and the competitive position of each is greatly influenced by the lubrication system employed. Thus, hot forging followed by finish machining may be replaced by cold forging, with all the associated advantages, provided that a suitable lubricant can be found. Indeed, economy of production has often been the major impetus for the development of new forging processes and associated lubrication techniques.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Gear Solutions

Cost savings, a streamlined production process, and increased quality are only a few of the reasons why die casting is an excellent alternative for manufacturing small gears.

Excerpt from the October 2004 issue of Gear Solutions by Stuart Burke

For many applications, zinc alloy die cast gears provide an opportunity to cut manufacturing costs dramatically and improve part-to-part consistency. The cost of simple spur gears, as well as complex helical and worm gears, can be cut by up to 80 percent. Die casting can enhance rack gear performance by incorporating features unattainable by other manufacturing methods.

Bold statements? Not really. High pressure, hot chamber die casting machines and high precision tooling debunk the myths that many have considered to be the limitations of the die casting process. Extremely tight tolerances can be held over long production runs, and gears are cast net-shape and flash free, ready for use with no secondary finishing operations required. And precision die casting leaves no room for variations. Part to part consistency is inherent in the tooling.

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Tags: Die Casting, Die Casting Release Agents, Die Casting Lubricants, Die Casting Release Agent, Die Casting Lubricant, Die Casting Process, die casting lubricant management, Gear Solutions