To reduce the cost of aluminium alloy die casting, practical strategies should be adopted. For example, simplify the part structure, maintain uniform wall thickness, and set a reasonable draft angle. Choose cost-effective aluminum alloys and reduce unnecessary processing steps. Optimize die casting mold design and stabilize key process parameters. Shorten the production cycle and reduce the scrap rate. These measures can greatly improve efficiency and effectively control costs while ensuring quality.
This article will comprehensively explain how to effectively reduce the cost of aluminum die casting from aspects such as design optimization, mold efficiency, material selection, die casting process, post-processing, and cost accounting. Let’s continue reading to explore each cost-saving strategy in detail.
Part Design Optimization
Simplify the Part Structure
Simplify the structure to reduce die casting parts’ complexity by removing sharp corners, undercuts, and unnecessary ribs. This can save material costs and shorten production cycles.
Maintain Uniform Wall Thickness
Uniform wall thickness helps molten aluminum fill and cool smoothly, improves dimensional accuracy, and reduces the scrap rate of aluminium die casting components, thereby reducing material waste and rework costs.
Reasonable Draft Angle and Fillet
The draft angle facilitates demolding, reduces wear, and extends die casting mold life. Fillet design helps improve flow and reduce the risk of defects. This reduces mold repair, scrap, and downtime costs.
Functional Integration Design
Combining multiple functions into one casting reduces assembly time and fastener use, as well as the risk of misalignment.
It saves labor costs and improves structural strength and reliability, especially for complex die casting products.
Optimize Dimensional Tolerances
Set tight tolerances only for key performance or assembly areas, and relax other part sections appropriately.
Excessive precision will increase processing and quality inspection costs in the die casting process.
Mold Efficiency Optimization
Design High-Performance Molds
Using multi-cavity molds or combination molds in large-scale production can increase production capacity and reduce unit costs.
Modular design facilitates rapid maintenance and configuration changes, improving die casting mold utilization.
Extend Mold Life
Select high-quality tool steel combined with heat-resistant coating to resist thermal fatigue and corrosion.
Regular mold maintenance can reduce downtime and replacement frequency, and reduce long-term use costs.
Optimize the Gate and Runner System
Optimize gate position through flow simulation, improve metal fluidity, reduce casting defects and rework, thereby reducing scrap rate and material costs for die casting products.
Material Selection
Choose Cost-Effective Aluminum Alloys
Avoid using high-cost special materials unless necessary. General aluminum alloys such as A380 or ADC12 can be selected, which have good strength, corrosion resistance, and castability.
Reduce Material Waste
By optimizing the volume and filling rate of parts, lightweight design can be achieved, and the amount of raw aluminum can be reduced.
At the same time, internal waste can be recycled to further reduce material consumption in die casting aluminum.
Optimize the Casting Process
Choose the Appropriate Die Casting Process
Depending on the size, complexity, and quality requirements of the parts, different processes such as cold chamber, vacuum die casting, or squeeze casting can be selected.
Proper matching can improve molding efficiency, reduce defects, and reduce production costs from the source.
Mold Temperature Control
Stable mold temperature can reduce defects, improve casting consistency, and yield rate.
The die casting process can be more stable, reducing manual intervention and downtime, thereby reducing production costs.
Shorten the Production Cycle
By optimizing the solidification and demolding rhythm, the molding time can be shortened each time.
By using automatic equipment, such as robotic arms, more parts can be produced per unit time, which can significantly reduce labor costs.
Optimize Post-Processing and Surface Treatment
Reduce Post-Processing
Castings should be designed to be as close to the finished product as possible to avoid unnecessary post-machining processes.
Only process key surfaces or assembly surfaces, which saves costs and speeds up the delivery of aluminium die casting components.
Efficient Surface Treatment
Only perform surface treatment on areas where functionality or appearance is required, and omit hidden or non-critical areas.
Choose cost-effective surface treatment methods, such as chrome plating and sandblasting, that are suitable for die casting aluminum.
Cost Accounting
Understand the Cost Structure
Breaking down the total cost into molds, materials, die casting process, processing, and surface treatment can help identify high-cost items and optimize them in a targeted manner, thereby effectively reducing overall costs.
Improve Manufacturability (DFM)
Introducing manufacturer opinions in the design stage can detect unreasonable structures in advance and avoid rework and complex post-processing.
Through DFM optimization, manufacturing difficulty is reduced, and die casting costs are controlled from the source.
CEX Casting: Drive Cost Optimization with Efficiency
CEX Casting is committed to helping customers reduce aluminium alloy die casting costs and improve production efficiency through full-process optimization.
Our key advantages include:
● In-house mold design, flow analysis, and DFM, optimized die casting mold structure design, accelerated project start-up, and reduced development costs.
● Centralized melting and alloy purification system improves aluminum liquid quality, reduces scrap, improves metal utilization, and saves raw material costs.
● Robotic automated production line reduces manual dependence, improves production efficiency and consistency, and reduces unit labor costs.
● Complete internal quality inspection laboratory ensures first-time pass rate, reduces rework and scrap rate, and reduces quality control costs.
● One-stop die casting supplier solution integrates design, casting, and post-processing processes, reduces intermediate links, and effectively reduces overall project costs.
Conclusion
Reducing the cost of aluminium alloy die casting requires multiple aspects from design optimization, mold efficiency, material control, to the die casting process.
These strategies not only save costs but also improve production efficiency and overall casting quality.
As China’s leading die casting supplier, CEX Casting provides end-to-end integrated solutions to help customers reduce costs and increase efficiency.
Contact us now to learn how we can optimize your next aluminum alloy die casting project.