Blogs Define die casting in order to better comprehend the process

  • February 24, 2022
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Automobile manufacturing is undergoing a transformation, and HPDC molds, in particular, are at the forefront of this change. However, what is high pressure die casting exactly?

Automobile manufacturing is undergoing a transformation, and HPDC molds, in particular, are at the forefront of this change. However, what is high pressure die casting exactly? Let us first define die casting in order to better comprehend the process. The online encyclopedia Britannica.com describes die casting as "the production of a metal item by pumping molten metal into a mold or die under pressure". The die is composed of heat-resistant steel.

The high pressure part shows that the molten metal is driven into the mold cavity under pressure. The correctly secured compartment retains the molten metal until it freezes into the appropriate form. Isaiah Richard writes for TechTimes.com, which covers the newest advancements and advances in business, science and technology. He addresses die-casting in vehicle manufacturing: "An automobile's die-casting machine is a press that creates metal around a piece of cast iron.

Introducing the world's biggest die-casting machine
People who know Elon Musk were not astonished when Tesla revealed in February 2021 that it possessed the world's biggest die-casting machine. Randy Garn, for example, said in an Entrepreneur.com piece that for Elon Musk, "It has no significance. It suggests he thinks anything can be done, even if many others say no.

Jeremy Johnson, a writer for TorqueNews.com who recently wrote on Tesla's die-casting machinery, couldn't help but be amazed. "He said," I replied "Tesla manufactures automobiles like they use 3D printing to automate tiny autos! Adding, "It's like a huge high-tech waffle iron!"

Tesla's die-casting machine may be the biggest in the world. On the other hand, as Musk himself put it: "This work was very tough and is still extremely challenging, but it represents a revolution in body design and production: lighter, more compact, with superior noise, vibration, and harshness isolation, as well as more accuracy and less damage. an investment with a lower unit cost"

FoundryMag.com, a website collecting news on metal casting technology, gives insight into the reasons behind Tesla's choice to transition to mass die casting. According to the site, Musk said in an interview that "vehicle bodywork are inefficiently designed and built since such components entail many welded or assembled castings and/or stampings."

of a modest home's proportions
Reuters.com's Edward Taylor and Paul Lienert use the name "Gigapress" to characterize Tesla's high-pressure die-casting machine "the size of a medium-sized residence. The Italian business IDRA Srl provides the machine. The firm claims to be the best in the industry "To far, Gigaprint has been the only company in the world to put its machine on the market. Why did Tesla choose IDRA Srl to purchase the machine? You may not have seen the revolutionary lens.

Develop hydraulic unit solutions that may reduce energy usage by as much as 35%
Creating massive structural molded pieces with thinner walls by providing more stable injection conditions in all phases.
Enhance the car's appearance and modularity through a radical redesign of the vehicle's body.
Construct a "die-casting cell with a central control center to oversee the press and all other peripherals" that makes it easier to set up client machines.
Thomas Fritsch, editor of Foundry-Planet.com, remarked, "Gigapress is more than merely XXL; it heralds a new way of thinking about die casting."

How is Gigapress helping Tesla make Tesla simpler, lighter and cheaper?
So what's the deal with Tesla's enormous high-pressure die-casting machine? Taylor and Leinart had an idea. According to them, the issues encountered by firms seeking to squeeze more aluminum into the car's frame would be solved by the high-pressure die-casting process.

Taylor and Lienert cite, as evidence, the fact that "Because of its difficulty in stamping into complicated forms, aluminum has been unable to be used for big components. Adding, "In order to obtain intricate edges and other forms, aluminum pieces must be bonded or riveted, since welding distorts the metal."

How will die-casting overcome this challenge? Taylor and Lienert provide the explanation once more: "Tesla is able to streamline production by injecting molten aluminum into cast iron and then removing the casting metal using a robot. This, they noted, enabled Tesla to reduce the number of pieces on the bottom of the rear body to two, making the biggest molded part the carmaker has ever built.

In Fritsch's opinion, firms using Giga Press will save money. In the assembly area, two Giga Presses are less expensive than four enormous 4,000-ton machines and may save a substantial amount of money "he wrote. Adding, "We're talking about 20 percent depending on the complete process, including fixturing, robots and quality control of individual components."

Superiority at its finest
Gigapress also helps with quality control. In this respect, Fritsch states, "The essential term is 'quality' - the justifications cited here are improved characteristics, stability and stiffness of the molded component, and the simplicity of quality control of zinc alloy die castings, which is done by a test code for the control of 3 castings."

The ecologically friendly
In a video released on YouTube, IDRA Director General Riccardo Ferrario emphasizes preserving the earth. He responds by saying: "We can alter the world and our children's and grandchildren's futures if we dare to dream big and believe in what we're doing.

Fritsch supports the need for energy efficiency. The notion of fewer and hence larger die castings may result in up to 20% less effort, notably in terms of energy consumption, in terms of sustainability and ecologically friendly manufacturing "he composes He adds, "In the long term, a 1-Shot technique for massive die castings may also save energy and resources."

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