Aluminum die casting design

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1.    There are a variety of casting methods to produce aluminum die casting and magnesium alloy casting, because of the low melting point of aluminum and magnesium alloy. So in the design of their structures, you should consider which kind of casting method to cast this casting at first, in order to consider the relative structural manufacturability.
2.    The aluminum alloy and magnesium alloy casting should try to use thin wall structure, and strive to the balance of wall thickness. This is helpful to prevent shrinkage cavity shrinking and improve the strength of the metal castings. But you can also thicken some part for the unbalance of wall thickness to set feeding aluminum and magnesium alloy casting. This can help filling shrinkage to guarantee the quality.
3.    The aluminum and the magnesium alloy is easy for oxidation and suction. The density is small, so as to make the static pressure of the metal fluid is small and be difficult to exhaust. Therefore, aluminum and magnesium alloy casting is easy to generate hole and oxidation slag, reduce the mechanical properties and gas tightness. So designing the casting structure should avoid big plane, and the transition should be gentle, and avoid causing the turbulence of metal liquid.
4.    Because of the low melting point of the aluminum and the magnesium alloy, to those castings that have some certain gas tightness requirements, you should avoid using core support to fixed core when design.
5.    The compression strength of magnesium alloy is higher than its tensile strength. So you should adopt asymmetrical section and box to undertake the compressive stress.
6.    Pay attention to adopting the method of double metal die casting and potting casting to solve the problems in the structural design of the aluminum alloy and magnesium alloy.
7.    The corrosion resistant of magnesium alloy is poor. Often use surface treatment to improve the corrosion resistance of magnesium alloy castings.

Mold manufacturer China

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We are a professional Plastic mold manufacturer China company located mold Town–Huangyan. Established in 1999, we have been striving to study, develop, injection mold, blow mold, injection molding machine,blow molding machine and relevant products. Up to now, we have around 60 skilled workers, 20 engineers and a factory, which covers 2000M2 area.

In the mold designing course, some 2D or 3D software (such as AutoCAD, SolidWorks, Pro-E and so on) applied for assisting in designing, pre-making etc. Before mold is put into physical making, the MoldFlow software will be adopted to analyze such course to make sure if it is rational and workable. In the making course, there is a set of making method< system design, individual making, concentrate assembling, scientific managing> to help us improving mold quantity and service life. Up to now, we have created some plastic molds whose cycle time are over 1,000,000; die casting mold, over 400,000.

Our molds have been sold to U.S.A. German, Italy , Malaysia, Iran , Indonesia ,Africa and so on. Meanwhile, we have established good business cooperation with many overseas companies. Look into the future, we will be at the principle of ‘scientific designing, wonderful making technical, accurately assembling’ to continuously improve our mold structure, machine technical, mold material and hot process technical and so on. ‘Making the toppest products, achieve the best benefit for our client’ is our top aim.

Do you need plastic mold and plastic molding manufacturing for your business? Contact us now

Magnesium die casting

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Our high-pressure magnesium die casting equipments provide an excellent range of casting capabilities. From magnesium die casting facility

200 ton (hot chambers) to 

750 ton (cold chambers),

we can offer the flexibility to provide our customers with the best solutions.

One-stop, Full Service

GC MOLD. can help your next product development right from the idea stage all the way to product delivery:magnesium die casting factory

Tooling design

Casting

Polishing

Machining

Painting (powder, liquid, etc.)

Packaging and delivery

Our background in magnesium die casting will provide the information you need to make an educated decision for product design, development, manufacturing and finishing.  We can provide the skills needed to ensure a smooth and efficient timeline to market. Then, our manufacturing capabilities will provide castings that meet or exceed your requirements

We offer you aluminum die casting service as well,

For example, many customers are transitioning from using plastics or aluminum parts to magnesium. Our expertise in magnesium die casting can help you smooth out the transition by: factory2.jpg (44762 bytes)

providing advice on better die design or modifications before production

Experience, Expertise, and Innovations

Magnesium die casting manufacturing is a high-precision, high-pressure process that requires in-depth know-how and experience in order to reach perfection. Our seasoned international staff includes magnesium die casting process

 International Magnesium Association award winner and

 Stanford University alumnus

and has a combined experience of:

20+ years in magnesium die casting,

16+ years in die casting and die making, and

15+ years in CAD/CAM and automation

and can provide you with the solutions you’re looking for magnesium die casting equipment

Our innovations include:

Improving yield in thin-wall magnesium die castings through in-house equipment design

Our proprietary magnesium pumping system that meets the needs of castings with a low volume of material and high projected area with extreme accuracy and speed requirements

Project Life Cycle

Magnesium die casting manufacturing is a high-precision, high-pressure process that requires in-depth know-how and experience in order to reach perfection. Our seasoned international staff includes

Step Description Customer Action  GC MOLD   Turn-around Time
1 Request for quote (RFQ). 1.Fill in RFQ formand 
2. provide product designs (2D/3D designs)  for Magic to provide quote.		 Engineering studies RFQ and provides quotes based on volume. 1 – 2 weeks.
2 Project go-ahead. Approves Magic’s quote. Project kick-off.   
3 Tooling design. Provides tooling design guidance or transfers existing tooling. Design new tooling or modify existing tooling.   
4 Build/modify tooling. Reviews and approves tooling design. Build or modify tooling. 1.New  tooling takes 30 – 60 days.
 2.Modification of existing tooling takes 3 – 15 days.
5 First sample production. Examines first production sample from GC to determine if any modifications are needed (e.g., minor sizing adjustments). Changes tooling based on customer feedback. 3 – 15 days.
6 First batch production. Examines first production batch and approves production readiness.   2 – 3 weeks.
7 Production. Places order and schedules production.    

Zinc Die Casting

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Zinc Die Casting

We have been in the foundry business since 3 generations and are proud to keep this going. Our chairman Dr. Dinesh Patel founded the company Dr. Dinesh and Ramesh Eng. Pvt. Ltd. in Ahmedabad. The company covers a space of 10,000 sq. yards (comparable to cricket field) which is only 40% utilized giving us an undue advantage for growth. We have had several metal castings (Cast Iron, Stainless Steel, Aluminum) catering to International and Domestic Companies like Ingersoll Rand, ABB, TVS and many others. However, since a decade we have shifted our focus primarily on Aluminum Castings producing from 0.5 kg to 100 kg in permanent mold. We have been adding new processes such as 

a) GDC (Gravity Die Casting)
Gravity Die Casting is the process of pouring liquid metal using Earth’s Gravity and hence it’s name. This method started on our end based on our customer’s demand leading us to develop a very difficult casting weighing almost 70 Kg in Permanent Mold for a German Company. Very few foundries can design this size of casting much less make it export quality. We are proud to say that soon we designed another such casting thereby establishing our niche in higher weight category giving an undue advantage for people with quality requirements in heavy castings. 

b) Tilt Pour
In order to satisfy the demands of our customers from around the world as well as in the domestic market we developed the Tilt Pour technology providing, engineering as well as aesthetic parts. Due to our in house building of the machine we have significant control over machine. This helps to significantly improve the quality and speed of casting manufacturing as the functioning of the machine can be customized over several parameters. Final result – better lead times and consistent quality. 

c) LPDC (Low Pressure Die Casting). 
Our goal is to keep on adding newer technologies and keeping in line with this principle we added the LPDC technology to our belt. Often when X-ray quality castings, dynamic movement (high r.p.m) is a requirement or some other quality standards dictate the usage of LPDC. 

In terms of our production capacity we have 
Production Capacity: 2000 tons per year 
Melting Furnances: 2
Holding Furnance: 5

GC MOLD was established in 1979 as a Private Limited company in the China. is Die Casting China company, Mike yang and his Engineers are manufacturers of Aluminium die casting, magnesium die casting and zinc die casting of various grades and sizes and weight ranges varying from 0.5 kg to 100 kg in permanent mould, Gravity Die Casting, Low Pressure Die Casting, sand casting and high pressure die casting.

The company provides end to end solution for Aluminium die Castings to customers including: Die Making, Die Casting: Low Pressure Die Casting & Gravity Die Casting (Permanent Mold Casting), Machining, Heat treating, Shot blasting, Testing & Inspection.


The company presently caters to the Textile Industry, Automobile Industry, Electrical Industry, Plastic Industry, Cooling Industry, Compressor Industry, Petroleum Industry amongst others.

Mike and his Engineers have modern furnaces, casting machinery, assisted with Computer Aided Design and modern C.N.C. machining centers. We also supply castings in fully machined condition. We have developed an expertise with Helium Leak Proof Castings with maximum leak rates of only 5 X 10-6 mbar l/s.

We help our customers in developing and improving their designs of various engineering components with highest quality, functionality with cost effectiveness.

Our team and Engineers detail as below

Dr. Dinesh S. Patel, Managing DirectorDr. Dinesh S. Patel is a Phd.

in Metallurrgy (1975, University of Missouri, Rolla, USA) with a Masters in Metalurgy (University of Missouri, Rolla, USA) and B.E. Metallurgy (Pune). He is the founder of the company in 1979 and through his vision the company has grown many fold since its inception. He has an experience of 40+ years in the field of castings. His experience with Aluminium die casting zinc die casting and magnesium die casting, Cast iron, SG iron, Steel castings, SS castings has been comendended in the field of metallurgy. Through his vision and planning the company continues to grow and provide the customer with the best service and quality in the industry today.

Smt. Sukesha D. Patel, DirectorSmt. Sukesha Patel, B.Com, Chartered Accountant, is the company financial controller for more than 40 years. Besides being a director at Dr. Dinesh & Ramesh Engineers, she has to her credit audits of Nationalized banks, statuatory audit of companies, panel level of state level Co-operative banks amongst other professional experience. She is also a partner at S.D. Patel & Co., Chartered Accountants. Smt. Sukesha has to her credit of being one of the first Chartered Accountants in the state of Gujarat in the year 1975. She brings to the company a wealth of experience in strategic finance and management and has been a torch bearer for the ever growing GC MOLD

Mr. Nipun D. Patel, DirectorMr. Nipun Patel is a Masters in Electrical Engineering (M.S., Penn State University, USA) and Instrumentatin and Control Engineer (B.E., Nirma University). He has varied experience in the medical, manufacturing and signal processing fields. He has worked for Harvard Beth Deaconess Research Center, Boston for 7 productive years as a Research Engineer. Before joining Dr. Dinesh & Ramesh Egnieers Pvt. Ltd. he has stayed in the USA for more than 10 years gaining valuable experience and knowhow of the latest in manufacturing and medical sciences. Mr. Nipun Patel brings along maturity, experience, knowledge and innovative operations approach to the company – the company which is on the stepping stone of exponential growth.

Mr. Harsh D. Patel, DirectorMr. Harsh Patel is a Masters in Industrial Engineering (M.S., Purdue University, USA) and Mechanical Engineer (B.E., Nirma University). He has been a work experience in USA with Deloitte & Touche LLP, New York and Baker Hughes, Houston before joining Dr. Dinesh & Ramesh Engineers Pvt. Ltd. He is inducted as the Director for the company from 2009. He has been in the field of
Aluminium die casting zinc die casting and magnesium die casting industry for more than 5 years. Alongwith his experience abroad he brings to the company strategic operational excellence and a drive for innovation.

Plastic Chair Mould

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Plastic Chair Mould

Plastic Chair Mould is needed every where on the world, but how ti purchase a good quality plastic chair mould from China mold companies  is not easy thing, normally all of  China Mold Makers can make Chair mould, but you need ti need to very carefully  to select your supplier,Please ask below questions to the mould company to see if they are good or not.

Quality points we need to take careful during Chair Mould Making

1, Can you tell your chair mould running cycle time?
If the cooling water temperature is from 8 to 12 centigrade degree, if the chair weight from 1700g to 2400g, the cycle time should be 35s to 50s. If the machine plastic melt and injection is with accumulators. Please check how they make the cooling channel? If the cooling channel is extra in and out? If the cooling channel is one according with the chair shape?
2, How you guarantee your chair mould run shorts?
The guarantee for a mould runs 1 million shorts without any flashes? Because if you accept to cut the flash by your workers, I think you can use this mould for 10 millions shorts. So you need to check the steel hardness, and in the mould if there is any parting area were welded. Normally the steel hardness should be HRC33.

3, How you make the parting line finishing is good, if there is any sharp edges?
Sharp edge on the chair is dangerous, in order to avoid the sharp edge, we have to do many points during the chair mould manufacturing.
– Chair mould parting design is correct or not.
– The chair mould cavity and core thickness is enough or not.
– How you make the CNC milling the cavity and core? Normally, we need 3 stages finishing. From rough milling to steel hardened, after hardening, take the 2nd stage milling, we call it half precise milling, normally we leave 0.3mm, Then make the steel stress releasing, after this we do final precise milling. When in this time, the machining operation is very important.

1). we have to use cooling on the milling area. 2). we have to be sure that each cutting, the depth will not bigger then 0.08mm. All these are because of the steel will be deformed when milling and after the hardening. The deforming will cause the cavity and core’s fitting are not accurate, there will be a lot of hand works on it. By hand works on the parting area, you can never work out a perfect parting line.
4, the wall thickness is even or not.
Hand working on the parting line also be one of the reasons for wall thickness is not even. Of course, most of the reason is from the plastic chair 3D design and poor polishing on the cavities and cores. So when we start a plastic chair design, we have to consider the wall thickness. Some time, we need to make some area a little thicker to be sure that the chair is strong enough. But we have to consider seriously when it is need. because the uneven thickness will caused the injection not balanced and also will caused the cooling time not even. This will affect the injection speed slow down and also will cause the shrinkage marks. If the CNC milling is too rough, you can never get a chair with thickness even.
5, how about the stackable?
When the chair plastic designs are doing, we have to check its stack ability. And you also need to consider the deform possibility of the chair molding.
6, how you can make the Plastic chair mould with less weight but strong enough?
When starting makes the plastic chair design, we have to consider the weight and the strength. You can make the bottom area be strong enough by add more ribs. But how about the leg, backrest and armrest area? For this reason, you need to calculate or analyze the force of each area…in order to make a light chair strong, you can choose a very low MFI PP material. But in this way, you need to make the mould very strong and also you need to be sure the injection filling are available, as because you are using a material with MFI 4 or Max. 6.
7, How to make the air venting on the chair mould backrest?
For some chair backrest design is very complex, there is a lot of material jointing line, and some air cannot venting out when material filling and flowing. For this reason, you need to analyze by mold-flow maybe, and there are a lot of area need air venting built in the chair mould.
8, how to keep your chair mould finishing long lasting?
In order to make your chair mould cavity and core will not be rust by the plastic material, you need to be sure that the steel are high chrome and also the hardness are bigger then HRC33. If you will use some recycled material for injection, you need your chair mould be hard chrome plated. Otherwise, you need to make the polishing from time to time.

HYX  is the leading plastic chair mould manufacturer in china, we has developed more than 300 sets chair moulds during these years. We are also professional in PC transparent chair mould gas injection. If you need a high speed, long time and nice finishing chair mould, please come to us. We are sure you will be satisfied.

Plastic Mold Making

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Plastic Mold Making

The remarkable revolution in the industry world is plastic mold making. The top and reliable manufacturers are belongs to china with the maximum year experience in the molding industry. They could lend their hand for entire firm such as industry, electronic, home appliance, agriculture, research and medical. Major companies offer a one stop solution for entire plastic components design, mould design, mould making, molding and accumulate the plastic elements. The customer can simply obtain the completed parts and merge in the profitable marketing.

Emphasizes of plastic mold making:

  • Entrepreneurs of any industry obtain the required design through the pre model order. Apart from the catalog design and structure, they have the comfy for design their own requirement.
  • Entire processes of plastic part moldingsare connected with the computerization and the derivation of any shape can easily designed through the software assistance.Plastic Mold
  • Manufacturing process management and prototyping are the extraordinary features of this firm.
  • The flexible design, time consuming, the experienced professionals support are the keys of the success path of a molding supplier.
  • The producers have the competence to deliver any kind of products in and out of the catalog within a deadline.
  • Through the dedicative employees, they could deliver the any kind of plastic product through a ground breaking technology.
  • There service is no ceiling and they lend their hand for casing, bottling, automotive, farming, air industry, medical service and so on
  • The experts of these kinds of firms have the extensive knowledge about the Plastic world and they could deliver a solution any kind of industry. The perfect software assist automate EDM system and stay away from the programming fault of EDM.

The exact solution for entire plastic molding generates a good rapport with the customer along with quality products. They could deliver a world of plastic on time for a large plastic components molding too. Automotive components, refrigerator

panels, air conditioner bezels and other kind of domestic purpose equipment are obtained through injection molding service and turnkey project solution. Mold flow analysis service, Reverse engineering are implemented for best and effect result. Exploit effective molding technology and merge with the innovation manufacturing methods like join the parts in the mold, solid basic, excellent cooling facility in large plastic plastic molding components are deliver a quality product within a deadline.

The exact cooling facility reduces the molding cycle of large plastic parts. Through online, anyone can acquire the guidelines and the quotation of the particular order. The experts of this firm can deliver a good solution for any kind of inquires related to plastic molds quality. You can view not only the catalogs but also the products of a specific industry which are delivered earlier from the same supplier. The virtual tour of the official website rally round to view the products such as automotive parts molding, home appliances parts molding, plastic chair mould, table molding, electronic device case molding and so on. Go through the products and the guidelines of the experts not only deliver a good idea for your product but also lead a path for your successful marketing.

Type of Castings

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Different Types Of Casting To Suite Your Casting Necessity

There are different processes that can be used in creating complex shapes of metals parts and one procedure is through casting. Casting is a manufacturing method wherein a liquid material is transfer

red into a mold, usually following a hollow cavity of the desired shape, and then allowed to solidify afterwards. It has been used even in the past and one example or type of casting is die-casting.

The die casting method is a process of forcing molten metal under high pressure into mold cavities similar to permanent mold casting. It best suites the purpose of making small to medium sized parts fashioned with good and precise details. By-products of this method are furnished with fine exterior finish and dimensional accurateness. Most materials used in this method are metals such as zinc die casting, copper, and aluminium die casting and magnesium die casting.

Another form of casting which is considered to be the most popular and simplest type is sand casting. It is a technique that has been used for many centuries now. Sand casting is a process of forming a mold out of a sand mixture through pouring a casting liquid into a desired shape. This type of casting allows manufacturers to create large number of products in such a small range of production expenses. Most metals are caste depending in the type of sand used for the molds in this method.

An additional process that can be also used is Plastic molding. It is a manufacturing technique in making parts from both thermoplastic and thermosetting plastic materials for production. It includes plastic injection molding wherein molten plastic is injected at high pressure into a mold, which is the opposite from the product’s actual shape. Example by-products of this method are bottle caps and outdoor furniture.

Moreover, a further technique is cold forming. It is also known as cold forging. Cold forming is a manufacturing procedure in which a metal is shaped at an ambient temperature to produce metal components in a definite shape. The techniques usually involved in this procedure are bending, cold drawing, cold heading, coining extrusion, thread rolling and others.

Some benefits of cold forming are enhancements in the component properties of the product because the grain structure of the material is being elongated during the formation process wherein it is forced to follow the structure and as a result its’ strength is increased. Another benefit of cold forming is that the aesthetic finish of the components gives out a brighter facade and formed with a consistent high tolerance. These somehow reduce the necessity of complex finishing and polishing.

These are only some of the different kinds of casting. Other types of casting aside from die-casting, cold forming and sand casting of metals are plaster casting, shell molding, investment casting, permanent mold casting, centrifugal casting, continuous casting and casting of plaster, concrete, or plastic resin. Each type of technique has specific and unique routine that allows you to produce superior outcome and high-quality by-products to best suite all your casting needs for your manufacturing use.

Plastic Molding Manufacturing

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Plastic Molding Manufacturing & Design

Many projects have come to us without the ability to manufacture the product the way the customer had intended. Largely due to the customers lack of knowledge in the plastic molding manufacturing processes when it come the plastic injection molded. Several projects have been renewed when it was discovered by our engineering department that the mold had been gated wrong and this lead to the part having too much stress molded into the part for the finished product to survive in its intended environment.

We pride ourselves in helping the customer by becoming involved early in the process of product design to help prevent end use product failures. One of our best customers asked us to bid on a project that others had already submitted their bids and the customer was complaining about not understanding what made the project so costly. We decided that before we would submit a bid that we would have to sit with the engineer at our customers facility and find out what the expectations were and see if we could find a way to help reduce the cost. As it turned out all that was needed was our engineers to sit with their engineers and we discover that one wall sections in the very complicated part, needed to be moved slightly so that the part did not have an undercut section requiring a side-core in the mold. The customers’ engineer had no problem with the slight modification which as it turned out was all it took to make the part cost justifiable. We got the order.

As we followed up on the sales engineering visit that produced this order we asked why such an obvious change had not been seen before we showed up in their engineering department. The answer was, “because you were the only people that bothered to show up and ask the questions and sit with our engineers.”

We like early involvement. We know how to make a product more manufacturability.

Advanced Quality Planning (AQP)

The ultimate objective of the Advanced Quality Planning system is to launch new plastic mold and plastic products with designs and mold and molding manufacturing processes that insure all cost, quality and delivery expectations of our customers are met. Cross functional teams who use checklists, question/action plans and team inputs to develop Process Flow, FMEA, Process & Inspection sheets, and tools and gauge plans accomplish this. The cross-functional teams consist of representatives from all of our internal departments and the customer. They make use of the best practice manuals, quality history and error proofing to identify the design and process that will provide zero defects at competitive prices.

Sample Submission/Dimensional Layouts

This discipline is responsible for PPAP scheduling, Project Management and complete PPAP certifications of all new and changed plastic parts per the AIAG PPAP requirements Dimensional layout of all plastic mold and plastic molding products is accomplished using traditional equipment as well as state-of-the-art measuring equipment, such as CMM analysis.

 

Plastic Mold

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Plastic Mold & plastic Molding

Several years ago we were in 2 business models. One was Plastic molding and the other was plastic  mold building. Shortly after the Chinese became a threat to our tooling or mold building industry we decided that we needed to pick one business model or the other. We decided that we would best serve our stockholders by choosing to be a manufacturer of plastic injection parts of a nature that we began to call “Crazy Jobs No One Else Will Do”.

Therefore we were no longer in the Plastic mold building business as a primary function to our end goals. What we have become is responsible for all the mold construction that we sell to our customers that is the means to the end better known as a finished plastic product. We turned our mold building facilities into a production machining line for value added services to the plastic products. We use our machining facilities to finish machine dimensions to the fourth decimal in plastic parts.

Now when it comes to building plastic mold what we now offer is much more valuable than we ever could have offered. We work with several highly qualified plastic injection mold builders around the world including China, Taiwan, Germany and England to get the customer the best possible mold to suit the application requirements. We take full responsibility from start to finish. Here is what we offer:

1) Tool design knowledge that will help us pick the best mold building facility
2) Tool construction project management.
3) First article testing and final approval of all dimensions to meet the customer’s requirements.
4) Free tooling maintenance for the life of the tool as long as it stays at PMT.

One stop shopping for the entire process. We will make sure you get off on the right foot from the start of the product design all the way to getting the parts through first article approval and ready for production.

 

Aluminium Casting

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We are an Aluminum die casting China company that has Hot Chamber Die Caster with 20 years of experience and a reputation for superior casting ability and exceptional customer service.

Die Castings…Zinc and Magnesium… Over 15 National and International awards for “Excellence of Castings”.

Twenty (20) Hot Chamber Zinc Die Casting machines from 100 ton to 20-0 ton capable of producing parts from fractions of an ounce to 5 pounds in sizes ranging from ½” to approximately 12″ X 16″ Read more