Tilting gravity die-casting machine is a die-casting machine that uses gravity to manufacture metal parts. It is designed to produce high-precision and complex-shaped parts by pouring molten metal into reusable molds called dies. Unlike other casting methods that rely on external pressure to fill the mold, gravity die casting uses gravity to draw molten metal into the mold. Molten metal is poured into an opening or “gate” at the top of the mold so that it fills the entire mold. After the metal has solidified, the mold is opened and the part is removed.
What is a tilting gravity die casting machine?
Tilting gravity die casting machines add an extra step to the process, using gravity to fill the mold with molten metal while controlling the flow and solidification of the metal by tilting the machine itself. Allowing the mold to tilt during casting is used to control the mold filling process. It is especially useful for parts with complex shapes or thin walls, as it ensures that the molten metal is evenly distributed throughout the mold. During casting, the machine tilts the mold back and forth, creating “waves” in the metal that help fill the mold more evenly.
Working principle of tiltable gravity casting machine
- Heating Metal: Heating the desired metal above its melting point, usually by means of an electric furnace. The furnace is usually located on top or on the side of a tiltable gravity casting machine.
- Prepare the mold: While the metal is heating, prepare the mold for casting. Molds can be designed and manufactured according to the shape and size of the casting required.
- Start Tilting: When the metal has reached the proper melting point, the tilting mechanism begins to tilt the entire unit. This process can be controlled by electric or hydraulic systems, allowing the machine to tilt both horizontally and vertically.
- Tilt Die: The tilt mechanism tilts the die to an angle so that metal can flow into the die. The choice of angle depends on the specific casting requirements and the fluidity of the metal.
- Filling with molten metal: Once the mold is tilted into place, molten metal begins to flow into the mold cavity by gravity. Gravity causes the metal to flow from top to bottom, filling the entire mold cavity, and the filling process can be vibrated or shaken as needed to eliminate air pockets.
- Metal solidification: Once the metal filling is complete, the metal in the casting is allowed to cool and solidify. During solidification, the metal’s structure and morphology begin to develop and gradually acquire the desired mechanical properties.
- Restoration Tilting: When the casting is completely solidified, the tilting mechanism restores the equipment to its original position. This allows the casting to be removed from the mold.
- Taking out the casting: the mold is opened and the completed casting is taken out.
Tilting gravity die casting machines can produce parts of all sizes, from small components to large industrial items. It is commonly used in the automotive industry to produce parts such as engine blocks, transmission housings and suspension components. It is also used in the aerospace, defense and medical industries, including the production of components such as gas turbine blades, turbocharging devices, nuclear power plant components, aircraft parts and medical equipment.
In addition to the above industries, tiltable gravity casting machines are also used to produce various parts in the general industrial field, such as water meters, pump bodies, valves, hydraulic components, motor housings, etc. Various metal materials can also be cast to meet the needs of different industrial fields.
The advantages of tilting gravity die casting machine
Compared with other casting methods, the tilting gravity die casting machine has the following advantages:
- It is a high-precision technology that can produce complex parts with tight tolerances.
The tiltable gravity casting machine is suitable for a variety of metal materials, including aluminum alloys, copper alloys, etc. The method also provides an excellent surface finish, reducing the need for additional finishing operations.
- The tilting gravity die casting machine can realize fast casting cycle, and through the flexible control of the tilting mechanism, faster casting cycle and higher production efficiency can be realized. The machine can be set up to produce multiple parts simultaneously, increasing productivity and reducing lead times.
- The tilting function can ensure that the mold is filled quickly and effectively, reducing the risk of defects caused by incomplete filling, reducing the occurrence of defects such as pores and shrinkage cavities, and obtaining higher quality castings.
- Tilting gravity die casting machines are a cost-effective technology. The initial investment cost of the machine is offset by the high-quality parts it produces, reducing overall manufacturing costs. In addition, reducing the need for post-processing and finishing operations helps further reduce production costs.
Compared with the tiltable gravity casting machine and the fixed casting machine:
- Fluidity control: The tiltable gravity casting machine uses a tilting mechanism to control the flow of metal, and affects the filling and solidification process of castings by adjusting the tilt angle and speed. While stationary casting machines usually use static molds, the fluidity of the metal is mainly dependent on gravity and mold design.
- Flexibility: The tiltable gravity casting machine has high flexibility. By adjusting the tilt angle and speed, it can adapt to different casting shape and size requirements. The fixed casting machine has relatively low flexibility and is suitable for producing relatively fixed casting shapes.
- Accuracy and surface quality: Tilting gravity casting machines generally provide high casting accuracy and good surface quality. The control of the tilting mechanism can reduce the internal defects and pores of the casting, and obtain higher quality castings. The precision and surface quality of stationary casting machines are affected by the mold design and casting parameters.
- Automation: Tiltable gravity casting machines usually have a certain degree of automation and can be equipped with automatic pouring systems, temperature and pressure monitoring and other equipment. This improves productivity and consistency. Stationary casting machines have relatively few applications for automation and generally require more manual operation and monitoring.
To sum up, the tiltable gravity casting machine and the fixed casting machine each have their own advantages and applicable scenarios. Tiltable gravity casting machines are suitable for castings that require high precision and good surface quality, and where high flexibility in shape and size is required. Stationary casting machines are suitable for castings with relatively fixed shapes and situations that are more sensitive to equipment costs. Selection of the appropriate casting machine type should take into account specific production needs, cost factors and casting requirements
Tilting gravity die casting machines are a versatile, precision casting method that produces high quality metal parts. Its unique tilting feature enables efficient mold filling so parts are free from defects due to incomplete filling. The high precision and surface finish produced by the machine reduces the need for secondary operations, making the process more cost-effective.