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Pressure Die Casting

Pressure Die Casting and High Pressure Die Casting

PM tooling is as  Pressure Die Casting Division is your one-stop, complete service Die Caster for various castings including die casting, investment casting, sand casting. We offer you a single source for engineered die castings

, together with cutting-edge engineering resources, advanced production capabilities and complete secondary finishing.

PM Die Casting supplies high quality aluminum, zinc, brass and magnesium die casting. We operate our casting factory in Shen Zhen, China for various castings, machining, assembly and die building, with over 20,000 square feet of total floor spac.

We are a leader in innovative quality control systems. Our quality manufacturing system includes a process failure detection system

At every casting press. Rigorous 100% inspection is as much a production operation as any other manufacturing step, and is woven into the sequential standardized work to assure manufacturing quality in finishing and machining.

As one of divisions of PM  Manufacturing Group, PM Die Casting can be more responsive to its customers and, simultaneously, offer more competitive, “made in China” pricing on quality products.

Die Castings

Die Castings

Conveniently located a few miles north of Milwaukee, Wisconsin. PM TOOLING is licensed to use the Meehanite process to provide ductile iron with the physical characteristics needed in many high-stress applications. Castings are

made in all grades of ductile iron for short runs, prototypes and longer production runs.

We are proud to count among our diversified list of customers many of America’s “blue chip” manufacturers whose product lines range from farm and construction equipment to railroad cars. Casting weights vary from just a few ounces to 150 pounds. We can also accommodate larger and heavier castings, depending upon quantity and delivery.

 

Our modern facilities, which are geared to 100 percent job shop production, feature coreless induction furnaces with a typical daily capacity of 5 to 6 tons of molten metal per hour. Because of their pollution-free operation, these units play an important part in meetingclean air standards established by the government. Pollution generated within other sections of our plant is controlled through giant air-scrubbing equipment.

Squeezer and cope and drag molds in a variety of flask sizes are employed. Loose molding is also available. For lower volume production we use CO2 cores to provide highly accurate, intricate castings. For long production and complex jobs we have shell core machines that assure castings of more uniform density, dimensional accuracy and finer finish – at the most economical cost. Both processes have their place in the foundry, many factors are taken into consideration when deciding which core is best for a particular zinc die casting.

Material handling throughout is designed for optimum, economical operation. Precision-made molds move on palletized production lines through the pouring

of metal to the finishing department. Here die castings are shot blasted, ground, chipped and tumbled before being shipped to customers.

Since we are vitally concerned with uniformly high quality, our services include an up-to-date control laboratory. Such metal tests as carbon determination, hardness and temperature and carbon readout are conducted as required.

PATTERN STORAGE
As highlighted above, a 1982 addition to the PM TOOLING facility is exclusively for the storage of patterns, in turn assuring that they receive the care needed for quality aluminum die casting, magensium die casting and zin die castings Patterns themselves are made by skilled craftsmen employed by local firms well known for their expertise in our industry.

FIELD ASSISTANCE
A network of capable representatives supplements our own sales personnel. They stand ready to help solve your casting problems and serve as liaison between you and our plant.

OUTSIDE SERVICES AVAILABLE
A variety of companies are used for such specialized services as casting x-rays, independent laboratory analysis of physical and chemical properties and heat treating.

EMERGENCIES
We realize that occasionally customers haveemergency requirements. PM TOOLING takes pride in having built a reputation for outstanding service to customers in these difficult situations. read more about aluminum die casting, zinc die casting or magnesium die casting.

 

What Is Casting Jewelry

All About Casting Jewelry

Casting is a process in which liquid material made from heating metals, is poured in a module, to give the liquid a desired shape. Then the liquid is cooled and a solid object in the desired shape and size is obtained. Casting Jewelry is the latest “in-thing” in the fashion markets. This jewelry is made from different materials like silver, aluminum die casting, zinc die casting, gold, bronze, alloy metals and even plated casting jewelry is available.

Casting Jewelry is very attractive and delicate. They are made using machines, but very finely crafted and hand made jewelry is also available in the market. This type of jewelry can be available at a very low, as well as high costs, depending on the design and material and design that you choose. Casting Jewelry is very fragile and should be handled with out most care as it can break easily. With the advent of casting jewelry, the fashion world has benefited a great deal. Today, free flowing designs, multicolored jewelry and even a special made to order jewelry is available in the market.Metal stamping

Before this, it was difficult to cast a metal in a desired shape but today it is as simple as it gets, all you need is a creative mind to create new designs and a group of well qualified workers and good machinery to make your own casting jewelry. This also gives you an option to make your own series of new designs. Casting jewelry is being widely used across the globe. With the prices of gold increasing day by day and with the entry of new metal jewelry like platinum, casting jewelry slowly but surely is making a mark in the fashion world. With the cost silver plated casting jewelry, the dream of wearing a new necklace or a new ear-ring everyday is a reality. You can actually afford new set of jewelry everyday. There are also costly models made of pure gold and delicate designs and with embedded diamonds that are available.

Casting Jewelry is not only about fashion, it has also opened a new avenue for small scale businesses. With proper knowledge and machinery, you can start your own company and make casting jewelry. It does not need any expensive material nor does it need a big capital. A small store room in your house will also be sufficient to set up your casting jewelry work-shop. You can then design your own range or hire a professional jewelry designer to create your range of jewelry.

Casting Jewelry has also helped the educational branch of “jewelry designing” grow considerably. Today it is considered in par with “fashion designing”. Many young students are nowadays looking at jewelry designing as a full time career.

The only draw-back of plated casting jewelry is that is they are used on daily basis, then they might lose their shine and the coated silver or gold respectively. If they come in contact with water regularly, then they can turn black. You can get them re-plated and use them. As casting jewelry is very fragile and delicate, even a slight mishap can change its shape or even break it.

Casting Jewelry

How to Cast Jewelry

Casting Jewelry parts is different to die casting parts,Casting Jewelry is an ancient skill that has been around for as long as there has been jewelry in the world. The Ancient Egyptians are usually credited with perfecting the process but casting jewelry was also practiced by meso American societies and cultures located in Asia and the Middle East. The casting process is called Lost-wax and is still very popular with craftsmen who enjoy making hand made jewelry.

By the name of the process, one can guess that wax is involved of which will be lost. While the Lost-wax process is mainly used for the casting of rings and bracelets, other items such as sculptures can also be created. Investment casting is another name of this casting jewelry method and both are acceptable terms it just depends on the speaker’s preference.

The Lost-wax casting process has many benefits. When making jewelry this way, the caster will be able to make identical pieces quickly and efficiently.

There are several companies and individuals willing to cast the piece for you for a price. Many of these companies may overcharge, the cost of commerce, so if you have the resources and ability you might be better of casting your own jewelry.

Lost-wax casting involves a number of steps. If followed properly and with precision the artist will find the process enjoyable. Before you begin, you will need to come up with an idea for the piece of jewelry. Generally, the sculpture of the piece is created using wax though some prefer having a metal master copy in case of mistakes. You are going to create the mold using the original. The molds used for casting jewelry allow a great amount of detail. When the mold is finished, you are going to fill it with wax to create a wax copy which will then be coated with sand and silica. This ceramic shell will then be heated so that the wax is melted out. The wax can be reused so make sure to safely collect it during this step. The ceramic copy will be hollow and you will have to test it for holes before pouring the molten metal.  Afterwards, you will lightly hammer the ceramic shell away to reveal the finished product.

The end result of the Lost-wax process is usually very detailed and exact creating a beautiful piece.

Casting jewelry can be a profitable business depending upon your skill level and creativity. This skill is diminishing as the jewelry companies switch to computerized and automatic means of creating their pieces. While this move is smart for the jewelry business as it reduces the production cost, the end result lacks a certain desirable element that hand made jewelry posses.

Casters will be able to use the mold created during the Lost-wax process a few times before a new mold has to be made. Extra care and attention has to be paid to polishing any imperfections or patching any variants during the casting process. Several things can go wrong during casting especially when you remove the mold so take care to be extra careful and attentive during this time.

Casting jewelry is a valuable skill to master and if you plan on making any money from your home foundry, this is a good place to start.

Metal Stamping

What is Metal Stamping?

Metal stamping is the process of cutting and shaping metal alloys into specific forms, especially to be used as components for large machinery or structures. Metal sheets can be molded into different pre-determined shapes for use as regular products like pans and cans. The most common alloys that are used in metal stamping are steel, zinc, nickel, aluminum and titanium. Metal stamping is a very cost-effective and productive way of producing many kinds of metal products on a large scale.

In metal stamping, the metal sheets are placed in a die or a press tool that has a specially designed cavity that gives the preferred shape to the metal sheet. The upper part of the die connects to the press slide while the lower component connects to the press bed. A specific component known as the punch pushes the metal sheet through the die, thus performing the actual shaping operation. After pressing, the metal is plated with gold, palladium, nickel or tin to prevent corrosion.Metal stamping

Plating also increases the wearability and solderable nature of the product. Sometimes, the sheet is also pre-plated before the stamping process, and then the product is cleaned to remove excess metal stamping oils and films. The product is then heat treated to make it stronger since it is still in the soft state after stamping. The product is then subjected to the deburring process for removing the sharp corners. This is done by using chemicals or abrasives. Metal stamping also involves other metalworking processes like piercing, blanking, forming and drawing on the same machines.

Stamping presses have specific force, speed and precision for giving a specific shape to the metal. There are two types of metal stamping presses: Mechanical and hydraulic. These are available in an extensive range of capacities, sizes, stroke lengths and operating speeds.

Metal stamping is slowly replacing other metal forming processes like die casting, forging, fabricating and machining. One reason for this is the very low costs involved in metal stamping. The dies used for metal stamping cost less than those used in forging and casting. Also, the metals used in metal stamping can be harder than those used in other processes, thus making the end product stronger. The cost of the secondary processes, like cleaning and plating are also considerably reduced.

Moreover, there are certain products that have to be produced only through metal stamping: Base weights, brackets, balance clamps, brake flanges, conveyer flights, bushing seats, engine bases, flywheel shrouds and friction plates. There are also different kinds of metal stamping including: Deep drawn stamping, electronic stamping, Fourslide stamping, medical stamping, progressive die stamping and short run stamping. The most commonly used type is the progressive die drawing wherein a metal sheet is drawn through a series of dies and stamping is done by all the dies simultaneously, thus considerably reducing the time it takes.

Metal Stamping Info provides detailed information about precision, custom, and sheet metal stamping, as well as metal stamping machines and metal stamping die. Metal Stamping Info is the sister site of Wire EDM Web.

Types of Casting Molds

Types of Casting Molds

Casting is basically the manufacturing process through which a liquid material is emptied into a mold that includes a hollow opening of the desired art or shape and is then allowed to harden. This hardened casting is then removed and broken out in order to complete the process. Apart from using sand as the main mold material there is a metal that is used as the mold. Normally, a cast meehanite or an iron is used as the material for mold and the objects are made from the sand or metal. The cavity surface is basically covered with a thin layer of material that is heat resistant which can be either sodium silicate or clay.

Casting Molds: The casting molds are actually pre heated to nearly 392 degree Fahrenheit before the metal is pored in the cavity. The design of cavity for these casting molds does not chase the same principle for shrinkage like in the sand casting molds. This is because of the fact that the metal casting molds heat up and enlarge during the pouring process and so the cavity does not need to be expanded like in the sand castings. Nevertheless, care should be taken in order to ensure a correct thermal balance as you can use external water source for cooling or you can also opt for suitable radiation techniques.

Permanent Casting Molds: Although these permanent casting molds are not as flexible as the sand castings which allow to be used in different metal patterns or designs but these lower the cost of producing the part. When there is a production run of more than 1000 parts the permanent casting molds would produce much lower piece of cost part. Apart from this, the break even point also depends on the density of the part. There are more complex parts that are favored when you use these permanent casting molds. The typical part size would be around 50g to 70 kg and the basic materials used are medium and small parts that are made from magnesium die casting, aluminum casting and brass and also their alloys.

Slush Casting Molds: The slush casting molds are actually a special type of permanent casting molds in which the molted metal is not allowed to solidify completely. After gaining the desired wall thickness the still not solidified molted metal is then poured out. This is basically used in order to make void ornamental objects like lamps, candlesticks and statues.

Corthias Casting Molds: This type casting molds is yet another variant of the permanent casting molds in which basically a plunger is used to pack the molted metal through the spure hole. This type of process allows thinner walls and to produce greater details.

Vacuum Permanent Casting Molds: This is also another type of permanent casting molds which is also similar to low pressure permanent casting molds. In this type vacuum is used rather than a pressure. You can make thin wall casting through this type of casting molds like in the other low pressure casting molds. Apart from this the results are high as there are no risers used.

Casting Molds

What is Casting Molds

Casting molds are an essential part of the metal casting process as it will be used to shape the final result. Nearly all metal casting methods will use some type of mold. The standard mold will consist of a cope and drag that when together is called a flask. The mold itself can be constructed of several materials depending upon the casting method.

Most molds will be made from latex, fiberglass, sand, and even metal. Sand molds are the most popular since Sand Casting is commonly used in small home foundries. In Permanent Mold Casting, the mold is created from metal. Most molds can be used over and over again, but not all of them. Certainly the metal molds can be used multiple times without loosing any quality from the finished product. However, molds created using sand or other materials will not have a very long shelf life. This is not generally seen as a huge problem just a minor annoyance since mold making is relatively cheap and easy.

No matter what material the mold is made from, the basic construction is pretty much the same. The molding box is called the flask which has a cope, the top, and drag, the bottom.  You will then fill the flask with the molding material and then place the original into the mold. So, if you want to cast a tiny metal elephant, you will place an original of the elephant usually made from clay, wax, wood, or even metal into the drag of the flask. If this is done in sand you will ram the flask until the sand is packed tightly around the original. The top of the flask, the cope is then placed on and more molding material poured in. The entire flask is then rammed or vibrated making sure everything is packed in nice and tight.

When the molding material is dry, you will remove the flask and carefully split the mold to retrieve the original, in this case the tiny elephant. Now, if you want to make sure that there are some empty spaces in the cast to be finished then you will place cores into the mold. The cores are made of sand or wax.

The type of mold used depends heavily on the type of aluminum casting, alloy casting, and complexity of the pattern to be cast. Metal molds have little use in small foundries unless you plan on casting a lot of tiny metal elephants.

In some cases, pre-made molds can be found in hobby shops or through company casting companies. Usually, pre-made molds are used in miniature castings. Many individual metal casters prefer to make their own molds since it is inexpensive and allows them greater control over the finished casting.

Metal casting involves several sets of skills and mold making is one of these skills. Mold making is an invaluable skill for metal casters as it is so very important to the casting process. Not only are molds used in metal casting but in other casting types as well. Resin casting, aluminium die casting, magnesium die casting and other plastic molding requires a mold as well. The flask can be made of wood, metal, and in some cases those toy building blocks, we all know the type. As long as the flask can hold the mold material until it dries it can be used.

Every metal caster should learn how to make a mold instead of relying on others. It’s not only about independence but about saving money as well. Making your own plastic molds is just cheaper.