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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.

 

Die Casting

CROFTS & ASSINDER LIMITED

From start to finish, the Crofts & Assinder service adds a new dimension to your production capacity.

One of the most advanced design and research facilities in the business, including the latest CAD/CAM systems, gives you total control of individual product development.

Initial consultation with our technical engineers, will help you optimise your product design for the most cost-efficient precision die-casting processes and finishing. You’ll save time, cut down on wastage and be sure of the highest levels of product quality.

Zinc Alloy Pressure Die casting – finished products in seconds

Latest technological advances make zinc based alloy die-casting one of the fastest production processes available.

Raw materials are converted into finished products in a matter of seconds, ensuring high volume production runs and fast changeover times.

The process allows complex shapes to be produced to fine tolerances, eliminating wasted material and often making secondary machining operations unnecessary. And, because zinc has a relatively low melting temperature, the life of the casting die normally exceeds that of the production run.

Our high power die-casting machines offer a choice of single or multi-cavity die formats on components weighing up to 2,000 grams. got to our website to know more about die casting parts

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.