Characteristics of commonly used die casting machines
Common die-casting machines play a key role in industrial production. Different types of die-casting machines, due to differences in design concepts and technical parameters, offer distinct performance advantages. Hot-chamber die-casting machines, the mainstay of die-casting for low-melting-point alloys, are most notably characterized by their extremely high production efficiency. Their shot chamber is directly immersed in the molten metal, eliminating the need for frequent scooping. This reduces cycle time to 10-15 seconds, and allows for production capacity of 300-500 molds per hour. This high efficiency has made them a dominant force in mass production of products such as zinc alloy toys and electronic connectors. For example, a toy factory using hot-chamber die-casting machines can produce over 100,000 zinc alloy toy parts per day, far exceeding other die-casting equipment. Furthermore, hot-chamber die-casting machines minimize oxidation of the molten metal, resulting in a smoother surface finish and significantly lower subsequent processing costs. However, due to the high-temperature resistance of the shot chamber, they cannot be used for die-casting high-temperature alloys such as aluminum and copper alloys.
Horizontal cold-chamber die-casting machines, thanks to their stable injection performance, have become the preferred equipment for die-casting medium- and high-melting-point alloys, particularly aluminum alloys. Their horizontally arranged injection system offers uniform injection force with a wide adjustable range (from 100 kN to 50,000 kN), meeting the molding requirements of castings of varying sizes. For example, in the production of automotive engine blocks, horizontal cold-chamber die-casting machines provide a stable, high-pressure jet stream, enabling molten metal to quickly fill complex cavities and ensure casting density exceeding 99%. Another key feature of this type of equipment is its strong mold adaptability. It can be equipped with auxiliary systems such as core pullers and insert placement devices to produce castings with complex structures, such as gearbox housings and motor end caps. Furthermore, horizontal cold-chamber die-casting machines offer a high degree of automation, making them easy to integrate with robots, conveyor belts, and other automated production lines. A fully automated horizontal cold-chamber die-casting production line installed at an automotive parts manufacturer automates the entire process, from scooping molten metal to removing and deburring the castings. This has increased production efficiency by 40% and reduced labor costs by 60%.
Vertical cold chamber die-casting machines demonstrate unique advantages in specific scenarios. Their injection system is arranged vertically, and the molten metal is pressed into the mold cavity from below, making them suitable for producing castings with deep cavities and thin walls. Compared with horizontal machines, the movement direction of the injection punch of a vertical cold chamber die-casting machine is consistent with the direction of gravity. The molten metal is less affected by gravity during filling, which can reduce the generation of air entanglement and oxide inclusions, and they perform outstandingly in magnesium alloy die-casting. An aviation parts factory uses a vertical cold chamber die-casting machine to produce magnesium alloy brackets. The porosity of the castings is controlled below 0.5%, meeting aviation-grade airtightness requirements. However, the production efficiency of a vertical cold chamber die-casting machine is slightly lower than that of a horizontal machine, with an hourly production capacity of approximately 150-250 molds, and the operation is relatively complex, making it more suitable for small-batch, high-precision special casting production.
Fully hydraulic die-casting machines feature flexible clamping force adjustment as their core feature. Their clamping mechanism is directly driven by a hydraulic cylinder, allowing for stepless adjustment between 500 and 50,000 kN, precisely matching the molding requirements of different castings. This characteristic gives them a distinct advantage in the production of large, complex castings. For example, in the die-casting of wind turbine housings, fully hydraulic die-casting machines can adjust the clamping force in real time based on cavity filling conditions, preventing mold deformation caused by excessive local pressure while ensuring dimensional accuracy of the casting. Another key feature of fully hydraulic die-casting machines is their stable clamping speed, which effectively reduces mold impact and extends mold life. A heavy machinery plant has used fully hydraulic die-casting machines, extending mold replacement cycles from three months to six months and reducing mold maintenance costs by 50%. However, this type of equipment consumes more energy, and operating costs are 15-20% higher than toggle die-casting machines.
As a new environmentally friendly device, the servo-electric die-casting machine represents the future of die-casting machines. It utilizes servo motors to drive the injection and clamping systems, offering low energy consumption, low noise, and high control precision. Compared to traditional hydraulic die-casting machines, servo-electric die-casting machines reduce energy consumption by 30-40% and keep noise levels below 75 decibels, improving the production environment. In precision casting production, servo-electric die-casting machines offer injection speed control accuracy of ±0.1 m/s and position control accuracy of 0.01 mm, enabling the production of thin-walled aluminum alloy parts as thin as 0.3 mm, such as laptop computer cases. After introducing servo-electric die-casting machines, an electronics manufacturer not only saw its product qualification rate increase from 92% to 99%, but also saw annual electricity bill savings exceeding one million yuan due to reduced energy consumption. Furthermore, servo-electric die-casting machines offer fast response times, with injection accelerations reaching 50 m/s², enabling rapid filling of complex cavities. They hold significant potential for future application in high-end manufacturing.
