DIE CAST MACHINING

When it comes to machining, different metals require different processes.

Zinc

There is usually very little machining required on our precision zinc die castings because of the accuracy we obtain. The machining characteristics of zinc and zinc alloys are excellent and a wide range of machining processes can generally be used.

  • Drilling—we can achieve better, more economical drilling under a wide range of operating conditions. To find out how, contact us directly
  • Tapping—zinc die casting alloys are readily tapped and form excellent thread and hole quality. Threads can be cut or formed with and without lubricants and can be easily tapped using fluteless taps to produce a rolled thread. Fluteless tapping is carried out at higher speeds than cutting taps, and lubrication is essential
  • Reaming—our precision zinc die casting process is so precise that holes are cored to the required size for reaming. This means we avoid drilling operations requiring the manufacturing of expensive jigs

Magnesium

Magnesium die casting alloys’ close-packed hexagonal structure makes them well-suited for the machining process.

  • Good results are obtained when magnesium alloys are machined with tools designed for machining aluminum. But because of the low resistance to cutting and the relatively low heat capacity of magnesium, we use tools with smooth faces, sharp cutting edges, large relief angles, small rake angles, few blades (milling tools), and a geometry that ensures good chip flow during machining
  • Traditionally, magnesium alloys were machined without using cutting fluids. However, we have found using cutting fluids reduces fire risk, eliminates material build-up on the tool, removes chips easily, and, most importantly, prolongs the life of the tool

Aluminum

The most widely used die casting alloy, Aluminum Alloy 380, is very good for machining purposes.

  • High-speed steel tools are generally used for machining aluminum
  • Spiral-flute reamers are preferable to straight-flute reamers when working with aluminum
  • It is not necessary to use high clamping forces when machining aluminum. By using moderate clamping forces we avoid the dimensional variations that occur as a result of distortion
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