Casting, and more specifically diecasting or high pressure die casting, is one of the most practical methods to manufacture both simple as well as complex parts and components. The process uses a mould, also known as a die, into which molten metal is injected under pressure.
Pressure this then further applied to the mould, eliminating any trapped air and ensuring even distribution of the molten metal. As soon as the metal is cooled and solidified, the mould or die opens in two and the formed part is released. Typically, this type of casting is completed with zinc, aluminum, and magnesium, but other metals and alloys can also be used.
Casting Machining Operations
After a part has been cast, there may be additional operations performed to finish the part. Today, these are largely completed with robotics and CNC machining operations, ensuring uniform results meeting the tolerances and specifications required by the OEM.
The most common type of castings machining is fettling. This can be done by robotics and is the process of removing the slight riser that is present on the surface directly under the point where the two sides of the die or mould connect. Robotic fettling is fast, effective, and provides a uniform grinding to create a perfectly smooth finish.
Other types of casting machining operations that occur after the part is manufactured include boring and drilling, grinding, and even threading. Each operation can be CNC or computer numerical control operations, or they can be controlled by an operator. Today, most casting machining is completed by CNC machining technology, with increased use of robotics in feeding workpieces into the machining processes.
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