Die casting is a manufacturing process in which molten metal is poured into a cast and then cooled till it achieves the right shape. Die casting has brought about a huge change in the entire manufacturing cycle by speeding up the process and enhancing product quality. Zinc alloy die casting gives manufacturers great potential for manufacturing products in large volumes at reduced prices. Moreover with precision castings even complex shapes and designs can be created with apparent ease. The castings are also very sturdy, which enhances their performance and durability.
As with most manufacturing processes, precision die casting also greatly reduces production costs and time in the manufacturing of small gears. Using zinc alloy die casting, one can manufacture spur, helical or worm gears, all using a single type of casting. From simple to complex sizes and shapes, die casting can be used to produce almost any type of gear. It may sound impossible, but die casting makes it possible as it has the ability to bring together the unique components of all gears into one cast.
When the tool design is created, four side cores can be put together to create the worm gear cavity. The molten metal is poured into the bore at the centre, which then evenly spreads across all the tooth casts and slowly sets into the right shape. As zinc alloy has great strength even when it is made into thin walls, you can be assured of the sturdiness and durability of the finished product. The exact amount of metal required to produce the gear is used, so you will be able to reduce a lot of metal waste.
Another reason why zinc alloy die casting is an affordable option for manufacturing of small gears is that it reduces the need for the secondary finishing options. Precision castings decrease the need for secondary tasks that are generally carried out after the product is manufactured. To illustrate:
Indicator, timing marks, date, part number or other details can be carved or embossed in the casting. So when the metal is cast, the details are automatically embedded into the gear. You don’t need a separate process to mark all these details.
Also, if you need a parting line in the gear, while die casting zinc, simply mark the exact position in the mould. The parting line will accurately appear in all the gears.
There are lots of other ways in which zinc alloy die casting proves to be beneficial in the manufacture of small gears, which is why it is used in precision castings of gears.