Aluminum Die Casting
Aluminum is cast at a temperature of 650C (1200F). It is alloyed with Silicon 9% and Copper about 3.5% to form the Aluminum Association 380 alloy (UNS A03800). Silicon increases the melt fluidity, reduces machinability, Copper increases hardness and reduces the ductility. By greatly reducing the amount of Copper (less than 0.6%) the chemical resistance is improved; thus, AA 360 (UNS A03600) is formulated for use in marine environments. A high silicon alloy is used in automotive engines for cylinder castings, AA 390 (UNS A03900) with 17% Silicon for high wear resistance.
Engineering
With a team of designers with over years of experience in designing, GAP combines together the latest technologies/platforms and rich experience. Once the tool design is complete, the design data is converted into machining data using softwares and this data is transferred directly to High Speed and High Precision Machining Centers.
Also acting as project manager, the engineers at GAP follow the process from the initial quote to production. Our engineers work closely with the customers to answer any questions and assist with design issues.
Our Department of Engineering provides:
- Information about die casting
- Collaboration on design with customers
- Reverse engineering
- 3 Dimensional modelling
- 3D samples prototype model
- Mold and tool design and fabrication
- Actual cast part prior to production
- Continued support with any part issues
Prototype Models
Our new Rapid Prototyping System can quickly turn computer design data into a 3D prototype.It can help us to communicate and evaluate design concepts more efficiently and collaborate with partners and vendors more effectively & gives 3D physical prototype in 24 hrs.
We finish all Prototype models to your specifications – from a basic fit-check model to a beautiful “show” model with custom paint, textured finish and graphics.
Die Casting
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
CNC
CNC mills can perform the functions of drilling and milling. The CNC Mills at PDC are controlled by sophisticated network of computers. The 3D mold file is converted into surfcam file which plots the 3D mold on an x, y, and z graph. Giving cooridinates to the required cuts. These coordinates control the CNC Mills according to the axes that they possess. Axes are labeled as x and y for horizontal movement, and z for vertical movement.
Mold & Fabrication
We design 3D models of parts, molds and components. Engineering is also compatible with Pro Engineering, Auto Cad and all major 3D & 2D design software.
Acme will quote insert tooling. Their customers have the option of paying for inserts only and using company owned holders. By using these holders or mold bases this allows for faster lead times and lower cost.
