Multi-slide die casting is a sophisticated metalworking process to form complex near-net-shape parts. The main objective of multi-slide die casting is to reduce or eliminate the need for secondary machining of parts. In this article, we have briefly discussed the process, application, advantage, etc. of multi-slide die casting.
Multi-Slide Die Casting Process
Multi-slide die casting is basically an upgraded version of the hot chamber die casting. This process is primarily used for miniature die casting of zinc alloys. Therefore, the process is quite similar to that of any regular die casting.
However, opposed to the conventional die casting process, multi-slide die casting usually has four perpendicular slides/dies. There are also multi-slide machines with five to six slides as well. The slides close to form a cavity. Then, molten metal is injected into the die cavity using a plunger.
The dies are tightly locked together by pneumatic force and a toggle mechanism. The casting is solidified in seconds and then the slides open and blow the part from the cavity with an air-blast. Then the next casting cycle begins.
Multi-Slide Die Casting Applications
Multi-slide die casting is mainly used for casting zinc alloy parts. Therefore, the process is also known as 4-slide zinc die casting. This process can cast complex small zinc parts with high speed and accuracy. Though, there are also machines capable of casting magnesium components as well.
One of the main applications of a four-slide die casting machine is to cast parts with internal or external threads. Because, a conventional die casting process can’t cast threaded objects and requires secondary machining afterward, which is rather costly.
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4-slide Zinc die casting is cost-effective when you need to diecast parts with intricate features. Though, the process is only ideal for small size parts at large volumes. A conventional hot chamber die casting can be more economical for parts with simpler details.
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What are the Advantages of Multi-Slide Die Casting?
Multi-slide or four-slide die casting offers many advantages over a conventional die casting process. Here we have discussed the main advantages to give you a rough idea.
Flexible Part Design
The Design for Manufacturing (DFM) of multi-slide die casting parts is much more flexible. Oftentimes, a complex shape that would be difficult to cast as a single part can be easily cast with a multi-slide machine. Also, you have more control over the direction of pull.
High Precision and Repeatability
Multi-slide die-cast ensures higher accuracy for the parts. The diecast parts require little to no secondary machining. This minimizes the chances for inconsistency in parts. Moreover, you can cast parts with intricate details and thin walls much more easily. Especially parts with threads are highly accurate when doing the casting.
Reduces Production Time & Waste
Multi-slide die-cast can significantly reduce the production time of parts as the parts don’t require any significant post-processing. Multi-slide die-cast parts have negligible flash, runners, and overflows than that of a conventional process. Therefore, this process generates much less waste as well.
Lower Production Cost
The lower production cost of multi-slide die casting technology is a result of various factors. The elimination or reduction of secondary operations, reduced scrap, production time, and labor altogether make the process more cost-effective.
What are the Limitations of Multi-slide Die Casting?
If the multi-slide die casting process is so advantageous, why not use it instead of the conventional one? Well, every process has its pros and cons. So, you need to take into consideration several factors before you can select the proper manufacturing process for your parts.
Four-slide die casting is limited to small and complex parts. Usually, multi-slide die casting is a better choice if the parts are less than 400g. Parts larger than that may not fit into the 4-slide zinc die casting machines available in the market.
In that case, it is better to stick with regular die casting. Because the multi-slide die casting machine is much more complex and sophisticated. Unless you are dealing with a large number of parts, it would not be economically sustainable to create a custom-made multi-slide die.
What are the Differences Between Multi-slide and Conventional Die Casting?
The main difference between conventional and multi-slide diecast technology is the die we use for casting. Though this difference significantly sets them apart in terms of their capability. Let’s have a look at the differences between them,
Number of Slides
The most obvious difference between conventional and multi-slide die-cast is the number of slides. A conventional die casting machine consists of two die halves which are a moving die and a stationary die. Whereas a multi-slide machine may consist of four to six slides. In this case, all of the slides can move in a direction perpendicular to the die.
Complexity and Precision
Multi-slide die casting can produce high-precision parts. Also, more complex shapes can be diecast using multiple slides, which would not be possible with a regular die casting process. For example, you can cast parts with internal and external threads more easily.
Post-Precessing
Conventional die casting has more post-processing costs involved. Whereas, multi-slide die cast can significantly trim down the post-processing cost. Because the finished parts have negligible flash and other residual features. And, typically doesn’t need any secondary machining after casting.