kineticdiecasting.com

Aluminum Parts Machining Differs from Steel Parts Machining. Aluminum can be used in many ways. However there are different ways on how you can work with it. Aluminum parts machining requires less power compared to steel parts or cast iron parts because they are light weight.

Aluminum parts machining can be different in cast iron machining. It’s the type of tools and tooling technologies that you will use will make a difference.

Kinetic Die Casting Company makes aluminum die cast parts. If you are working with aluminum parts, the spindle of the machine should be strong and forceful. Spindles require higher speeds along with a lesser low-end torque compared to machining other metals like steel. Also, the spindle should be stiff because it will work in very fast conditions. Other experts on this field recommend the use of HSK tapers to ensure accuracy and rigidity. Moreover, if you are using very fast tools, rotating inertia can be reduced with the use of closed-loop spindles powered by a motor.

Furthermore, it requires little cutting forces if you are working out with aluminum parts. The machine has to be well-damped and stiff.

Since you are working with high speeds, there’s a chance of thermal growth. It can create a major problem if you are working out with light metals. It can lead to a major problem if you are working with light metal parts like aluminum.

Find yourself a machine with thermal control system. A cooling system is recommended in order to reduce the frictional heat in the bearings when the higher spindle speeds up. Also, you must protect the spindle against coolant penetration by sealing it because the entire machining operation of a light metal is not dry.

Heat Sinks in Aluminum draw heat from another source from thermal contact. These are mainly used in electronic parts and automobile parts but there are other uses like:

• Airplane parts
• Circuit boards
• Microwaves
• Cell phones
• Satellite components
• Laser components
• Motor housings
• Automotive
• Lighting parts

Aluminum Heat Sinks absorb and dissipate the heat from another object. It is a piece of molded aluminum or copper that usually sits directly on top of a feverish source or processor. In many cases, you won’t be able to see the processor unless you take out the aluminum heat sink first.

Wherever there is a need for efficient dissipation of heat, there will surely be aluminum heat sinks installed. A major industry that uses heat sinks is refrigeration.

The aluminum heat sinks manufactured these days come in different shapes and sizes. The typical heat sink though, has long fins and thin protrusions for conducting the heat from the processor to the cooler environment inside the aluminum heat sink. Die Casting Companies make heat sinks.

Most of the heat sinks in the market these days are equipped with fans that blow the cool air to the fins to dissipate heat more effectively. These fans or blowers are usually placed on top of the fins or in the middle.

Aluminum heat sinks are designed to require less machine processing. The fins can be manufactured simultaneously with the mounting holes. Typically, about 250 to 2500 heat sink parts can be produced per day.

Aluminum Heat Sinks are objects that draw heat from another object through thermal contact. They are mostly used in electronics and automobiles. Aluminum is a lightweight and sturdy material that has good thermal and electrical properties, that’s why it has become the material of choice for most heat sinks.

Aluminum heat sinks are produced by die casting by a Die Casting Company, a process wherein molten metal is forced is forced into mold cavities. The die casting process is beneficial if you are producing large quantities of small to medium sized automotive parts with good details. Prior to the introduction of die casting, most heat sinks are made by welding several pieces together and drilling holes, if required, after. This process is time consuming, costly, and labor extensive. Die cast aluminum heat sinks are good as raw parts but they can be powder coated and anodized easily.

Die Cast Aluminum heat sinks can be manufactured in a much faster rate—ranging from a few hundreds to a few thousands small to medium sized parts a day—because they can be produced in net shape and there are no welding and drilling methods needed after. Die casting saves time, money, and energy all together.

Die cast aluminum heat sinks are definitely lighter than their stainless steel counterparts, with a specific gravity of about 0.10 pounds per cubic inch. Because they are electrically conductive, aluminum heat sinks are used for radio frequency (RF) and electronic magnetic inductance (EMI) shields. This quality also allows them to be grounded easily.

Aluminum heat sinks are used in airplane parts, circuit boards, microwaves, cellular phones, satellite components, laser components, motor housings, automotive, lighting parts and many more.

Another California Die Casting Company closed their doors in 2007, Cascade Die Casting/ Pacific (aka CDC).

This is the information Cascade Die Casting/ Pacific published as their capabilities and mission:

Cascade Die Casting/ Pacific
950 Turnbull Canyon Road
City of Industry, California 91745

Mission for Cascade Die Casting/ Pacific:
We are a leader in the manufacturing of high quality, high value aluminum and zinc cast products and services for our customers. We will accomplish this mission through:
- employee involvement and commitment
- continuous improvement of our people and processes
- ongoing advancement of design and engineering capabilities
- utilization of our national presence

Materials:
Die Cast Aluminum Alloys: A380, A383, zinc and specialty alloys upon request

Capabilities:
Die Casting
High Pressure Die Casting Machines: 400 to 1200 ton
Fully automated die cast cells, shot and process monitoring

Secondary Finishing
Full service finishing including sanding and vibratory deburring
CNC and dedicated machining, testing and sub-assembly

Facilities
Plant 1: 80,000 sq. ft. manufacturing and office space

Customer Service
Production control & material handling JIT/EDI services
Coating processes with certified sub-suppliers
chem-film, anodize, plating and powder paint

Engineering Services
Product, tooling & process engineering, project management
Solid Works, AutoCAD Mechanical Desk Top
Solid Modeling, flow simulation rapid and die cast prototyping capabilities

Major Products:
safety restraint components
seating frames, components
electronic heat sinks, housings
compressor/pump components
power tool tables, brackets, covers
speaker and telephone housings, frames

Key Markets:
Automotive
Telecommunications
Consumer Electronics
Power Tools
Office Furniture
Other

Cascade Die Casting/ Pacific is another example of how difficult it is for a die casting manufacturing company to stay in business in California. Cascade had a long history of being a great supplier here in California and Cascade Die Casting/ Pacific will be missed by their former employees, their suppliers and their customers who need aluminum die casting parts.

Kinetic Die Casting continues to be strong while other die casting companies are closing down or selling out.

Extruded aluminum heatsinks are made by heating aluminum to the point of a semi-solid state. Then this aluminum is pushed (extruded) through an extrusion die. These aluminum forms have the profile of the die it was pushed through, much like the play dough toy extruder. The simple shapes are stars or circles. These forms are cut to the length needed.

Aluminum Heatsinks that are extruded typically have a flat bottom and ribs on the top. They can be extruded in lengths of several feet an cut to shorter lengths. Because these extruded aluminum heatsinks were formed by pushing through a die, there is a limitation on details that can be formed on the top and bottom surfaces. If a depression is needed to mount components then it will need to be machined into the part as a pocket as an after operation, dramatically increasing the part cost. More typically, if holes are needed for mounting, they too will need to be machined into the parts as a secondary operation. Any other holes needed so wires or components can pass through have the same limitation.

The Aluminum Die Casting Process injects metal into a mold or die that forms the top, bottom and sides. Mounting holes, through holes and cavity indentations formed into the part are in the die halfs on the top and bottom. Aluminum Die Casting Heatsinks will have all the features necessary for installing the components and the holes for mounting during the original manufacturing operation. Die casting heatsinks will not require secondary operations for holes and features.