Um guia completo sobre fundição sob pressão versus usinagem CNC

Na produção de peças complexas, tanto os processos de usinagem CNC quanto os de fundição sob pressão apresentam algumas propostas de valor. No entanto, consider certain aspects in selecting a suitable process for the project. These may be the material requirements, production rate, e custo, entre outros. Então, this guide will also aim to provide an overview on the major differences between die-casting vs CNC machining. It will also discuss their advantages and disadvantages, and what needs to be considered when choosing between CNC machining and die casting.

O que é usinagem CNC?

CNC (Controle Numérico Computadorizado) machining is a form of production known as subtractive manufacturing, ou seja. the elimination of material from a block of metal. This elimination is generally called a piece to form a finished part with specific geometry. It includes cutting materials into the desired shape with the help of computer-controlled machines. These machines can be Mills, Lathes, and routers. CNC or computer numerical control machining is highly valued for its accuracy, versatilidade, and versatility in material choice, incluindo metais, plásticos, e compósitos.

O que é fundição sob pressão?

The die-casting process involves injecting fluid material into a mold cavity through applying high pressure. The mold generally fabricated from steel enables the formation of parts that are intricate in form and with excellent features. After the metal has cooled down and has gained its solidity the part is then expelled from the mold. It is used where large quantities of the same metal part like nonferrous metals are being manufactured. These materials can be alumínio, zinco, e magnésio.

Key Factors for Choosing Between CNC Machining or Die Casting

Here are some key factors we know for selecting between CNC machining and Die-casting.

1. Requisitos de materiais: CNC machining can work with a very broad range of materials. While die casting can only be used on specific metals.
2. Volume de produção: When it comes to the type of production die casting is cheap in the production of large quantities of products as compared to CNC machining. Então, it is quite advantageous for small quantities of production.
3. Complexidade da peça: CNC machining is the most preferable for detailed designs. While die casting is perfectly suitable for complex shapes and small details.
4. Tempo de espera: Compared to traditional machining, CNC machining usually has a smaller lead time. Então, it is ideal for creating prototypes or small production runs.
5. Custo: The advantage of die casting is that it offers more economic value in the case of larger production runs. No entanto, the cost of tooling is high in this process. Por outro lado, CNC machining is more cost-effective at the initial stages of production than at the latter stages of production.

Como does CNC Machining Work?

CNC machining means Computer Numerical Control machining and is a subtraction process in which a machine is used to direct a tool, which cuts a part out of a block of material. It is an electronic machine that keeps the correct shape of the design while cutting. além disso, it helps shape as well as polish the material. This method is very precise and can be used on a whole range of substrates from aluminum and other metals to plastics.

Como does Die Casting Work?

Die casting is where metal is forced under pressure into a mold that forms from steel. The equipment and the material used are mechanical. They first cool and then solidify into the shape of the mold as per the desired requirement thus achieving a high degree of accuracy. além disso, it is most suitable for manufacturing a large quantity of intricate metal parts or relatively soft metals such as aluminum, zinco, e magnésio.

What are the Differences Between Die Casting vs CNC Machining?

The following are the major aspects to differentiate between Die-casting and CNC machining.

1. Tipo de processo

Die casting is a short-cycle process of making metals into shapes of the required design by pouring molten metal into a mold. CNC is the other category of machining. It is subtractive for a solid block material is cut away using tools controlled by computers, It gives highly accurate results and is good for complex shapes.

2. Compatibilidade de materiais

Die casting involves working with non-ferrous metals such as aluminum, zinco, e magnésio. Por outro lado, CNC machining uses a wider range of materials, ou seja. metais, plásticos, e compósitos. Então, it shows flexibility in material selection.

3. Volume de produção

Die casting tends to be more economical in the creation of large numbers of items. Aqui, the cost per part is considerably cheaper when the die mold is made. CNC machining applies to low to medium volumes so they’re ideal for quick and easy changes than larger runs.

4. Complexidade da peça

As for die casting, it enables the creation of different shapes with high detail in the final part of one cycle. Thus it is suitable for application in large quantities. CNC machining offers excellent accuracy and is highly suitable for creating complicated shapes. Além disso, simple shapes can be built in a single step in the CNC machining process.

5. Lead Time and Setup

Die casting has relatively longer initial lead times especially due to mold making. Aqui, the production times are relatively fast after mold manufacturing. Another reason for the wide use of CNC machining is the short lead times and relatively quick changes than other conventional machining methods.

6. Cost Considerations

Die-casting aluminum has considerable fixed costs intact. No entanto, it operates at a low cost per unit in large numbers. CNC machining is cheaper in the long run but may be costly for single-part production. It takes a longer time to produce parts than the cast aluminum process. Então, it is suitable for small-volume or precision-requiring projects.

This table will briefly describe the Die casting vs CNC machining. Então, you can get a better understanding of their differences concerning different aspects.

Aspecto	Fundição sob pressão	Usinagem CNC
Tipo de processo	Here the molten metal is injected into a steel mold.	Material removed from a solid block using CNC tools.
Compatibilidade de materiais	Non-ferrous metals (alumínio, zinco, magnésio).	Metais (alumínio, aço, titânio), plásticos, compósitos.
Volume de produção	Economical for high volumes (por exemplo., 10,000 para 1 million parts).	Suitable for low to medium volumes (por exemplo., 1 para 1,000 parts).
Complexidade da peça	Handles complex shapes and fine details effectively.	High precision for intricate designs; multiple setups may be needed.
Lead Time and Setup	Mold creation takes 4-12 semanas; fast production cycle (por exemplo., 10-30 seconds per part).	Setup time typically 1-5 dias; faster production for small batches (por exemplo., 1-20 parts per hour).
Cost Considerations	High initial tooling costs ($5,000 para $50,000+); low cost per part ($0.10 para $5.00 per part).	Lower initial cost; higher per-part cost ($1 para $100+ depending on complexity).

Vantagens e desvantagens da usinagem CNC

The following are the pros and cons of CNC Machining. These will help us understand how CNC machining is better for our projects and its limitations.

Prós:

1. High precision and accuracy.
2. It can be used with many different materials and many colors.
3. Applicable for firms that produce moderate levels of units with low to medium variability.
4. Faster time to deploy and lower lead time.
5. Flexibility in design modifications.

Contras:

1. This process consumes a lot of materials to arrive at the final product. Portanto, it leads to wastage.
2. Different cost structures for mass production are based on the total cost per part in a mass-production operation. This cost is higher for a large number of operations performed.
3. Of course, working extra hours on complicated parts is another critical issue to consider in machining.
4. If the tool is only used and the technique is not implemented in the existing machines. It is limited to the tool’s mobility.
5. Geometries that involve hatchings and other such structures, may need several operations to be completed.

Advantages and Disadvantages of Die Casting

The following are the pros and cons of die-casting:

Prós:

1. Cost-effective for high-volume production.
2. High detail and the possibility to make complicated forms, due to thin walls.
3. No need for re-shaping which reduces the use of more material than required.
4. It lengthened the life of cast parts making it possible to achieve high strength.
5. High and uniform dimension accuracy, along with fabrication accuracy.

Contras:

1. High initial tooling costs.
2. These limitations apply only to several metals and alloys.
3. Portanto, longer lead times are expected to be inevitable when it comes to the development of tooling.
4. Not very useful for small-batch production.
5. Some features of the castings that may be attained with sand casting method: Potential for porosity and other casting defects.

Which Process is Mminério Appropriate for My Project?

For a given project, you can choose between CNC machining and die casting depending on what will suit the project best. If you require high precision parts, low volumes, or require materials that cannot be used in die casting. Então, you can opt for CNC machining as it is suitable for use. Por outro lado, if you are making large iron machined parts with small features. Then die casting can prove to be more economical and effective.

Aplicações de usinagem CNC

1. Componentes aeroespaciais
2. Partes automotivas
3. Medical devices
4. Precision tools
5. Electronics housings
6. Custom prototypes
7. Industrial machinery parts

Applications of Die Casting

1. Automotive engine components
2. Consumer electronics casings
3. Hardware tools
4. Household appliance parts
5. Telecommunications equipment
6. Lighting fixtures
7. Industrial machinery components

Conclusão

Para concluir, CNC machining and die casting are two distinct manufacturing procedures. They both need to be compared based on certain factors including material type, parts quantity that you want to produce, complexity of the part, and price. além disso, each of the two processes has its strengths and weaknesses. Então, we know these will help determine which method to adopt in the manufacturing process.

perguntas frequentes

1º trimestre. What can be fabricated in CNC?

CNC machining can manipulate a lot of materials such as metal, plástico, composite, and even wood.

2º trimestre. Is die casting appropriate for making small quantities of parts?

Absolutamente sim. Die casting is more suitable for large production since it requires high initial costs for tool preparation.

3º trimestre. Is it possible to create parts with complicated shapes using CNC machining?

Sim, the machining done with the use of a computer can create such small designs. But it may require more than one process.

4º trimestre. What are the main benefits of die-casting?

It is suitable to manufacture parts in a large number of pieces. These pieces have uniform quality and small intricate features.

Q5. What is the difference between lead times for cnc machining and die casting?

CNC machining normally takes a shorter time than die casting. Portanto, it is preferable for prototype runs and limited production quantities.