Whitehouse Machine Tools has provided three four-axis high-speed machines to enable diecasting company Kemlows to step up production of a complex telecommunications component

The three Brother twin-pallet machining centres have enabled Kemlows to reduce manufacturing costs for its aluminium and zinc castings by modifying the design and machining it from a high-pressure aluminium diecasting, rather than from solid billet.

As a result of using the near-net-shape technique, 70 per cent of the material is saved from being turned into large volumes of swarf, avoiding the inconvenience of managing it on the shop floor and the expense of recycling.

The machining cycle is much faster, as only 0.75mm has to be skimmed from the surface of the castings.

A further 10 per cent of material has been taken out following consultation with the customer and re-engineering its IGES solid model in Kemlows' Solidworks CAD system.

The additional saving was achieved by reducing the size of internal bosses and other unnecessarily thick sections.

Material was also taken away from the exterior by introducing pockets all around the part, including on the base.

The resulting casting combines minimum material volume with a geometry capable of being cast without cooling problems or difficulty in...

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Tags: alloy casting die, aluminum die casting, automotive die casting, die casting design, die casting finishing, die casting molds, low pressure die castings, zinc die casting, zinc die casting alloys

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