2 MILES FROM JUNCT 21 M62 MOTORWAY      FINISHES THAT ARE AVAILABLE      TOOLS FOR CLIPPING      UNIT TOOLING FOR FASTER CHANGEOVER TIMES      WE ARE A B.S.I REGISTERED COMPANY

 

   

 

Technical Information  about Zinc Die Casting

Zinc.

Zinc die casting is an efficient, economical process which provides complex shapes with thinner wall sections held at closer tolerances than any other high volume production process, offering components that are durable and dimensionally stable with little or no requirement for post casting machining. Zinc castings are suitable for the application of a multitude of surface finishes with minimum preparation, a wide variety of cast on surface textures can also be achieved, zinc castings are also fully recyclable.

Holes can be cored to size in the line of draw or otherwise ready to be threaded for example, external threads can be cast on along with other fixing methods such as bosses, spin rivets and metal inserts for cost saving during assembly.  

 

  

Design.

In order to produce the best possible casting quality we work along side our material suppliers employing DMT CASTFLOW software to first simulate and then produce the best possible runner and gate design in order to achieve optimum cavity fill characteristics.  

Being involved with our customers from the very beginning of a project allows for many post casting operations to be designed out.

 

 Tool Design

 

 

Tooling.

As each individual project requires tooling designed specifically for it we liaise closely with our customers and toolmakers in order to achieve the optimum choice, for smaller parts on a tighter budget we offer unit tooling resulting in a low cost tool with very quick change over times to keep production costs to a minimum, through to full tools of either single or multi-impression

 

  

Unit Tool

 

 

Capacity.

Kenwell operates seven diecasting machines of varying sizes and capacity ranging from 80 to 120 tonne locking force offering casting weights that range from under 1g to over 1500g.

 

 

  

Samples of castings we produce

 

 

Post Casting Operations.

Although we attempt to design out as many post casting operations as possible some usually remain, at Kenwell we have the capacity to drill or ream holes to size, tap internal threads and cut external threads (where they can not be cast on) and also spin/standard rivet mating parts together.

An area that we pay particular attention to is the clipping operation as this offers a great deal of scope for not only removing the runner and gate but actually clearing holes to size and position and forming the external/internal profile as well, increasing production speeds, accuracy and repeatability greatly.

 

 Clipping tool
Where possible we use machinery such as multi spindle drilling machines to increase productivity and reduce the cost of the component.  

Multi spindle drilling machine

 
We also use a number of selected subcontractors for the application of various surface finishes from painting and powder coating to chrome plating delivered in a finished condition to our customers.

 

Various finishes and coatings available

 

 

Material Specification.

We are currently producing castings in ZP3 (see specification below) however production in any other zinc alloy, ZP2, ZP5, ZP8 or ZP12 is possible if required, for detailed specifications of any or all of these alloys please contact us.

 

 

 

Zinc ingots