Magnesium or Aluminium, both materials have their merits, and the choice often depends on factors like weight, cost, and specific performance requirements.

In the realm of aluminum die casting, the process unfolds through a meticulously orchestrated series of steps, especially crucial when crafting bespoke components tailored to specific industrial needs. Here's a detailed breakdown of the steps involved in this intricate process :

Review of e-bike's brand Specifications:

The journey commences with a comprehensive review of the e-bike's brand 2D drawing and a 3D CAD model of the desired part. This critical step establishes the foundation for the subsequent phases of the aluminum gravity die casting process.

Creation of 3D Pattern and Prototype Confirmation:

Building upon the initial design, a 3D pattern of the part is meticulously crafted. This pattern serves as the prototype, and its confirmation with the customer ensures alignment with their exact specifications before progressing further.

Development of Reusable Sand Cores and Metal Molds:

With the prototype approved, the next step involves the creation of reusable sand cores and metal molds. These molds will be instrumental in shaping the molten aluminum into the desired form during the casting process.

Completion of PPAP Process:

The Production Part Approval Process (PPAP) is a crucial checkpoint in ensuring the quality and conformity of the manufactured components. This step involves a comprehensive evaluation and validation of the production process.

Melting and Pouring of Die-Cast Aluminum Alloys:

The heart of the process lies in the melting of die-cast aluminum alloys, which are then poured into automatic gravity die-cast machines. This step demands precision and expertise to guarantee the accurate formation of the intended components.

Cooling, Solidifying, and Gate Removal:

Subsequent to the pouring process, the cast aluminum undergoes cooling and solidification. Once the material has taken its final form, the gate, which facilitates the entry of molten metal into the mold, is meticulously removed.

Heat Treatment for Mechanical Properties Enhancement:

To enhance the mechanical properties of the castings, a crucial step involves subjecting them to heat treatment. This process optimizes the material's strength, durability, and overall performance.

Shot-Blasting for Surface Refinement:

Shot-blasting comes into play to remove contaminants and smooth any rough surfaces. This meticulous refinement process ensures that the final product meets the highest standards of quality and aesthetics.

CNC Machining for Precision Refinement:

The concluding touch involves refining the components further through CNC machining. This step ensures the utmost precision, meeting tight tolerances and providing the finished parts with the desired specifications.

In conclusion: 

The aluminum gravity die casting process is a symphony of precision and craftsmanship, ensuring that the end products not only meet but exceed the expectations of the customer. Each step in this intricate dance contributes to the creation of high-quality, customized components for diverse industrial application ...