Casting Study: Frame Cover

Major Selection Criteria: Integration of Multiple Functions, Mechanical Properties
Alloy: Zamak 5 (ZL5, ZL0410, ZnAI4Cu1, alloy 5)
Application Field: Industrial
Application Size: 250 x 60 x 80 mm (E=1.5-2 mm) / 9.84 x 2.36 x 3.15 (T=0.06-0.08) inches
Surface Finish: Other
Casting Technique: Pressure Die Casting
Source: A.M.I. Fonderie

frameco2_photo2_caseID113The high dimensional tolerances possible with zinc die casting permitted precise and reliable seating of 6 bushings, diameter 8 mm/0.31 inches, with a diametral tolerance of ± 0.015 mm without additional machining. The complex shapes achievable in zinc die casting also permitted integration of various functions (motor bracket, axle housings that provide the motion for input and output of the ticket, positioning of the detection cell far more reliably than press formed steel sheet which reduced assembly cost. The zinc die casting provided electromagnetic shielding that was not possible in plastic, and a much more rigid part compared to the assembly of multiple parts that would be required in aluminum or steel.