Casting Study: Housing for electro-tool

Major Selection Criteria: Complex Shape, Dimensional Precision, Mechanical Properties, Net Shape
Alloy: Zamak 5 (ZL5, ZL0410, ZnAI4Cu1, alloy 5)
Application Field: Hand/Power Tools
Application Size: >250 g
Surface Finish: As-Cast
Casting Technique: Pressure Die Casting
Source: Kaspar Lüther Germany

ima09The drive head of this tool, made out of 2 parts, is cast in ZP5.  This casing contains the gear that translates rotating and oscillating movements at very high rpm and frequencies. The part need to comply with low tolerances for shape and position in both horizontal and vertical direction, without any additional machining operations.

Total weight of the cast parts: 351 gr.
Casting machine: FRECH DAW80 RC

Reasons for choosing zinc alloy:
The client changed to zinc pressure die-casting with ZP5 because of its strength and ability to cast very narrow tolerances without additional operations.  The cast part is ready to be mounted and represents a cost reduction as compared to the previous material.