Shenzhen Alu Rapid Prototype Precision Co., Ltd.

Cutting die-cast metal, such as aluminum or zinc, requires careful selection of tools and techniques to achieve clean, precise cuts without damaging the material or compromising its integrity. Die-cast metals are typically softer and more brittle than wrought metals, so specific considerations apply. Below is a concise guide on how to cut die-cast metal effectively:

Steps to Cut Die-Cast Metal:

1.Prepare the Workpiece:

Clean the die-cast part to remove dirt, grease, or coatings that could interfere with cutting.

Mark the cutting line using a marker, scribe, or caliper for accuracy.

2.Secure the Workpiece:

Clamp the die-cast part firmly in a vise or use C-clamps to secure it to a stable surface. Ensure the cutting area is accessible and the part won’t shift during cutting.

3.Choose the Right Tool and Blade:

For aluminum: Use a bi-metal or carbide-tipped blade with fine teeth (24-32 TPI for hacksaws, 10-14 TPI for band saws). Aluminum is soft but can gum up blades, so choose one designed for non-ferrous metals.

For zinc: Similar blades work, but zinc is more brittle, so avoid excessive force to prevent cracking.

For precision or thin parts, a Dremel or jeweler’s saw with a fine blade is ideal.

4.Apply Lubricant:

Apply cutting fluid or lubricant to the blade or cutting disc to reduce heat, prevent blade sticking, and extend tool life. For aluminum, this also prevents chip welding.

Cut the Metal:Hacksaw: Use steady, even strokes with light pressure. Let the blade do the work to avoid bending or breaking the die-cast part.

5.Band Saw: 

Set a moderate speed for non-ferrous metals and feed the material slowly to avoid blade deflection.

Angle Grinder: Use a thin cutting disc and make slow, controlled passes. Keep the grinder steady to avoid gouging.

Dremel/Rotary Tool: Use high RPM with a cut-off wheel for small or detailed cuts, applying minimal pressure.

CNC/Industrial Cutting:Program the machine for the correct feed rate and cutting parameters based on the alloy and thickness.

6.Cool and Clean the Cut:

Allow the cut area to cool naturally or use compressed air to remove debris. Avoid water cooling unless the alloy is resistant to corrosion.

Wipe away excess lubricant and metal shavings.

7.Deburr and Smooth Edges:

Use a metal file, sandpaper (400-600 grit), or a deburring tool to smooth rough edges and remove burrs.

For polished finishes, use progressively finer sandpaper or a polishing compound.