Die Casting Mold
Die Casting Mold Making
Die casting is the process of using a heat-resistant mold to make different products under intense pressure. It is a complex process involving molten metal to produce components with minimum wall thickness.
Die casting molds have quickly substituted the sand casting molds because they give better results and can be reused multiple times. Investing in a die casting mold is worth it because you can use the mold to create thousands of components. However, for the best results, you need high-quality steel for the steel insert.
For production processes requiring aluminum die castings, you must source the highest quality of aluminum alloy. However, molds made from molten metal are most common because they give a wide range of high-quality parts, thinner-walled castings, and dimensional accuracy.
The design phase for die casting mold production is essential since it influences the outcome.
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Die casting mold has gradually gained popularity in the industrial sector because it outfits many applications. The die casting mold is a crucial element in the process of die casting. The shape and properties of the mold influence the attributes of the finished product.
Consequently, it is important to comprehend the die casting mold design. This will assist you in creating the ideal mold and selecting it for your die casting tasks. Additionally, you can ensure that the finished product will adhere to specific specifications.
Every metalworking operation requires a mold, and die casting is no different. When referring to a mold, the phrase ” die ” and ” tool ” is frequently used interchangeably. Metal is injected into a die casting mold to create metal components.
It greatly increases the efficiency of producing several pieces. However, given that die casting molds are made using computer numerical controlled (CNC) machines, they can be quite expensive. CNC machines are expensive to operate and need qualified personnel.
However, a knowledgeable die casting manufacturer can help you improve your design and significantly lower the cost of mold tooling. Therefore, your experience with die casting may be significantly impacted by your choice of die casting supplier.
Die Casting Process
Our molds are heat-resistant and are made through high pressure die casting process. A complicated technique using molten metal is required to create components with minimal wall thickness.
Die casting molds have quickly replaced sand casting molds because they produce better results and can be used again. The investment is worthwhile because you can use a die casting mold to make thousands of components. However, if you want the greatest outcomes, you need premium steel for the steel insert.
It’d be best if you got the highest grade of aluminum alloy for production procedures that call for aluminum die castings. However, molten metal molds are more frequently used because they produce many high-quality parts, thinner-walled castings, and accurate dimensions.
Materials Used To Make Die Casting Mold
The materials used to make the casting mold should be resistant to high heat and pressure. There are several alloys that can be successfully subjected to die casting procedure forces. The best materials for making mold are copper, brass, aluminum, zinc, and magnesium.
Other suitable strong metal alloys can also be considered to make the die mold.
Advantages of Die Casting
As mentioned before, the die casting mold is perfect for designing and creating different parts through the die cast process. Here are some of the advantages of using die cast mold:
- Die casting offers complicated designs with tighter tolerances compared to many other mass manufacturing methods.
- High manufacturing rates are used to create die castings. There is little to no machining needed.
- Die casting produces sturdy, dimensionally stable parts that feel and look premium.
- The walls of die castings can be made thinner than other casting techniques and significantly stronger than plastic injection moldings of the same size.
- Before additional equipment may be needed, die casting dies can create hundreds of identical castings within predetermined tolerances.
- Zinc castings can be simply polished or plated with the least effort.
- Die castings can be made with surfaces that mimic many different textures.
- Compared to most other casting methods, including sand, permanent molds, and investment procedures, die cast surfaces are smoother when cast.
- Die casting holes can be cored and made to fit specific drill diameters.
- Parts’ external threads can easily be die cast.
- Die castings include built-in fastening components like bosses and studs, which can lead to assembly cost savings.
- Other metals and some non-metals can have their inserts die cast into place.
- Die casting alloys range in corrosion resistance from good to high.
Die castings are monolithic. This is because they combine several functions into a single, intricately formed component. Since die castings are not made of discrete sections that are welded or joined together, the strength, not the threads or welds, is that of the material.
When exploited to its fullest extent, die casting is an effective and affordable method that may replace assemblies of multiple parts made using different manufacturing processes while saving money and labor.
Disadvantages of Die Casting Mold
While the die cast mold is advantageous for many reasons, it also has some setbacks. Here are a few disadvantages of the die cast mold:
- It can’t be used for all metals and alloys
- The price of the tools, dies, and another machinery is high.
- Starting with small-scale production is expensive.
- In order to prevent porosity, it is important to take certain steps to evacuate the air from the die cavity.
- It is impossible to obtain a die casting prototype during the product development process.
You have to consider these disadvantages and their implication on your manufacturing process before deciding to use die cast mold.
Benefits of Die Casting Mold To Companies
Die cast mold is a great tool for manufacturing companies producing bulk parts and items. Here are some benefits companies can get from using die casting mold design:
Easy Mass Production
Since die casting is produced using a die casting mold, the tolerance and shape requirements can be met. Numerous similar castings can be manufactured without the need for extra tools and little to no machining. Thus, mass production is quite simple.
The die casting mold’s enormous manufacturing capacity is its most significant benefit. One of the quickest methods of production is die casting. It is also made possible by molds. Now, many parts can be produced quickly and in large quantities.
Strength And Weight
Comparable-sized die cast pieces are more durable than plastic injection molded parts. Castings with thin walls are more durable and lightweight than other casting techniques. Additionally, the strength of die castings comes from the alloy rather than the joining process since they do not consist of distinct sections that are welded or connected.
Die Casting molds can work efficiently for a very long time. Therefore, over time, die casting costs per part are greatly decreased. And a high-pressure aluminum die casting mold manufacturer is where you can find the most affordable manufacturing solution.
Dimensional Accuracy And Stability
Die casting creates components with tight tolerances that are dimensionally stable and long-lasting. They can withstand heat as well.
Parts that are produced using die casting molds have exceptional dimensional stability. Tight tolerances and thin walls can be incorporated into the design. Therefore, it is simpler and quicker to produce parts with intricate details.
Typically, non-ferrous metals with a relatively low melting point are cast using die casting molds. Materials with a greater melting point than those used for die casting are employed to create the mold. Additionally, the molds can endure extremely high pressure.
Complex Thin-walled Components
Aluminum die casting has an advantage over other metal molding castings and investment castings because it can produce intricately formed, lightweight components with high strength-to-weight ratios. The wall thickness of cast parts created using zinc can even be as thin as 0.3mm for parts made by die casting aluminum alloys.
Strong Mechanical Characteristics
Die cast goods have superior mechanical qualities. The liquid metal appears fine, dense, and crystalline as it solidifies under intense pressure. Die cast pieces have a high degree of rigidity, hardness, and strength. They also offer higher durability and conductivity.
Die cast components have a crystalline surface that is uniformly smooth. The molten metal alloy is used in the die casting process to fill the molds and produce precise shapes. Therefore, the parts will be fine and smooth if the die is well-shaped and the process is in good working order.
Making glossy parts reduces the need for further post-processing steps, with the exception of unique requirements. Additionally, after die casting is complete, goods can be dispatched for delivery. This may shorten the length of the entire production cycle.
Customized Die Cast Molds
You can order a customized die casting mold from us. We guarantee to offer unique die cast molds for your needs because we utilize cutting-edge technology and machining.
Further, we ensure that all our products are in accordance with all industry regulations and standards of quality.
Die Casting Mold Design
When you know what you want, die casting mold design becomes simple. To ensure that you end up with a great design for your die cast mold, you’ll need the help of a professional dedicated to precision and accuracy.
In addition, our professionals make sure the procedure is covered for cast alloys, cast suppliers, cast tools, size holes, and pricey tooling adjustments. We also work with a skilled tooling provider to obtain a variety of size examples and the quickest approach for the specified application.
The following stages take place during die casting mold design:
Die casting technology must be used to assess the part’s production before creating the mold. In this stage, the product’s viability is evaluated from a geometrical and dimensional standpoint.
During this phase, a professional takes time to consider the possible mold geometry and decide on the practicability of the design. If it’s not practical, we consider alternatives or ways of improving the design.
There are two main areas that must be considered during the preliminary stage:
At this stage, it’s crucial to ensure that you know the dimensions and the number of cavities a part should have. These are crucial elements that must be present in the mold. This will make it easier to determine the casting’s opening force and volume. Possessing this information will make feasibility assessments much simpler.
Another component of the preliminary stage is drawing the parting line as part of the product’s geometry. The die casting mold is divided in half by the parting line, making it simple to open and eject the final casting.
Additionally, the arrangement of pieces relative to parting lines affects their smoothness. Surfaces must therefore be created with the mold opening in mind.
This is important because it informs your decision on the materials and process of die casting. For instance, due to the shrinkage brought on by metal cooling, it might not be easy to manufacture the geometric accuracy of the quotations found on a 2D model.
Therefore, once you’re certain that a part can be manufactured from a geometrical view and a dimensional view, you can then proceed to the next stage.
Another important consideration in the mold design is the number of cavities required for the parts. To determine how many cavities are needed in a mold, the following aspects must be considered:
- Quantity of pieces being manufactured.
- Mold cavity orientation.
- Estimated cycle time.
These components can help decide whether the mold being made should be single-cavity or multi-cavity.
When choosing a multi-cavity mold, remember that the production process may be impacted by the cavity’s size and product disposition in addition to the ejection phases and increased difficulty filling deep bosses.
Volume And Shape Of The Die
For mold design, the die’s size and shape are crucial. Along with the intended volume, keep in mind that larger pieces will shrink faster than smaller ones due to prolonged cooling. Consequently, it is necessary to size the mold cavities appropriately.
Additionally, it is a good idea to take into account several factors that influence the final mold size. The following are the most crucial considerations:
Type Of Die Closing
The simplest die closing is an open/close mold closing. It works best with items that have clear, straightforward shapes that can be quickly removed. For parts with complex geometry, there are better choices than this one. Because removing products with intricate geometry would be challenging, the manufacturer must increase the overall die size.
The quantity of cavities and the placement of the gates and pieces affect the size of the injection channels. The form of the injection channels must meet some fluid dynamics specifications.
For instance, when there’s poor material flow, manufacturers reduce the section to ensure proper adhesion to the inner walls. This makes the molten alloy dislodged from the walls due to the rapid flux caused by the shrinking.
Thus, turbulence, air trappings, and other flaws can be avoided by having a smoother external layer.
Presence of Overflows
Small wells called overflows are positioned strategically throughout the die cast mold. Because the first metal shot is frequently cooler than the following ones, they are crucial in collecting them.
As a result, chilly laps and other comparable aesthetical flaws can be avoided. Overflows also act as a heat source, raising the temperature in the die in locations that are important for the final casting.
The surface created by the projection of cavities on the plan is known as the projection area. It is parallel to the direction that the mold opening is going. A crucial aspect of the design phase is the projection area. It connects the molten metal’s opening force to the die walls.
As a result, the direction of the shape dimension will affect how strong the force is. Burrs will develop as a result of an overflow of material brought on by a powerful force.
To avoid this casting flaw, you must thus calculate the forces generated by the molten metal. The force is a function of the projection area, the machine pressure, and the predetermined safety parameters. The factor provides a larger buffer to withstand the greatest pressure upon filling. It’s frequently referred to as a water hammer.
At the end of the procedure, the machine transfers the dynamic and static force. As a result, a pressure pick is created that the closing machine force must handle. The press model and stroke dimension both affect this closure force.
Simulation Through Semi-Empirical Modes
The semi-empirical modes simulation of die filling comes after the basic design stage is finished. Calculating the modality of mold filling is made easier by simulation. Additionally, the modality is influenced by the filling procedure and the purpose of the cast piece.
Compactness and mechanical resistance should ideally be induced for parts with intricate structural details. The surface quality must be of the highest caliber for purely ornamental parts.
You can change the properties by adjusting the fill time. The surface quality increases with faster filing, while component strength increases with longer filing. Once the analysis is finished, it will be simpler to identify any casting difficulties.
The design of the aluminum die casting mold begins with a manufacturability analysis, followed by a force calculation and injection channel inspection. These channels are optimized and designed using simulation to determine the filing mode and find any problems. When this phase is successfully finished, you can proceed to create the intended mold.
Key Points On The Die Casting Injection Mold Design
The amount that a mold core can tapered is known as the draft. The depth of the mold, the type of molten alloy used, and the shape of the wall can all have an impact on the process since a precise draft is required to expel the casting from the die smoothly.
However, the draft is not constant and fluctuates according to the angle of the wall. Additionally, mold geometry might affect the draft. Untapped holes typically need to be tapered due to the possibility of shrinkage.
Similar to how outside walls might shrink, interior walls can also necessitate more drafting than outer walls. You can look up draft angles to learn more about the manufacture and design of die casting molds.
The dividing line or parting line connects different parts of the mold. Material may seep through the space between the mold components if the separating line is not exactly placed or deforms due to job strain, resulting in uneven molding and excessive seaming.
A concave junction called a fillet is used to smooth an angular surface. Many molds contain fillets to generate rounded edges and lower the possibility of production errors because sharp corners can impede the casting process. The only place on a mold where fillets cannot be added is the separation line.
Die cast knob bosses are used in mold design as mounting points or stand-offs. Manufacturers frequently enlarge a hole in the boss’ internal structure to guarantee uniform wall thickness in a molded product. Deep bosses are notoriously difficult for the metal to fill; thus, filleting and ribbing may be required to solve the issue.
Holes And Windows
A die-cast mold’s ability to easily eject a finished molding and allow for the development of significant drafts is directly impacted by the inclusion of holes or windows. Additional features like overflows, flashovers and cross-feeders may be required to avoid unwanted casting inside the holes or inadequate material flow around the holes.
Die cast ribs can be used to improve material strength in products lacking the wall thickness required for certain applications. Selective rib placement can reduce the chance of stress cracking and non-uniform thickness. It is also beneficial for decreasing product weight and improving fill capabilities.
Die casting mold designs always include brand names or product logos from the manufacturer. Certain castings have a date to distinguish one batch of casting from another.
Despite not adding complexity to the design process, symbols might raise production costs. An indented symbol will require less metal than a raised logo, which will require a different metal for each manufactured product.
Die castings have a thin wall, and neither a maximum nor a minimum wall thickness exists. The wall thickness must be maintained consistently throughout the portion. When filling, uniformity will provide a smooth metal flow and decrease deformation brought on by cooling and shrinkage.
The primary objective is to prevent cold closes by filling the die casting mold before solidifying.
The cooling system for a die casting mold is distinct from that for a plastic injection mold, which must not have an “o” shape since its temperature will exceed 200 degrees, and it must get hotter before casting can take place. The casting component quality and cycle time are optimal with the conformal cooling system.
The die cast mold is an important element in manufacturing different parts. There are many mold designs for different parts. A mold’s design process must consider the precision and dimensions of the intended parts.
It might be best to make a die cast mold using the cold chamber method to avoid shrinkage. Nonetheless, molds are crucial in the mass production of identical parts.