February 25, 2024

Die casting in engineering is mold casting in which molten metal fills the mold cavity due to gravity or external pressure. The cavity is made of two hardened steel molds into the shape of the desired product. Die casting is usually made of non-ferrous materials such as zinc, tin-based alloys, aluminium, and copper. Its working principle is similar to injection molding.

There are two types of die casting:

  1. Pressurized Die Casting
  2. Gravity Die Casting

Some key points are given below:-

Draft Creation

The draft is the taper of the core. To gently push the casting out of the mould, a precise draft angle is required. However, the throw angle is not constant and will vary depending on the angle of the wall, the type of cast alloy used the type of shape it will get. You can search for draft angles to learn more about die casting mold design and die casting manufacturer.

Fillet 

For smooth sloped surfaces, fillets are used by the manufacturers. Sharp corners can make the casting process difficult, which is why many molds have rounded corners to create rounded corners and reduce the risk of production errors. Except for the parting line, you can add fillets almost anywhere in the pot.

Parting line 

Mold is connected with the parting line. If the parting line is incorrectly positioned or deformed due to working stress, the material will leak through the gap between the mold parts, resulting in uneven molding and excessive joints.

Holes and windows 

Whether the die-casting mold contains holes or windows, that will directly have an effect or molding process, and it will produce a large number of different angles. Additional features for overflow, flashover and cross feeder may be required to prevent undesired overflow of the well or poor material flow around the well.

Cooling system 

The cooling system of die-casting molds is different from that of injection molds. Injection molds should not have an “O”-shaped design because the temperature of the mold will exceed 200 degrees, and the mold must be heated before casting. The conformal cooling system is most suitable for cycle time and part casting quality.

Symbol 

Manufacturers usually include the brand name or product logo in the die design of the die-cast product. Although symbols usually do not complicate the die-casting process, their use can affect production costs. The customized logo or symbol get an additional amount in the cost. In contrast, embedded symbols require fewer raw materials, which can reduce costs.