designing die-cast parts for manufacturability - die casting mold design
Casting processes are used in various industries to produce high
High-quality metal parts with close tolerances and fine surface finish.
When designing a part to be made using a mold-
Several factors must be taken into account during the casting process in order to successfully manufacture the parts.
Basic manufacturing considerations some basic manufacturing and design considerations include: Draft-
Molds for making molds-
The casting part must be designed so that after the part is cast and cooled, the part can be easily removed from the mold.
Draft is a small angle designed to the vertical surface of the mold, so that it is easier to pop the part from the mold after the moldCasting process.
The angle of eating water between 1 ° and 3 ° is common. Fillet -
The rounded corners are the radius of the corner where the two surfaces meet instead of having a sharp corner.
The internal fillet reduces the stress that occurs at this position when the part is bent or stressed.
The external fillet radius is used to eliminate sharp edges. Undercut -
Weakening is a feature of the mold-
Prevent castings from popping up from the mold after casting.
The design that needs to be weakened requires a complex mold with a removable slider in order to extract the part after casting.
It is often more cost-effective to redesign parts to eliminate weakening.
In order to create different design elements in the mold, the mold assembly-
Casting parts, several parts are used in the mold.
The mold can also include removable slides or other parts to produce components with grooves, cuts, or cores.
The use of these components increases the complexity of the mold design and casting process, but their use often results in fewer metal alloys used and better tolerances for the entire part.
Some mold components include: Core-
The core is a section or pin used to create a void in a die-casting part in a circle or other shape.
Depending on the design of the part to be manufactured, the core can be movable or fixed. Slide -
The slider is a mold part that can be used to create gaps or lower cuts in the manufacturing part.
The slider is usually parallel to the mold parting axis.
These components can be complex and can be designed into parts with design elements such as threads. Insert -
Complex parts that can be pre-generated
Pre-cast insert parts installed in the mold before casting.
Then package the plug-in the mold-
Casting parts to become part of the finished parts.
Other mold design considerations include the placement of Gates flowing from molten metal and the addition of water lines for cooling parts after casting.
While these design elements do not contribute to the final design of the part, they are an essential part of the mold design process. Post-
Processing according to the design, it is easier to carry out post-processing
Processing on the mold
Instead of trying to design elements into parts.
For example, it might be easier to drill a hole in a part, rather than designing a threaded hole in a mold design.
This simplifies the mold
Casting molds and processes save time and money in manufacturing. The die-
The casting process needs to take unique considerations in the design process.
These considerations can be met by using specific design elements in parts and custom mold assemblies.