For mass production of metal products and components the technique of die casting is used. In the process die casting mold design is one of the most important steps because the final product is directly affected by the shape and attributes of the mold. Using high pressure the die casting procedure and die casting tooling forces molten metal into molds and to achieve the task it requires a mold with exact specifications.
Importance of Die Casting Mold Design
In a product that is created through the die casting procedure, the mold design affects the uniformity, configuration, shape and quality. Tool, material corrosion as well as inferior product quality can occur if there are any improper specifications, while efficiency and production time can be improved by an effective design.
Factors Involved in Quality Die Casting Mold Design
When deciding on the appropriate specifications for a project there are a number of mold design factors to consider. Some of these factors include:
- Parting lines
- Die draft
- Wall thickness
- Holes and windows
From all the above some crucial factors out are:
Holes and Windows
In a die cast mold including holes or windows from die casting tooling manufacturer directly enables the creation of substantial drafts and affects the ease of ejecting a completed molding. To prevent unwanted casting within the holes or poor material flow around the holes additional features, such as cross feeders, overflows and flash overs may be necessary.
To smoothly eject the tooling die casting from the die a precise draft is required, but since draft varies according to the angle of the wall and is not constant, then features such as depth of the mold, the type of molten alloy used and shape of the wall can affect the process. Draft can also be influenced by mold geometry.
Different sections of the mold are connected together by the parting line or parting surface. Material may seep through the gap between the mold pieces if the parting line is imprecisely positioned or becomes deformed from work strain, leading to non-uniform molding and excessive seaming.