Guide For Tips of The Die Casting Process Design
Die casting process is a manufacturing process that utilizes a hot or cold chamber manufacturing process. It relies on high pressure to force and inject molten metal inside reusable steel die to form a part. Many products, in part or whole, have their origin from the die casting process. The production of parts is from a versatile assortment of non-ferrous metals, such as magnesium, zinc, aluminum, and other composite materials. Most manufacturers prefer it due to the process’s fast turnaround at high precision. We can achieve fine details like lettering and getting textured surfaces without requiring additional process. As a bonus, achieving tight tolerances is possible. Here are some insights on how to design any product or part for designers concerned with die casting.
Five Main Points of The Die Casting Process To Share
Wall Thickness and Features
In general, die casting parts are made with a thin wall structure. When designing your part, ensure the wall are uniform even for the sections with a variation. It ensures the molten metal flows smoothly and fills the cast uniformly. The outcome is the minimal distortion that occurs from shrinkage and cooling. Another important consideration is ensuring the entire mold fills before solidification starts. This risk is avoidable by not having any unnecessary sharp corners or turns that disrupt the flow of the molten metal. We recommend you use radii to reduce such sharp turns.
Alternately, you can use ribs to enhance the molten flow of molds with thicker walls. If the main wall possesses any protruding features, ensure they do not supplement to the bulk of the wall. It delays the overall cooling of the part formed. For features protruding from the sidewall, avoid putting them behind one another to avoid die casting depressions. The designer should also avoid the usage of interior undercuts while designing parts. It is difficult to operate the interior core mechanics. Instead, opt for the production of the interior undercut through a machining process.
Fillet and Radii
We recommend the use of both radii and fillet to improve the structural integrity of your part. Make use of a large transition and radii to enhance the metal flow in your design. The purpose of the fillet in your design is to prevent high-stress concentrations, especially at intersecting surfaces that meet at an edge or sharp corner. It also decreases the accumulation of heat in the part along with the die. Add drafts for fillets that project into a vertical location to the parting line. Design a constant radius fillet for the continuity of the smoothness and edges of the components. Shallow castings have smaller fillets while inside corners and deep pockets need larger fillets.
Parting Lines For Die Casting Process
It is important to decide the type of parting line to produce a contact surface and split the part. The designer has two options for a suitable parting line. Either a broken parting line or a straight parting line. Some factors exist before making a decision on which parting line to use. They include
- Die costs – a straight line has a lower cost of tooling. However, in some scenarios, a broken parting line may incorporate side pulls that lessen the overall cost.
- Ejector pins – a parting line location may determine the amount of force needed to eject the part cast. Ejector pins should not be placed parallel to the parting line.
Ribs and Metal Savers
Designers should ensure the addition of ribs to thin walls. Ribs add strength and increase the stiffness of the wall thus allowing fabrication of a more solid part. Also due to their unique feature of porosity, the component made is lighter compared to the use of solid material. It is important to use a proper rib design to lessen the concentration of working stress. Ribs additionally aid in the flow of molten metal. When used along with radii and fillets, they reduce the time’s quick changes that occur at sharp corners.
Metal savers are the empty spaces that exist in between ribs. They serve no functional purpose but it is important to consider them while designing. Keep in mind the ribs positioning should not be too close as it may result in weak metal savers. This may result in weakened structural integrity which may compromise your entire part design.
Lettering, Ornamentations, and Symbols
Casted parts often require some form of identification in the form of a logo, lettering, or trademark. There exist two techniques to achieve this in your design parts. The first method involves embedding the lettering into the cavity with the use of raised letters. It is the most common and cost-effective technique of the two. Letterings formed from this technique also last longer. The second method involves forming protruding letterings on the die. In this case, the lettering is depressed into the cavity. The technique is more costly to make and needs more maintenance due to its susceptibility to wear.
At Creatingway, we aim to fully optimize the design of your part for an economical and successful casting. After following the guide above you are heading in the right direction. To get more information concerning die casting services, contact us now.
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