Critical Points in Die Casting Components
There are rules to consider when designing products or components in a die casting. Applying these tips will result in a design that is logical, efficient, and cost-saving.
To optimize the process and successfully avoid critical points in cast iron pressure of foundry components, it is important to know material reactions at each phase.
The geometry of the parting line
When the organization of the separation line, which is given by the design of the component. The Aluminum Die Casting Supplier must consider the position and length available for the liquid metal to flow into the cavity. It is also important to remember that an adequate entrance area will be needed and if the length of the entrance is restricted. It will have to be thick with the possible consequence of trimming problems. To overcome these problems, the solution might be to change the geometry of the component.
It is better to develop the components with a fairly constant cutting thickness. However, in actual production, exceptions to this rule are possible, if the Aluminum Die Casting Manufacturer is experienced and knows how to do that.
Tilt angles could be useful to prevent the casting from sticking to the moving part of the moving mold.
Strengthening an Aluminium Gravity Die Casting piece without thickening is possible with the ribs, which must be rounded, mixed and arranged to join the adjacent sections.
Smooth or flat surfaces are the widest design feature from zinc molding to production. There are many ways to make a more attractive product, and at the same time to reduce the cost of production. Collaboration between designers and the zinc die casting supplier, in a co-design activity, could help achieve the goals without wasting resources.
Fillets and mixes
Sharp corners can be avoided by using fillets, as these have a reinforcing effect. It is common practice in die casting to use a fillet with a minimum radius of 1.6 mm at the inner edges. A slight radius at the outer corners is an effective measure to decrease expenses.
If letters are required, designers should use raised letters, rather than printed letters. Embossed letters allow to limit costs and minimize risks in terms of mold erosion.
Depositing the inserts inside the dies or molds slows down the process times, for this reason, today the inserts are used less than in the past. Although it can also save you machining costs.
Best achievable linear tolerances
It is very important to work closely with the die inclination in the ongoing co-design activity. During the casting process, the linear tolerance band dies by 0.1% of the dimension and a level is allowed of confidence eight standard deviations. This dimension can be achieved only when the component geometry is favourable to consistent shrinkage without distortion after ejection from the die.
Design to avoid local matrix overheating
Designers must develop products or components to pay attention to problems caused by die overheating, which can lead to surface porosity, drag marks and cracks.
Design to avoid moving cores
Complex three-dimensional shapes are achieved through the use of moving nuclei, which slide into the matrix. If designers can achieve sufficient effect without moving cores, this will be a cost-saving action.