Die casting is a manufacturing process, which allows to create clearly defined textured or smooth metal parts. Hot or cold chamber manufacturing technique, which depends on high pressure is used. The process pushes and injects molten steel into reusable steel die speedily [60 to 100 miles/hour].
During injection, cooling as well as solidification phase, multiple clamps hold the mould in place.
For precise diecasting, manufacturers even use durable non-ferrous metals like magnesium, zinc, aluminium and many other composite materials. Type of material chosen will depend in determining whether hot or cold chamber technique needs to be applied to inject liquid metal in the die.
Die casting method is much preferred because of its ability to create products and parts at high speed with precision. Current uses of die casting method include sporting goods, appliances, vehicles, machinery, toys, office equipment and many more.
Designing of die cast
Where designer places parting line will depend on geometrical shapes and different surface tolerance. Designer gets two choices for parting line – straight or broken. Other factors are considered for determining the parting line are –
- Customer’s specs
- Die costs
- Metal flow
- Knockout pins
Metal flow considerations is crucial because if mould doesn’t get properly filled, there can be visible defects and air pockets. Ejector pins also needs proper consideration so it can leave minimal number of remaining pin marks on casting surface. Designer also needs to incorporate drafts in the early phase. Radii and fillet helps to increase structural integrity.
Designing uniform walls ensures smooth metal flow to reduce distortion possible from cooling & shrinkage. Addition of proper ribs adds strength and ribs help in molten metal flow.
Along with functional needs, designer incorporates multiple manufacturability related aspects like proper filling, consistent & quick solidification, easy ejection, minimum die construction & maintenance issues and parts fulfil customer’s tolerance needs.