Die Casting Tooling
The design of a die casting tool is very important to ensure that it fits seamlessly into the project requirements. A die casting tool is a multi-part piece of equipment that's made from high-quality steel. It's composed of two parts: the ejector die and the cover die. The molten metal is then injected into the tool's two halves. It is then ejected into a net shape after solidification.
Before a die is made, the customer presents a concept or an existing part to a die casting engineer. The die casting engineer will then work with the customer to develop a part that will meet their requirements. He or she will also discuss various aspects of the project, such as the wall thickness, mating parts, and project timing. During the initial discussion, the die casting engineer will talk about the various aspects of the project, such as the requirements for cosmetic and functional factors, as well as the desired mating parts.
Prototype Die Casting at TEAM MFG
A fully-featured production die is typically not enough to test a part in several different scenarios. Instead, a prototype die can be used to make small batches to test the part in various scenarios. Although 3D printed parts and gravity castings are often used for prototype production, these methods can also involve tradeoffs between the properties and design of the finished product.
Producing a prototype can be done in less time and cost than traditional production methods. It can also be produced with standard components and pre-hardened steels, which are commonly used in the production of tool steels. Compared to a traditional production die, a prototype die can produce parts faster and at a lower cost. Compared to a traditional production die, a prototype die can also be produced with less engineering. It can also be produced with less cooling and ejection techniques. Compared to a production die, a prototype die can produce parts faster and at a lower cost. It can also be hand cleaned to remove any traces of flash.
Die Casting Production
Production dies are commonly used when all design specifications are finalized and approved. They can be produced with multiple cavities and can also have slides. Aside from the production die, trim dies are also used for high volume production. These machines are designed to remove flash from the part immediately after it's cast. Some trim dies require an open/close function or multiple stations to remove all of the flash. Sometimes, a part's geometry can prevent the machine from completely removing flash from the part. In this case, a custom trimming device or mechanical de-flashing technique will be used.
Mold Unit Dies
A unit die is a type of production die that keeps the customer's cavity block or unit die intact. It can be produced with a single or double unit holder. Usually, unit holders are used for smaller parts with lower volume. They can also be used for complex parts with multiple slides and complex geometry. Since unit holders are usually used for smaller parts, they are often not used for complex ones. Instead, complex parts can be produced with a custom die that's designed to meet their exact requirements.
Die Components and Terms
Some of the common components and terms used in the production of a die include cavities, ejector plates, parting lines, core pins, ejector pins, and slides.
Cavity Blocks or Cavity Inserts
The cavity blocks are the parts of a die that are formed into the part geometry. They are made of premium grade steel and are usually heat-treated to a high degree of hardness. The ejector pins and water cooling lines are also connected to the cavity blocks. The cavity blocks made of premium grade steel are usually heat-treated to a high degree of hardness and are coated with a long life. The water cooling lines and ejector pins are also connected to the cavity blocks. Usually, the cost of the die casting process is mainly due to the custom design and engineering of the cavity blocks.
Parting Lines
After the two die halves have closed, metal is injected into the cavities. The ejector lines and the cooling lines are then connected to the cavity blocks.
Cores or Core Pins
A core is the part of a die that has internal features that are separate and replaceable. It can be a circular or fixed to the die cavity.
Slides or Slide Cores
A slide core is the portion of a die that cannot be made with the usual opening and closing of the die. It is required to move at an angle relative to the parting line to form a feature of the casting. The term slide refers to the entire moving section of the die, while slide core refers to a pin that moves in and out on an angle. The term slide refers to the entire moving section of a die. A slide core is commonly used for a pin that moves in and out on an angle. It can also be used for a simple core pin or a pin within a larger slide mechanism. Hydraulic cylinders and angle pins are commonly used as sources of motion for slides. These components have to be designed to avoid interference with the part ejection/removal process. Hydraulic cylinders and angle pins are commonly used as sources of motion for slides. These components have to be designed to avoid interference with the part ejection/removal process. Angle pins are generally the more economical option since they do not require hydraulics or other equipment to move. They can be produced using a hydraulic method, which has a wider range of options.
Ejector Plates and Ejector Pins
When a part is cast and cooled, the halves reveal the part's design. The part's size gradually decreases as it cools, allowing the ejector pins to push it off the die. The imprint left by the ejector pin on the casting helps determine the location of the pin in the non-crucial surface area of the casting. The size and configuration of the pin are also affected by the part's configuration and orientation.
Contact a TEAM MFG Die Cast Engineer
Our engineers are available to answer any questions related to the process of making a die. If you have any questions, feel free to contact us through our sales department .
