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The 10 things you need to know about die casting mold

What is Die Casting Mold?

Die casting tooling In Sunrise Metal--Die Casting MoldA die casting mold decides the forms of a die-cast part and influences its properties. It’s an assembling tool used to make die-casting parts. In any case, it’s, for the most part, consist of the cavity, core, and ejection system. Mold design is one of the essential steps in the production process according to the fact that the shape and the attributes of the mold to influence the finalized part. The die casting procedure begins with forcing molten alloy into the die casting toolings with the help of high pressure, and it requires the mold with the same specifications to accomplish the required product.

Die Cast Mold Working

The die-casting molds are made of excellent, heat-resistant steel grades, comprise of two halves that structure a cavity into which the fluid melt is pressed during the die casting process. The mold halves are situated on a fixed and a movable plate. During the casting process, a high amount of pressure is applied to the die halves, which is the reason the mold is outfitted with latches. Also, certain parts of the die-casting mold are cooled or heated with the goal that the die casting sets as wanted. The creation of the tooling is expensive, yet a few several thousand to over a million castings can be delivered rapidly. A further favorable position of the reusable casting molds is that the melt cools down quickly.

The Die Casting Mould Design Importance

Die Casting Mold Design-Die Casting MoldThe die-casting mold design is responsible for the shape, quality, configuration, and uniformity of the finalized part manufactured through the die casting process. Inappropriate or incomplete specifications can result in part corrosion, and second-class output part quality, while a valuable design can improve efficiency and production speed. There are many die casting molds design factors to consider when it comes to the precise specifications for a project like Die Draft, Fillets, Parting Lines, Bosses, Ribs, Holes & Windows, Symbols, and Wall Thickness.

The Mould Flow Simulation

Die Casting Mold Flow Simulation-Die Casting MoldIt’s essential to predict the mould flow through moldflow simulation software to ensure the die-cast component quality before the production even starts. This outcome in a decrease in pre-production inspecting costs as upgraded flow simulation prompts time, energy, material, and cost saving. It’s essential to check the working and flow of the dies before starting the manufacturing process. This way, critical thinking and problem-solving time are primarily decreased, and expected results are prompt. Besides, we can proactively reduce errors and scrap rate in die casting production.

Mould Manufacturing Process

The initial tooling design is finished, the base, steel, and other accessories are sourced. Afterward, the CNC machining process is activated, and we evacuate 95% of the additional material from the cores, cavities, and sliders. For a precise manufacturing EDM, we generally keep 0.3~0.5mm. Since the molds are required to withstand high temperatures,  the entire die steel (for core, cavity, and slider) must be solidified with HRC 48~54 degree relies on the lifespan. As soon as CNC machining work is finished, the steel is transferred for tempering. After performing EDM, Milling, Drilling, or Wire Cutting (if necessary), the die is polished enough to obtain a perfect and precise part surface. In the final step, all of the casting mold parts are fitted together and tested if everything assembled correctly and precisely. If we can make accurate and precise mold components, it’s easier to get the casting mold assembled and worked.

The Lifespan Of Die Casting Mould

Sunrise Metal guarantees a life-long quality for die cast molds.  The mold life ranges from 100,000 to 300,000 shots depends if it’s a die casting aluminum mold or other. However, its lifespan can be increased by applying different techniques. The most effective way to extend the mold life is by using a cooling system. It extends the lifetime, as well as enhancing molds’ efficiency of manufacturing parts. Preheating is another technique that can increase the lifespan of the mold. Furthermore, the cracks on molds can occur when the hot molten alloy is pounded into the dies, which results in a quick exchange of temperature. Preheating the die-casting mold can prevent the formation of any cracks and extend its life.

Die Casting Mould Benefits

There are numerous benefits regarding the usage of die casting moulds. At Sunrise Metal, we provide you with high-quality and exceptional die casting molds that match your design specifications. Some of the crucial benefits of die cast moulds are the following.

  • Achievable Net shape part configuration
  • Achievable high dimensional accuracy
  • Fast production
  • Achievable Thinner walls when compared to the sand castings
  • Wide range of possible die casting product/parts shapes including complex
  • The die casting mould can achieve the right heat balance
  • Can solidify uniformly and quickly
  • Help the pressure transfer
  • Maintain good fluidity to fill the excellent formability of the mold
  • Improve the surface quality of the finalized part

Cavities Of Die Casting Die

To calculate the number of cavities, it’s very crucial to consider hypothetical cycle time, the number of pieces that have to be produced, and cavities orientation. It is possible to pick between a single cavity or a multi-cavity. However, selecting the multi-cavity can increase the complexity of tooling filling and tooling ejection phases, as well as influence the die-casting production process by cavities’ disposition and dimensions of the finalized part.

Tooling Projection Area

The die-casting tooling projection area represents the molds’ theoretical surface that can easily be achieved through the projection of a mold’s cavity, which is perpendicular to the die-casting mold opening location. Projection area vitally affects the die-casting mold designing stage: it relies upon the initial power produced by liquid alloy on die walls. Furthermore, depending on shape dimension orientation, more robust/weaker pressure can be applied in the filling phase. An ultra-solid power may bring to a material overflow. If the powers are unreasonably loud compared to the end-force of the press, the result could be a resistant item or, in the most exceedingly terrible situation, an unfeasible procedure. To prevent this, the most extreme force created by molten alloy in the filling stage can be evaluated. This force is comparable to the consequence of the projection area, the most extreme express pressure of the die-casting machine, and a pre-set security factor.

Sunrise Metal-Your #1 die casting mold manufacturer in China

Sunrise Metal has an in-house die casting mould shop.   We have specialized in die cast mould manufacturing for over 10 years.

To know more about Sunrise Metal’s die casting mould manufacturing capability, you can get the answer to why Sunrise Metal is your #1 die cast mould manufacturer.

Here is just a small part but an important way that we’re serving you on die casting mold projects.

Sunrise Metal can offer full chain service for you if you have any demands on aluminum die casting projects, looking learn more about aluminum die casting.

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