The things you need to know about die casting mold

What is Die Casting Mold?

A 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. A die casting mold design is one of the essential steps in the production process according to the fact that the shape and the attributes of the die casting mold to influence the finalized part. The die casting procedure begins with forcing molten alloy into the die casting mold with the help of high pressure, and it requires a die casting mold with the same specifications to accomplish the required product.

Die casting tooling In Sunrise Metal--Die Casting Mold

Die Casting 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 die-casting process, a high amount of pressure is applied to the die-casting mold 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 die-casting molds 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 Mold Design Importance

The 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 die casting mold design can improve efficiency and production speed. There are many die casting mold 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.

Die Casting Mold Design-Die Casting Mold

The Die Casting Mold Flow Simulation

It’s essential to predict the die casting mold flow through mold flow 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 die casting mold flow simulation prompts time, energy, material, and die casting mold cost saving. It’s essential to check the working and flow of the die casting mold 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 molds.

Die Casting Mold Flow Simulation-Die Casting Mold

Die Casting Mold Manufacturing Process

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

Die Casting Mold Lifespan

Sunrise Casting guarantees a life-long quality for die casting molds. Our industry prefers to die-casting molds, which ranges from 100,000 to 300,000 shorts depends if it’s an aluminum die casting 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 mold cooling system. It extends the lifetime of the die-casting mold, as well as enhancing molds’ efficiency of manufacturing parts. Preheating the die casting mold 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 die-casting mold, 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 Mold Benefits

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

Die Casting Die Cavities

To calculate the number of die casting mold cavities, it’s very crucial to consider hypothetical cycle time, the number of pieces that have to be produced, and cavities orientation on die casting mold. It is possible to pick between a single cavity or a multi-cavity die-casting mold. However, selecting the multi-cavity die-casting mold can increase the complexity of mold filling and mold ejection phases, as well as influence the die-casting production process by cavities’ disposition and dimensions of the finalized part and it’s crucial to remember these things. A related model can be found in logistics since a higher amount of impressions infers a direct extended progression of die-casting material to move.

Die Casting Die Projection Area

The die-casting mold 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 die-casting mold 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 die-casting mold 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 mold shop.   We have specialized in die casting mold manufacturing for over 10 years.    To know more about Sunrise Metal’s die casting mold manufacturing capability and figure why Sunrise Metal is your #1 die casting mold manufacturer, please visit the webpage https://www.sunrise-metal.com/capability/die-casting-tooling/.