Non-ferrous castings made via Die Casting (also known as Permanent Mould Casting) are commonly made from aluminum, zinc, and bronze alloys, although other metals can also be cast, such as copper. Designing problem-free casting geometry is easy when you follow these 10 tips.
Ensure that your design is tailored to your specific needs. Increased metal usage and weight are incurred as a result of thick wall sections, which also lengthen the fill and cooling times. However, keep in mind that the minimum wall thickness is 3mm, and it may need to be even thicker depending on the size of the section. Learning the die casting process is one of the most cost-effective and time-efficient options available when it comes to forming
Avoid clumps of heavy content. The lack of metal flow can lead to shrinkage flaws such as internal tears, and stress concentrations can also be produced as a result. To make cross sections narrower, consider the use of pockets, however keep in mind that these can induce shrinkage discrepancies
Adding ribs will give you more strength. Thin wall reinforcement, thermal profile management, metal flow improvement, and strengthening of ejector pin positions can all be accomplished while reducing weight throughout the component. Ribs can be used for all of these purposes.
In die casting, the use of draft. Casting from the die is made easier by introducing a little taper to the cavity's side walls. There must be a 2° draft angle on the walls of Aluminum box sections, for example, when they're perpendicularly aligned with sliding interfaces.
Consider the impact of shrinking on die release. It is common for cast metals to shrink toward the center when they cool to room temperature after being cast. This facilitates in the release of components from the die's outside borders, but tends to keep inside areas of the die from being released. When shrinkage locking is a problem, use a higher draft.
Make slow and steady adjustments to the sections. Try to keep the number of section switches to a minimum. Blend sections with tapers to reduce stress concentrations and allow sections to be fed without turbulence in the metal flow.
Cooling issues might arise from acute angles. Heat dissipation is hampered by acute angles, resulting in significant thermal gradients. Sharp re-entrant angles also generate hot spots, in a similar way to the first. As a result of corners altering the cooling rate, it's possible for shrinkage tears and distortion faults to form.
Use junction design as a primary tool for reducing mass accumulations. A higher volume area is created in each of the junction portions because of the shape of their geometry. Localized flaws or weaknesses may result as a result of hotspots leading to differential solidification. By modifying the joint layout slightly, Design Engineers can avoid potential casting flow difficulties.
Then add Radii and Fillets:. A design engineer may utilize fillets or external radii to reinforce corner sections and enhance metal flow. In order to keep the thickness of the section equal, adding fillets without radii is acceptable.
Getting ready for the split. The separating line is the point where the two halves of the die come together. It is best to keep the dividing line straight as flat as possible in most cases Undercuts, draw, drafts, and flash must be considered when deciding where to place a dividing line. Flatness and dimensional stability must also be taken into account while making this decision.