Prior to beginning the mold design phase in high-pressure die casting, the foundries gauge the viability of producing the component. In fact, two aspects are looked for when the engineers design the mold and these are the dimensional aspects and component geometry. For calculating the casting volume and the opening of the die cavity, the component dimensions are often determined alongside cavities. In fact, calculating these aspects would ensure the viability of producing the end product right at an early stage of die-cast mold making. When it comes to determining the component geometry, the parting line’s arrangement is also considered.
The parting line would split the mold into two halves, which would then enable the die casters in opening the solidified mold and eject the casting from the die cavity. In fact, the surface tilting of the component is reliant on the parting line position and hence they are aligned as per the direction of the die opening.
Simulation software is used by the die casters for analyzing the phases in mold design that gathers data on the component volume, the die opening, as well as the overall cavities required for the process. For calculating the cavities count, it is important to take into account the approximate die casting cycle, the component count and also the mold alignment, which can be a single cavity or dual cavity.
While accounting for the dual-cavity mold it is necessary to ensure that the pouring and mold ejection stages are perfect. The entire manufacturing process goes hand-to-hand with ideal cavity opening and the component dimensions calculated. The die cavity opening plays an instrumental part in mold design phase and stays reliant on the force of opening created by the metal flow on the wall of the dies. As per the alignment, either stronger or weak pressure would be applied to the die walls during the process of pouring the molten metal.
In fact, excessive pressure may cause an overflow of the molten metal and hence leads to burrs on the component. For preventing this issue, the maximum pressure that the machine can create when pouring the molten metal is gauged using simulation tools in mold design phase. These factors help have a feasible mold design.