Die casting is a mass production technique used to manufacture metal components and parts. Designing the mold is a very important step in the die casting process, as the features and shape of the mold will greatly affect the finished product. As per the die casting procedure, molten metal is forced into molds using high pressure. To finish the task successfully, a mold with exact specifications should be designed.
Die Cast Mold Design
The design of the mold will affect the shape, quality, configuration, and uniformity of the product that is made through die casting. Improper specifications and designs can lead to material or tool corrosion and inferior quality of finished products, whereas an efficient mold design can lead to improved production time and efficiency, which is very desirable for die casting process.
Important Factors in Quality Die Cast Mold Design
Die casters consider many factors while deciding on the specifications for mold design. Some of these factors are explained below.
Draft
Draft is a term used to indicate the degree to which the core of the mold can be tapered. A proper draft is necessary for the smooth ejection of the casting from the die, but as draft is not constant, and changes depending on the angle of wall, attributes like the shape of the wall, type of alloy used, and depth of the mold can affect the overall efficiency of the die casting process.
Another factor that affects draft is the mold geometry. Generally, the inner walls need more drafting than the outer walls.
Parting Line
The parting line or parting surface connects different parts of the mold together. Care should be taken to position the parting line clearly while designing the mold. If it is positioned wrongly, or is deformed due to work strain, there are chances of material seepage through the gap between the pieces of the mold. This can result in a need for excessive seaming and non-uniform molding.
Fillets
A fillet is a concave junction used in an angled surface to smoothen the angle, as sharp corners can cause issues in the die casting process and ejection of casting. For this reason, die casting companies use fillets in their molds to offer rounded edges and decrease production errors. Expert die casters say that fillets can be added to any part of a mold, expect the parting line.