Die casting is a quicker and much cost effective method for producing a large number of components. It is done with various metals and the parts created using this process will differ. The quality and benefits obtained from die casting process is dependable on the design. However, the designing process of die casting varies a lot and it is necessary to understand the differences in them. The tips shared here will help you in understanding the various design process of die casting.
Adding Graft to Parts
This is one of the most commonly used designing method used in the die casting process. It involves applying on the exterior and interior of a part a small amount of taper. The advantages of this is that the effects of shrinkage is compensated, thereby making it easier for the removal of the casting from the cavity. The addition of the draft will make the casting of a part much easier.
There are recommended draft angles for the process, which is ¼ degree to one degree per side. This is dependent on the alloy and die casting process choices. While designing the component, professionals look out for the draft and apply it liberally in non-critical areas for better results.
Incorporating Fillets and Radii
Including fillets and radii into the component design is vital and use them wherever possible. They aid in strengthening of the component and advancing the metal flow. It can also help in easily applying the ensuing finishes on the component. So when in the process of component drawing, it is good to include the areas where fillets and radii are not possible.
Ribs and Bosses
Increasing the strength of a part is possible with the use of ribs and bosses in the design. The presence of non-critical side surfaces in them will require applying the draft accordingly. Utmost care should be taken to blend them with the fillets and radii, in order to remove sharp corners.
Pockets
Pockets are designed in solid sections for the design to become lightweight. Apart from reducing the weight, it also aids in cost reduction and reducing the cycle time. In this design too, the drafts and radii must be applied carefully.
Uniform Parts
Uniform parts have smooth corners and sections that enable the metal to flow through the die faster and without producing metal flow turbulence. This is difficult to make since ensuring such uniformity is difficult and can restrict the metal flow.