The die-casting process is a very versatile method for manufacturing a large number of non-ferrous metal parts. This manufacturing process manufactures parts by injecting molten metal into a mold at high pressure and high speed. This process can cost-effectively manufacture very complex parts. This process can create parts that vary greatly in size and weight. Different alloys can also be selected according to the application and working environment of the product.
Designing products for die casting may be easy. This is especially true when designing the housing because of its aesthetic and mechanical requirements. Thin-walled chassis can be particularly difficult, and ribs and bosses are often required inside to increase strength. Other external and internal features (such as draft angle) are needed to easily eject the part after the die casting process. We will also often see housings with connectors and buttons on the sides, which involve the use of a sliding core in the mold to cast those features onto the part.
The design of die-casting parts will greatly affect its manufacturing cost. However, if the design is optimized and optimized for batch products, the results will be very beneficial. Well-designed die-cast parts are easier to cast and can be manufactured at higher speeds.
Since there are many different aspects to consider, here are some basic points to consider:
The die casting process uses high pressure and high speed to inject molten metal into a mold to manufacture parts. After the curing process, the two halves of the mold will open and the part ejected from the moving side of the platen. It is essential that there is no undercut area in the opening direction of the mold. This is why it is necessary to determine the direction of the die-cast part before manufacturing the mold or die to ensure that there is no undercut in these areas. However, as die-cast parts became more and more complex, many functions were added to the edges of the parts to incorporate other functions. It is common for these features to have undercuts, so a sliding core is added to the mold design. The sliding core will slide into place during the casting process to form those undercut features on the die cast part and will slide out for the ejection process. It is important to note that there should be no undercut in the direction of the sliding core.
The draft angle is the slope or taper on the side wall of the die-cast part. These surfaces can be identified by analyzing the opening direction of the mold and the opening direction of any sliding core on the mold. In other words, the outer and inner walls of the part and the opening formed using the sliding core. This allows the casting to be easily ejected from the die casting mold. By adding an appropriate draft amount to the die casting, the tendency to adhere to the die can be greatly reduced, thereby improving cycle time and surface quality.
3.Uniform wall thickness:
The consistency of wall thickness is the key to manufacturing high-quality die castings. Any unnecessary changes in thickness or sudden changes in component geometry will cause the flow of metal into the cavity to be interrupted. These may result in an airtight enclosure in the casting and lead to poor surface finish.
Die castings will always have parting lines. This is where the two halves of the mold meet. This is usually recorded as parting line or income statement on the parts drawing. The best practice is to make the dimensions with critical tolerances related to one side of the mold, that is, half of the top mold or half of the upper cover of the mold, because it is more difficult to control critical tolerances on the parting line. It is also recommended that this area should not have strict appearance requirements, as doors and vents will exist along this line and will be visible. Additional processes will be required to minimize or remove die cast parts.
Die castings are rarely flat, so it is important to add curved surfaces at the intersection of two surfaces or at the intersection to avoid sharp corners or edges. By including rounded edges in the part design, sudden changes in direction can be avoided and the flow of molten metal into the mold cavity can be enhanced. In addition, the rounded edges minimize the thermal stress on the die-casting mold during the production process and ensure the life of the mold.
Bosses are usually added to die-cast parts as mounting points with other components. Center holes are usually added to the bosses because they help minimize additional processing and keep the wall thickness more uniform. Bosses are narrow parts embedded in die casting molds, so because molten metal cannot easily flow into these areas, filling them is often more difficult. This problem can be minimized by adding appropriate fillets and draft angles to ensure that molten metal can flow into these areas and also help the ejection of die-cast parts.
Die castings are usually designed as housings or housings for electronics and telecommunications applications. These products usually have keyboards and displays, which will require smaller openings for keys and connectors of die-cast parts, while LCD or LED displays have larger openings. Since these features prevent the flow of molten metal and thus cannot fill the cavity, it is recommended to add a bridge and a cross feeder at the opening of the die-cast part. In order to ensure that these areas have sufficient temperature, the best practice is to add overflow ports in these areas. These additional functions will greatly improve the manufacturability of die-cast parts and improve the quality of parts. Depending on the quality requirements, these functions can be easily removed through the finishing process or machining process. Secondly, adding appropriate draft angles to these openings is also critical. Without these features, the opening on the die-cast part will still be tightly clamped to the mold after the curing process and will be difficult to eject.
Usually, logos, logos, identification numbers and other letters are added to the parts. Some die-casting parts will also have a date stamp to identify the date of manufacture of the part to distinguish a batch of production. There are two options to create these functions. The first method is to form raised letters, which is the first choice because it is the most economical and effective way to produce letters on die-cast parts. Second, because these features are embedded in the mold cavity, they tend to last longer because they prevent the wear that occurs when metal flows into the cavity at high speed. The second option is recessed text, which will form prominent features on the mold, making them more susceptible to mold wear and requiring more maintenance.
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