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Home> News> Aluminium Die Casting moulds and products
October 18, 2019

Aluminium Die Casting moulds and products

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Die casting mould



The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high-volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.



Two variants are pore-free die casting, which is used to eliminate gas porosity defects; and direct injection die casting, which is used with zinc castings to reduce scrap and increase yield.



Die casting equipment was invented in 1838 for the purpose of producing movable type for the printing industry. The first die casting-related patent was granted in 1849 for a small hand-operated machine for the purpose of mechanized printing type production. In 1885 Otto Mergenthaler invented the Linotype machine, an automated type-casting device which became the prominent type of equipment in the publishing industry. The Soss die-casting machine, manufactured in Brooklyn, NY, was the first machine to be sold in the open market in North America. Other applications grew rapidly, with die casting facilitating the growth of consumer goods and appliances by making affordable the production of intricate parts in high volumes. In 1966, General Motors released the Acurad process.

Die casting mould for automotive



There are a number of geometric features to be considered when creating a parametric model of a die casting:

Draft is the amount of slope or taper given to cores or other parts of the die cavity to allow for easy ejection of the casting from the die. All die cast surfaces that are parallel to the opening direction of the die require draft for the proper ejection of the casting from the die. Die castings that feature proper draft are easier to remove from the die and result in high-quality surfaces and more precise finished product.



Fillet is the curved juncture of two surfaces that would have otherwise met at a sharp corner or edge. Simply, fillets can be added to a die casting to remove undesirable edges and corners.



Parting line represents the point at which two different sides of a mold come together. The location of the parting line defines which side of the die is the cover and which is the ejector.




Bosses are added to die castings to serve as stand-offs and mounting points for parts that will need to be mounted. For maximum integrity and strength of the die casting, bosses must have universal wall thickness.



Ribs are added to a die casting to provide added support for designs that require maximum strength without increased wall thickness.




Holes and windows require special consideration when die casting because the perimeters of these features will grip to the die steel during solidification. To counteract this effect, generous draft should be added to hole and window features.



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