Improve Design of Die Casting Tooling

Tooling for die casting and plastic injection are quite similar.However,some factors have to be took into consideration:Multi-Spure,Dimension of spure and runner.overflow layout,Ventilation layout,flashes disposal.

Each die castings own different structure and shape,which cause potential risk during manufacturing.Therefore,some software will be useful for design of die casting tooling.3D flow simulation is most important software in die casting tooling design.Some potential risk can be found by 3D simulation software,such as sequence of filling,air trap,gas porosity etc.By compare two different design,we can analyze potential risk and solve the problem which might happen in manufacturing and find most suitable and reasonable die casting method.

Flow Simulation

Flow Simulation

Risk

Risk

In design 1,4 gate apply on tooling so the alloy fill cavity smoothly and steadily.The sequence of filling and ventilation is good,which will not cause any air trapped in tooling.

In design 2,2 gate apply on tooling so alloy do not fill cavity properly.The sequence of filling and ventilation is not good,which affect final castings badly.

Most of die casting parts request nice surface finishing and air tightness.The air will go into melted alloy if it not get out of tooling properly,which will make blister on surface of castings or make porosity inside castings.Therefore,overflow and ventilation of tooling is key for quality of castings.

straight overflow layout

straight overflow layout

For straight overflow layout,it is pretty simple and easy.However,Some of melted alloy will be excess from tooling,which cause pressure lose and bad air tightness.

Bridge overflow layout

Bridge overflow layout

By bridge overflow layout,the tooling can obtain better ventilation.The melted alloy will not excess from tooling and quality of die casting parts are good.

In die casting,flash is very common.The flash will accumulate inside tooling slide structure if they are not clean properly.Especially,sliders are easily blocked by flashes.Therefore,it is necessary to make some flash excess line underneath slider,which will make sure sliders work smoothly.

 

 

 

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