| The die-casting process is used in a variety of | | | | process, but their use generally results in less |
| industries to produce high-quality metal parts with | | | | metal alloy being used and better tolerances |
| close tolerances and fine surface finishes. When | | | | throughout the part. Some of the mold |
| designing a part to be manufactured using a | | | | components include: |
| die-casting process, several considerations must | | | | Core - A core is a circular or other shaped section |
| be taken into account so that the part can be | | | | or pin that is used to create a void in a die cast |
| successfully fabricated. | | | | part. The core can be moveable or fixed, |
| Basic Manufacturing Considerations | | | | depending on the design of the part to be made. |
| Some of the basic manufacturing and design | | | | Slide - A slide is a mold part that can be used to |
| considerations include: | | | | create voids or undercuts in the fabricated parts. |
| Draft - The mold used to create a die-cast part | | | | Slides are usually incorporated parallel to the die |
| has to be designed so that the part can be easily | | | | parting axis. These components can be complex, |
| removed from the mold after the part has been | | | | allowing for design elements such as threads to |
| cast and has cooled. Draft is a slight angle | | | | be designed into a part. |
| designed into the vertical surfaces of the die to | | | | Insert - A complex part can be generated using a |
| allow easier ejection of the part from the die | | | | pre-fabricated insert part that fits into the mold |
| after the die-casting process. Draft angles | | | | prior to casting. The insert is then encased in the |
| between 1º and 3º are common. | | | | die-cast part and becomes part of the finished |
| Fillet - A fillet is a radius at a corner where two | | | | part. Other mold design considerations include the |
| surfaces meet, rather than having a sharp corner. | | | | placement of gates for the flow of the molten |
| An internal fillet reduces the stresses that occur in | | | | metal and the inclusion of water lines for cooling |
| that location when the part is bent or stressed. | | | | the part after casting. Although these design |
| An external fillet radius is used to eliminate sharp | | | | elements do not contribute to the final design of |
| edges. | | | | the part, they are necessary parts of the mold |
| Undercut - An undercut is a feature of the | | | | design process. |
| die-cast part that prevents the piece from being | | | | Post-Machining |
| ejected from the die after casting. Designs that | | | | Depending on the design, it can be easier to |
| require an undercut necessitate complex dies with | | | | perform post-machining on a die-cast component |
| removable slides so that the part can be | | | | rather than attempting to design the element into |
| extracted after casting. It is generally more cost | | | | the part. For example, it may be easier to drill and |
| effective to redesign the part to eliminate | | | | tap a hole in a part rather than to design the |
| undercuts. | | | | threaded hole into the mold design. This simplifies |
| Mold Components | | | | the die-casting mold and process, which saves |
| In order to create different design elements | | | | time and money in manufacturing. The die-casting |
| within a die-cast part, several components are | | | | process necessitates unique considerations to be |
| used within the mold. The die may also include | | | | taken during the design process. These |
| removable slides or other sections to produce a | | | | considerations can be met through the use of |
| component with recesses, undercuts, or cores. | | | | specific design elements in the part and custom |
| The use of these components increases the | | | | mold components. |
| complexity of the mold design and the casting | | | | |