Designing Die Casting Dies
 

The Designing Die Casting Dies Series is a set of 6 documents formulated in a shorter more concise “how-to-do-it” fashion to better assist the practitioner or any user in understanding and implementing the steps necessary in developing a die design that meets die caster expectations.  The documents allow the die designer to quickly find and utilize the information effectively.  In addition, the documents are designed to assist the die casting technical employee in working with the customer, tool maker, and production staff to specify particular product design features, tooling design features, process control technologies and plans to assure that a casting meets the customer’s expectations. 

The Series is as follows, and presented in sequential order for designing a die from A to Z.

  1. Die Casting Dies: Dimensional Control
  2. Die Casting Dies: Gating and Process Planning
  3. Die Casting Dies: Thermal Design and Control
  4. Die Casting Dies: Designing the Basic Die
  5. Die Casting Dies: Moving Cores
  6. Die Casting Dies: Ejection Systems and Processing Aids

Item #E-506, 6 parts, 2006.

 

TABLE OF CONTENTS

Book 1: Dimensional Control

1. Introduction 3
2. Standard, Precision, and Thermal Control Tolerances 5
3. Dimensional Capability Analysis 7
4. Shrinkage Variation and Shrink Factor 9
5. Draft 11
6. Linear Dimensions 13
7. Linear Cross Parting Dimensions 15
8. Slide to Cavity Dimensions 17
9. Parting Line Shift Variation 19
10. Flatness Variation 23
11. Die Warpage 25
12. Parting Line Placement and Cavity Orientation 27
13. Plan Parting Surface and Slide Fit 31
14. Dimensional Philosophy for Steel Safe Tool Development and Tolerancing 33
15. Comprehensive Example 35

Book 2: Gating & Process Planning

1. Introduction 3
2. Porosity & Surface Finish Management 5
3. Cavity Fill Pattern 9
4. Compute Ideal Fill Time 11
5. Compute Gate Velocity 15
6. Determine Machine & Plunger Size using PQ2 19
7. Calculate Gate Area and Dimensions 21
8. Designer Runner System 25
9. Overfl ows &Vents 27
10. Impact Reduction 29
11. Plan Shot Profi le 33
12. Comprehensive Example 37

Book 3: Thermal Design & Control

1. Introduction 3
2. Plan Heat Flow Zones 5
3. Specifi c & Latent Heat Calculations 7
4. Cycle Time Capability & Determining Optimal Cycle Rate 9
5. Calculate Cooling Rate & Heat Loss During Fill 11
6. Calculate Heat Redistribution During Cavity Fill 13
7. Heat Flow Area 15
8. Delete Heat Loss Due to Die Spray 17
9. Heat Flow, Heat Flux, & the Neutral Thermal Axis 19
10. Convection Equation 23
11. Conduction Equation 29
12. Water Line & Bubbler Flow Rates 31
13. Converging & Diverging Heat Flow Paths 33
14. Determine Cooling Line Length, Depth, & Diameter 35
15. Design Cooling System 39
16. Hot Oil Heating & Cooling 41
17. K-Values & Other Die Materials 43
18. Insert Segregation for Heating & Cooling Effectiveness 45
19. Thermal Simulation 47
20. Porosity Management Strategy - Shrinkage 49
21. Process Control 51
22. Die Life 53

Book 4: Designing the Basic Die

1. Introduction 3
2. The Die Design 5
3. Getting Started 11
4. Features Near the Cavity 13
5. General Arrangement 29
6. Completing the Design 39

Book 5: Moving Cores

1. Introduction 3
2. Basic Design Issues of Moving Cores 5
3. Fitting Submarine Cores to the Cavity 7
4. Fitting Parting Line Cores to the Cavity 11
5. Angled Pin Core Actuation 17
6. “Dog Leg” Cam Core Actuation 19
7. Hydraulic Core Actuation 21
8. Rack & Pinion Core Actuation 23

Book 6: Ejection Systems & Processing Aides

Part One:
1. Introduction to Ejection Systems 5
2. Hydraulic Bumper Plate 7
3. Center Hydraulic 9
4. Self Contained Ejection 11
5. Angled Ejection 15
6. Force Balanced Systems 17
7. Other Issues 19

Part Two:
1. Introduction to Processing Aides 25
2. Trimming 27
3. Operations Before Trimming 33
4. Casting Features 35
5. Mechanically Forming the Casting 37