Product Design for Die Casting

The sixth edition of this design sourcebook, revised and updated in 2009, presents a logical structure of how to pursue improvement and cost-reduction programs with a die cast product design. The steps presented are applicable to both new product concepts and upgrading of existing components. The principles and sequences outlined are useful for any strategic approach to product development, design and engineering. They are also integral to emphasis on design for manufacturability.

Item #E606, 122 pages, 2009.

 

Product Design for Die Casting

TABLE OF CONTENTS

Introduction    
1 The Die Casting Option 1
  1.1 Die Casting Advantages: Summary 1
  1.2 Advances in Die Casting Process Technology 1
  1.3 Developments in Die Casting Alloys 2
  1.4 Die Casting’s Range of Product Capabilities 2
  1.5 The Economic Equation 6
  1.6 The Benefits of Designing for Manufacturing 6
  1.7 Miniature, Squeeze & Semi-Solid Metal Casting 6
2 Product Development 9
  2.1 Working Environment 12
  2.2 Structural Criteria 17
  2.3 Manufacturing Economics 26
  2.4 Die Casting Versus Other Processes 32
3 Product Design   37
  3.1 Geometry Optimization 38
  3.2 Assemblies 47
  3.3 Machining 64
  3.4 Surface Finishing 67
  3.5 Prototyping 79
4 Alloys   87
  4.1 Range of Properties 87
  4.2 Aluminum Alloys 90
  4.3 Magnesium Alloys 95
  4.4 Zinc Alloys 98
  4.5 Zinc Aluminum (ZA) Alloys 101
  4.6 Alloy Selection 103
  4.7 Alloy Supply 106
  4.8 Restriction of Hazardous Substances (RoHS) 107
5 The Die Casting Process 111
  5.1 Understanding the Die Casting Cycle 111
  5.2 Characteristics of Die Castings 118
  5.3 Preventing Casting Defects 119