Every high-quality die-casting always starts with its top-notch tooling. And the quality of tooling initially determines the holding tolerances and the number of shots from a mold.
Additionally, it concerns the achievable strength, repetition, and complexity throughout the project life.
The die-cast mold optimizing process requires a detailed review of the product design and the manufacturing process. Knowing how to optimize the tool design and partnering with an expert supplier is essential for your production success by gaining maximum project ROI.
What is Die Cast Tooling?
The term tooling is another name for die-cast molds. However, the process to create/machining these molds may be referred to as tooling as well. It features a cavity of empty interior space. Direct injection of molten metal fills the void and forms the mold after cooling down.
The hardened tooling requires separation into multiple pieces to allow the casting’s removal. There are different die casting mold types in practice. The noteworthy ones are –
- Prototyping Dies
- Unit Dies
- Rapid Tooling Dies
- Trim Dies
- Production Dies
Each type has particular features depending on the requirements. They offer various strengths based on the project specifications and scales. Sunrise Metal is ready to deliver conventional or multi-side tooling services for any project.
Tool/Mold Design Process
The design process for a die-casting mold will be different for each project. However, high-pressure casting involves five broad actions –
- Preliminary Phase
- Number of Cavities
- Projection Area
- Volume and Shape
- Semi-empirical Simulation
The initial design of the mold and its subsequent analysis can justify the tooling. Each action includes multiple variables required in the design for a precise outcome.
Manufacturability analysis is an essential step in the design of an aluminum die-casting mold or tool. Then it requires the calculation of the forces while checking the injection channels. Any major issues with the channels can be detected beforehand by the simulation.
Sunrise Metal has a dedicated engineering team to consider every design aspect. It includes material selection, tolerance stacking, and potential runner site. We use state-of-the-art software analysis for the die-cast mold optimizing approach.
The analysis also includes finding the best runner system sites and cooling ports. A feature like cooling ports can limit tool wear, prolong die cast tool’s lifespan, uniform porosity, and high strength.
Mold Optimizing Design for Manufacturability (DFM)
All the well-valued and perfectly executed engineering to design the tool before casting is the core concept of Sunrise Metal. This Designing for Manufacturing or DFM guarantees success and longevity long before the cast occurs in production.
Designing for maximized manufacturability is what makes a top-quality die-cast tool. DFM expedites the entire design process by providing a usable and long-lasting mold. It also enables more consistency and superior performance for the component.
There are various parameters in a DFM process to ensure the smooth production of parts. Die casting design parameters such as drafts angle, radii/fillets, bosses & ribs, parting lines, etc. requires careful attention. Having the most effective solutions is never easy with tooling.
Die Casting Mold Optimizing: Care and Maintenance
Proper care and tooling maintenance are always necessary to achieve the best results. Our tooling features ensure longevity, strength, and performance. Still, the repeated heating cycles (over 1200°F) and subsequent cooling will eventually degrade the tool. Die-cast tools mostly go through core wear and gate erosion, requiring light maintenance from time to time in their service life.
Adherence to any rigid maintenance program can effectively extend the lifespan. This slight yet crucial care further ensures consistency and timely production of quality parts. However, some particular and specialized alloy material selection and processes may require additional maintenance.
For example, a multi-slide zinc tooling should withstand nearly one million shots. But conventional aluminum tooling can withstand roughly 200,000 shots. Proper design and occasional maintenance make this enormous difference in expected shot numbers between the two components.
However, a tool’s average shot number depends on multiple variables. The list includes selected materials, the complexity of components, project requirements, and associated factors. Considering a realistic extent of tool wear during design can greatly reduce maintenance needs.
All the tools remain in “like fresh and new” condition at Sunrise Metal throughout the project. We have one of the best maintenance programs within the cost of tool up-fronts. Therefore, investing in a die-cast mold with us means a one-time investment for the entire project.
Gaining the Maximum ROI from Die Cast Mold Optimizing
A cheap and low-quality tool may incur a reduced price. But they will need more investment in frequent defects, maintenance, and replacement. Instead, high-quality tooling guarantees greater ROI with prolonged life, lower scrap yield, and superior performance.
The following suggestions can help produce high-quality die-cast parts –
- Flexibility for Draft Angles：
Increased draft angles of a non-critical design element enable easy extraction, leading to an extended lifespan.
- Tolerance based on requirement：
Allowing for die-casting tolerances only how much is necessary can greatly reduce the cost, especially for non-critical elements.
- Getting Involved with Supplier：
Collaboration with engineers for necessary adjustments early in the design can avoid expensive revisions.
Every die casting part is different in function and design. Get started on the die cast mold optimizing strategy with engineering value. Contact us for professional die-cast mold services ensuring turnkey solutions for your project.