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D IE -CAST
What is Die Casting?
Q - What is Die Casting?
The term "gravity die casting" refers to castings made in metal molds under a
gravity head. It is known as permanent mold casting in the U.S.A. and Canada.
What we call "die casting" here is known as "pressure die casting" in Europe.
Die casting machines, large or small, vary fundamentally only in the method
used to inject molten metal into the die. These are classified and described as
either hot or cold chamber die casting machines.
Hot chamber machines are rapid in operation. Cycle times vary from less than
one second for small components weighing less than one ounce, to thirty
seconds for a casting of several pounds. Dies are filled quickly (normally
between five and forty milliseconds) and metal is injected at high pressures
(1,500 to over 4,500 psi). Nevertheless, modern technology gives close control
over these values, thus producing castings with fine detail, close tolerances and
high strength.
Figure 2: Cold Chamber Machine. Diagram illustrates die, cold chamber and
horizontal ram or plunger (in charging position).
CASTING DIES AND THEIR CONSTRUCTION
Die casting dies (Fig. 3) are made of alloy tool steels in at least two sections
called fixed die half and ejector die half. The fixed die half is mounted on the
side toward the molten metal injection system. The ejector die half, to which
the die casting adheres, and from which it is ejected when the die is opened, is
mounted on the moveable platen of the machine.
The fixed die half of the die is designed to contain the sprue hole through
which molten metal enters the die. The ejector half usually contains the runners
(passage ways) and gates (inlets) which route molten metal to the cavity (or
cavities) of the die. The ejector half is also connected to an ejector box which
houses the mechanism for ejecting the casting from the die. Ejection occurs
when pins connected to the ejector plate move forward to force the casting
from the cavity. This usually occurs as part of the opening stroke of the
machine. Placement of ejector pins must be carefully arranged so force placed
upon the casting during ejection will not cause deformation. Return pins
attached to the ejector plate return this plate to its casting position as the die
closes.
Fixed and moveable cores are often used in dies. If fixed, the core axis must be
parallel to the direction of the die opening. If moveable, they are often attached
to core slides. Should the side of a die casting design require a depression, the
die can be made with one or more slides to obtain the desired result without
affecting ejection of the casting from the die cavity. All moveable slides and
cores must be carefully fitted, and have the ability to be securely locked into
position during the casting cycle. Otherwise, molten metal could be forced into
their slideways causing a disruption of operations. Although slides and cores
add to the complexity and cost of die construction, they make it possible to
produce die castings in a wide variety of configurations, and usually more
economically than any other metalworking process.
Figure 3
DIE TERMINOLOGY
Sprue holes are tapered with the small end located at the breaking point when
the die is opened. A sprue pin, located in the ejector half, makes the sprue
hollow and deflects metal entering the die into the runner system.
Runners are channels located at the parting line to route liquid metal from the
sprue hole to the gate.
Gates are passages through which metal enters the die cavity. They have an
important function in directing metal flow so that the cavity is correctly filled.
Air is expelled through vents as molten metal enters the die cavity.
Guide pins assure proper alignment of die halves and correct register of
cavities.
Side walls and cores are designed to have a slight taper or draft. The largest
diameter or cross section of a cavity must be located at the parting line (unless
slides are used) so the casting can be removed from the die. As molten metal in
a die cavity solidifies, it shrinks away from walls onto core pins and other
projections. The design of the die must permit withdrawal of core pins, and
ejection without applying too much pressure which could cause deformation to
the die casting.
Cores, fixed or moveable, as well as "loose pieces," must be positioned to
facilitate removal either mechanically or by hand. Loose pieces used to form
undercuts must be positioned by the operator. This requires extra labor, and
usually slows the casting cycle.
Inserts can be cast integrally to provide special characteristics.
Most dies are cooled by water circulating through channels drilled for that
purpose
TYPES OF DIES
Dies are classified as: single cavity, multiple cavity, combination and unit dies
(Figures 4-A to 4-D).
A single cavity die requires no explanation. Multiple cavity dies have several
cavities which are all identical. If a die has cavities of different shapes, its
called a combination or family die. A combination die is used to produce
several parts for an assembly. For simple parts, unit dies might be used to effect
tooling and production economies. Several parts for an assembly, or for
different customers, might be cast at the same time with unit dies. One or more
unit dies are assembled in a common holder and connected by runners to a
common opening or sprue hole. This permits simultaneous filling of all
cavities.
Figure 4