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Alucast India
EC-506 Engineering
Die Casting Dies
Part 1
– Quality engineering,
– Quality materials and heat treat,
– Quality toolmaking, and
– Quality die casting processes and
practices.
Introduction
• Is porosity important?
• Surface treatment
• Sample run
• Layout
• Stress temper
• Corrections and core movement
• Second sample run
• Layout
• Stress temper
Components of Good Die Design
• Gating
• Heating & Cooling
• Structure
• Mechanisms
• Material
• Standard DME items
• Steel safe concept
• Undersize cores that can be moved
Components of Good Die Design
:
Standard & Precision Tolerances
• Why do we need tolerances?
:
Standard & Precision Tolerances
• Standard Tolerances
– Developed in the 1950's and 1960's before
the electronics revolution that resulted in
precision machines, precision dies, and
process automation.
• Precision Tolerances
- Recognizes process automation, precision
dies and precision machines with closed
loop processes made possible by the
electronics revolution over the past 40
years.
Standard & Precision Tolerances
Wikipedia
With a Normal Distribution
• Variable Behavior can be described with
statistics
• Average
N
x i
X i1
N
• Standard Deviation
N
x X
2
i
2 i1
N
Improving Capability
• To improve CPK capability (quality)
either:
– Move X closer to the nominal – the
target dimension or,
– Reduce variabilty – reduce σ.
Improving Capability
• Moving X closer to nominal can be
done by changing the casting die
steel. We build the die steel safe so
this can be done without welding.
Improving Capability
• Reducing dimensional variability is
not so easy. To reduce variability we
need to reduce process variability or
find a robust parameter combination
that reduces variabilty (Taguchi).
Improving Capability
• Taguchi experiments help reduce
variability and improve capabilities
with little or no investment.
Shrink
.
Processs & Die Design
• Shrinkage Porosity
– Intensification pressure, start, rise time
– Neutral neutral axis
Gas Porosity
• Venting
– Let the cavity air out
– During the slow shot phase
– During the fast shot phase
Venting Principles
• Vacuum
– Helps reduce gas porosity.
– Allows for a lower shot pressure during
cavity fill.
– But vacuum needs proper setup that
works every hour, every shift, every
day. Two methods:
• Pull vacuum through a value,
• Pull vacuum through a freeze block.
Die Spray
• Die spray heat removal is ineffective
in removing heat.
Shrinkage Porosity
• Intensification
• Higher intensification
pressure can yield less
visible porosity, but it
will not move porosity.
Higher metal pressure
just makes the
porosity smaller.
• Atomization
• Outgates and overflows
• Vents and vacuum runners
• Runner system
• Planned shot profile
Gating
• Slides
• Avoid interrupted fill
• Avoid unbalanced fill
• Use shortest flow distance
Cavity Fill Pattern
• Follow product
features
• Gate location
• Feed critical areas
Cavity Fill Pattern
• Overflows/vents at last points of fill
t = k x (Ti – Tf + S x Z)
(Tf – Td) x Th
• Percent Solids
0-10 Chrome finished casting
10-20 Painted casting – class A
20-30 Painted casting – class B
30-40 Functional casting
40-50 Pressure tight casting
Filling
Ladle Pour Shot
Sleeve
30% fraction
solid temperature
Ingate Velocity
2
Density Q
Pm =
772 apparent Ga Cd
•Q=V/t
• G a = Q / Gv
• G l = G a / Gt
Book 2 – Design Runner System
• Fan Runners
• Tangential Runners
• Wedge Runners
Fan Runners
• Fan Runners with decreasing areas
from beginning to end can be two
forms:
• 45 deg maximum
flow angle
• Fan length > gate
width
• Minimum 10% area
decrease through
fan
Tangential Runners
• Directed flow with calculated flow angle
• Actual gate velocity > apparent gate
velocity
Wedge Runners