HIGH PRESSURE DIE

CASTING
Productivity Improvements
Through
Better Die Design and Die Maintenance
By
G.Ramasubramanian
RAM & RAM FOUNDRY CONSULTANTS
Mobile : +91 98412 83025
E-Mail : gramasubramanian@hotmail.com
19.12.2009
 DEDICATED TO

MY GURU - Mr.S.SAMU
AND
MY MENTOR - Mr.S.ADHIMOOLAM
DIE DESIGN
 INTRODUCTION
HIGH PRESSURE DIE CASTING

• Molten metal is forced with High Pressure in to the Cavity of Steel Mould.

ADVANTAGES

• Thin Walled Casting with High Tensile Strength.

• Less Material Wastage.

• Mass Production on Fast running Machine.

• Better and Clear Surface Finish.

• Intricate Castings with High Dimensional Accuracy.

 TYPES OF DIE CASTING
GRAVITY DIE CASTING
• Molten metal is poured under gravity in to permanent mould.

• No External Pressure except Gravity force.

• Large runners and feeders required.

• Metallic and Sand cores can be used.

• Holding furnaces are separate.

• Initial Investment is low.

LOW PRESSURE DIE CASTING

• Metal enters at Low Pressure directly from holding furnace.

• Holding Furnace is part of the Machine.

• Complicated Casting can be made.

• Metallic and Sand cores can be used.

LPDC MACHINE SEQUENCE
HIGH PRESSURE DIE CASTING

• Die is closed with High Pressure.

• Molten metal is injected at a High Pressure by a powerful piston.

• Only Metallic Cores can be used.

• Holding furnace is separate.

• Die Casting Machine is very Costly .

• Intricate and Complicated Casting can be made.

 THE CREDENTIALS OF A DIE DESIGNER

¾MUST BE AN EXPERINCED DRAUGHTSMAN

¾MUST BE ABLE TO USE AND APPLY CAD – CAM
¾ TOOL MAKER EXPERIENCE
* IN DEPTH KNOWLEDGE OF CORRECT TOOL MAKING
PRACTICES
* FAMILARITY WITH CNC MACHINING AND
EQUIPMENT
¾HEAT TREATMENT AND METALLURGICAL TRAINING
¾ DIE CASTING KNOWLEDGE
* UP TO DATE THEORY AND TECHNOLOGY
* PRACTICAL EXPERIENCE GAINED ON THE SHOP FLOOR
¾MUST BE AN EXPERT NEGOTIATOR AND ABLE TO SPEAK THE
LANGUAGE OF ACCOUNTS
 DIE DESIGNER – CO -ORDINATORS

PRODUCT
DESIGNER
BUYER OF
STEEL
DIE AND
SUPPLIER
CASTINGS

DIE CAST DIE TOOL

PRODUCTION DESIGNER MAKER
MANAGER CAD-CAM

DIE CASTING HEAT

ENGINEER TREATER

TOOL ROOM
ENGINEER
 DESIGN PHILOSOPHY

¾ We can design a cheap die or an expensive die.

¾ We have to follow the physical laws of nature during the design stages.
¾ These are the laws relating to

™ FLUID FLOW / FLUID MECHANICS

™ HEAT FLOW / THERMO DYNAMICS
™ MECHANICS
 GUARRANTEED RECIPE FOR CERTAIN FAILURE

¾ DESIGN TO CUT DIE COSTS TO THE MINIMUM

¾ CHOOSE THE SIMPLEST SOLUTIONS

¾ ACCEPT EVERY COMPROMISE SUGGESTED BY YOUR

CUSTOMER AND MANAGEMENT
 GUARRANTEED RECIPE FOR SUCCESS

¾ DESIGN FOR PERFECTION.

¾ CALCULATE EVERY DETAIL, DO NOT GUESS.

¾ CONSIDER EVERY FEATURE FROM NATURE’S VIEW POINT.

 HOW DO WE ACHIEVE THESE OBJECTIVES

¾ DESIGN IN A LOGIACAL SEQUENCE

™ USE THE DIE DESIGN FLOW – CHARTS

™ FOLLOW THE DESIGN GUIDE LINES

¾ CALCULATE EVERY DETAIL

™ Die casting die design Programs.

™ Stress / Strain strength Calculations
™ Suppliers data sheets and recommendations
™ Reference works and data banks
¾ Documentation must be impeccable – Demand certified reports
From suppliers and subcontractors.

™ Certificate of steel quality / grain structure and homogeneity from steel

supplier.
™ Stress relieving certificate machining data, EDM current and erosion rates
from Tool Maker.
™ Heat treatment certificated from Heat treater.

¾ Verify the certified conditions by sample analysis performed in the testing lab
of the steel supplier.
 DIE DESIGN
Design of a die plays a vital role in the profitability of a company.

Poorly designed dies

• Can be expensive to make

• Difficult to maintain

• May have low shot rates

• Produce poor quality castings

• Flash will add to trimming costs, increase metal losses and lower the foundry
environment.
Die designer should consider three basic principles while designing a die

1. The metal has to get through the die and fill the cavity to make a quality
component.

2. The casting has to move away from the fixed half of the machine and open
without distortion

3. The casting must be completely ejected.

¾ While designing a die, a close understanding between die designer, product

designer, tool engineer and foundry engineer is required.
 VARIOUS STAGES OF DIE DESIGN

• Flow analysis using flow softwares like Magma

• Preparation of Die Layout and Assembly Drawings.

• Mould Base detail drawings.

• 3D Modeling of the Casting using Modeling softwares like PRO-E, UG and

CIMATRON.

• Insert and Cores Splitting.

• Preparation of Inserts and Cores 2D detailed drawings.

 FUNDAMENTAL PRINCIPLES INVOLVED IN
DIE DESIGN
¾ Elimination of stress concentration.
¾ Provision of adequate shrinkage allowance

Type of stresses developed in dies during Casting Process.

1. The mechanical stress encountered in closing and locking the die.

2. The mechanical shock stress involved in making the casting.

3. The thermal shock stresses resulting from bringing the molten metal in contact
with the die.

4. The thermal shock stresses caused by flushing cooling water through the hot die.
 FACTORS AFFECTING SHRINKAGE
ALLOWANCE

1. Material alloy composition

2. The temperature at which metal is injected into the die.

3. Die temperature.

4. Contour of the part.

 PRESSURE DIE CASTING MACHINE
There are two principal features on a Die Casting Machine.

• The locking mechanism that forces the die plates together to withstand the
high pressure built up in the dies.

• The injection system that presses the molten metal with considerable force
into the dies.

There are basically two different injection systems, which classify the Die
Casting machines.

HOT CHAMBER MACHINE:

In this type of machine, the metal chamber is submerged into the molten metal
pot of the furnace.
COLD CHAMBER MACHINE:

In this type of machine the molten metal is to be ladled or in some cases

mechanically
from the furnace, which is placed at convenient distance away from the machine
into the
filling sleeve of the machine.

Types of Cold Chamber Machine:

Horizontal Cold Chamber Machine

SEQUENCE OF METAL FLOW IN HORIZONTAL COLD CHAMBER MACHINE
VERTICAL COLD CHAMBER MACHINE
 THEORITICAL ASPECTS OF PDC PROCESS
INJECTION OF MOLTEN METALS
FILLING OF DIE CAVITY

• The filling of the die cavity takes place in three successive phases.

• First Phase – Slow movement of molten metal fills up to sprue bush and runner.

• Second Phase – Actual filling of Cavity under Hydrodynamic force.

• Third Phase – Final Squeeze of molten metal with hydrodynamic pressure.

IMPORTANT CASTING VARIABLES

• Velocity of entering Metal.

• Injection Pressure developed by machines.

• Gating Section, Direction and Travel Distance

• Alloy and its Physical Characteristics

• Die and its Physical Characteristics.

FORCES APPLICABLE ON DIES

The locking force L, which is fixed by the machine type had to be minimum,
equal or more than the hydrostatic pressure F developed by the injected metal.

L≥F

The casting pressure F is developed on various factors of which some are

adjustable.

P’ – Hydraulic line Pressure (adjustable)

I - Injection force = P’ X Area of shot cylinder (adjustable)

S - Area of Plunger tip (changeable)

P - Specific injection Pressure.

A – Total projected area of casting inclusive of runner, slug, overflow etc.

FORCES APPLICABLE ON DIES
 INJECTION SPEED

¾ Injection speed is one of the most important variables in making a casting.

¾ Injection speed – The length of time required to inject the molten metal into
the Die cavity.

¾ The Main factors which control the Injection speed are

1) The latent heat of fusion and specific heat of the alloy

2) The heat conductivity of the alloy.
3) The solidification temperature of the alloy
4) The die temperature
5) The heat conductivity of the die
6) Whether the casting is largely of thin section or heavy sections
7) The average distance which the metal must travel to fill the impressions.
 Moving die Housing Thickness - Calculation
¾ The injection of molten metal into the mould develops internal stresses which have
to be taken up by the die.

¾ As per the hydrostatic rules, the pressure would act equally in all directions.

¾ The pressure developed in the cavity will be finally transferred to the frame.

¾ The fixed die housing is resting with the full surface on the stationary machine plate
and so it is not necessary to calculate the thickness of the fixed housing.

¾ The moving housing of the die which is supported by two side plate of the ejection
box is subjected to a bending force.
 Programme selection
¾ Programme 1 Die closing –shot – die opening –ejection forward and backward.

¾ Programme 2 Core 1 in- die closing – shot – die opening – core 1 out – ejection
forward and backward.

¾ Programme 3 Core 1 in – core 2 in – die closing – shot – die opening – core 2

out – core 1 out – ejection.

¾ Programme 4 Core 1 in – core 2 in – die closing –core 3 in –shot – core 3 out-

die opening – core 2 out – core 1out – ejection.

¾ Programme 5 Core 1 in – die closing –core 3 in –shot – core 3 out- die opening
– core 1out – ejection.

¾ Programme 6 Die closing –core 3 in –shot – core 3 out- die opening – ejection.
 SINGLE CAVITY OR MULTI CAVITY DIES

Introduction

¾ For higher volume of castings, Multi-cavity dies are preferred.

¾ Casting cost will be minimum, if the maximum number of cavities are

utilized for the available machine capacity.

¾ Investment in Multi-cavity dies should be justified.

 Single Cavity Vs Multi-Cavity Dies
• Single cavity die is the only solution
• If centre gating is necessary
• If movable cores are needed in four directions
• If available machine capacity does not permit more than one
component.

• Multi-cavity dies has to be decided from the economical point of view.

 Factors to be considered for
Multi-Cavity Dies

• Annual requirement of components

• Casting machine available.

• Number of shifts available to complete annual

requirement.

• Total cost per hour of machine available inclusive of

all overheads.
 Factors to be considered for
Multi-Cavity Dies

• Expected number of shots per hour with single and

multi-cavity dies.

• Cost of Single and Multi-cavity dies.

• Expected rejection, material loss etc.

 Factors to be considered for
Multi-Cavity Dies

• Cost of material loss for the runner & overflows are

to be taken into account when planning for multi-
cavity dies .

• If only one type of machine is available, the only

consideration will be the annual requirement and the
die price
Effect of Metal Momentum
 Effect of Metal Momentum
• In both cases, the overall length of the runners and
the cross-sectional areas are almost same.

• Momentum of the injected metal has a much more

direct influence on the effective pressure at the cavity
gate.

• The above statement is confirmed by the comparison

of the following two runner systems.
 Effect of Metal Momentum

• When metal is injected into the system, it is

continually constrained to change directions as it
passes around the curved runner arms.
 Effect of Metal Momentum
• There is a strong outward redial force acting on the
metal stream and it is centrifuged into the cavities.

• The cavities near the sprue begin to fill first and those
near the ends last.

• If the cavities are of small volume, they may fill

completely before the runner itself is full of metal as
in the above figure and the injection pressure will be
applied afterwards.
 Effect of Metal Momentum

• There is no force on the metal normal to its direction of flow .

• As the metal stream divides at the junction, it is thrown against

the far side of the runner channel.
 Effect of Metal Momentum
• Thereafter its inertia keeps it moving in a straight line
until the end of channel is reached

• The filling begins when the metal backs up in the

runner channel.

• Cavity nearest to the end of channel fills first and the

middle cavity will fill last.

™ In practice the above two trends can be greatly

modified by details of gate and feed geometry.
 Runner Problems in Multi-
cavity Dies
• Initial choice of runner layout is of major importance,
since it radically affects the order in which the
cavities begin to fill, the rate at which filling occurs
in each and consequently , the order in which cavity
filling is completed .

• On hot chamber machines & vertical cold chamber

machines, the cavities are placed around the sprue
bush and the runners can lead directly from the sprue
in any required angle to the cavities.
 Runner Problems in Multi-cavity Dies

• Even in this case, simultaneous filling at exactly the same rate

cannot, in practice, be achieved because air carried ahead of
the injected metal does not build up an identical back pressure
in every cavity at the same rate.
 Runner Problems in Multi-cavity
Dies

• On horizontal cold chamber machine, the runner can be

machined initially in any angle, but only to the top
direction of the die. This fact makes it necessary to
provide a ring runner first.
Runner Problems in Multi-cavity
Dies
• On a 18 cavity die, the initial runner layout was
as shown below.
 Runner Problems in Multi-cavity Dies

• The two runners ‘a’, are to feed the long ring runner
‘b’.

• While the metal is forced through the long runners,

some of the metal is already reaching the gating
points of some cavities before the ring runner is
completely filled.

• The thin section of gating obviously provides more

resistance to the metal flow than the bigger section of
the runner.

• Only after the runner is completely filled, the

injection pressure is applied and forces the metal
through the gatings into the cavities.
 Runner Problems in Multi-cavity
Dies
• To avoid the filling problem, the runners were
modified as shown below
 Runner Problems in Multi-cavity
Dies
• The ring runner ‘b’ was divided into three sections
and additional runners ‘c’ were provided to feed the
two lower runner sections directly from the sprue
bush, hence the travel distance and filling time was
considerably reduced.

• During the second trial, the filling problem was

completely eliminated
 CASE STUDY
• FLANGE RING CASTING
– Flatness – 0.15mm.
For this 2 cross ribs are provided
– Concentricity between hole & boss (4Nos.) should be
within 0.3mm.
– Ejection system at the cover die insert in each cavity.
– No ejector pins on the face so over flow ejection system has
been provided.
– 4 core pins at the moving die side insert with less taper.
– Compound trimming tool is being used for trimming inside
and outside profiles.
– No machining operations.
– Shot blasting, inspection and packing.
 Runner – Over Flow Layout
• Cavity Layout for

– 250T

– 420T

– 660T(OLD)
 Twin Cavity Layout in 250T
Cold Chamber Die Casting Machine
 Four Cavity Layout in 420T
Cold Chamber Die Casting Machine
Six Cavity Layout in 660T Cold
Chamber Die Casting Machine
 Estimation of Casting Cost
• This is based on the following factors:-

• Die life

• Machine cost inclusive of all overheads

• Production per hour & Rejections etc.

 Die Casting Machine Cost Per
Casting
Actual
M/C Machine Number Actual production Machine
Capacity Cost in of Rejection production per hour cost in
in Tons Rs. Cavities per hour in minus Rs. per
per hour Nos. rejection casting
in Nos.

250T 1100 2 2% 110 216 5.10

420T 1250 4 3.5% 100 386 3.24

660T 1100 6 5% 90 513 2.14

(OLD)
 Die Cost Per Casting
Total
Die cost in Number of Die Life in production Die Cost
Rs. Cavity Shots minus Per
rejection in Casting
Nos. (Rs)

5,00,000 2 100000 1,96,000 2.55

6,50,000 4 100000 3,86,000 1.68

7,80,000 6 100000 5,70,000 1.37

 Cost of Casting without Materials
Description Twin Four Six
cavity die cavity die cavity die
Machine cost per 5.10 3.24 2.14
casting in Rs.

Die cost per casting in 2.55 1.68 1.37

Rs.
Cost of casting without 7.65 4.92 3.51
materials (Rs.)

With annual
production of 18,00,000
castings the die will 1.3 2.6 months 3.8 months
work for months
• On Multi-Cavity Dies for Components with lesser
annual requirement, the capital investment of the die
will depreciate only after many years.

• This is a considerable disadvantage for the investor.

 MACHINE SELECTION
CASTING PRESSURE - P IN Kg/Sq.cm

ALUMINIUM ZINC

AVERAGE STANDARD PARTS 400 200-250

HIGHER FINISH 500-600 300-400

PRESSURE TIGHT PARTS,

NO BLOW HOLES 700-1000 400-600

ELECTRO PLATING PARTS - 250

MACHINE CAPACITY = 1.2 x A x P/1000 tons

A= Projected area of (casting + Runner +Sprue biscuits + overflows)

Safety Factor = 20%

 DIE CASTING DIES
DIE DESIGN IN GENERAL
HORIZONTAL COLD CHAMBER MACHINE

a) FRAME DESIGN
b) PLATE DESIGN
c) CENTER GATING DESIGN
d) ALTERNATE CENTER GATING DESIGN
e) DIE WITH STRIPPER PLATE
DIE LAYOUT DRAWING
DIE ASSEMBLY DRAWING
DIE DESIGN-BASIC PRINCIPLE
HOT CHAMBER DIE
VERTICAL COLD CHAMBER DIE
SPRUE BUSH FOR HOT CHAMBER & COLD
CHAMBER DIE
CENTRE
OF
GRAVITY
OF SHOT
CASTING
CENTRE OF GRAVITY
CENTRE OF GRAVITY
CENTRE OF GRAVITY
TOLERANCE ON DIES

THANK YOU
 DIE COOLING

• In order to obtain quality castings, it is important to maintain the die

temperature on all cavity points within a small range.

• The maximum temperature increase will be around the gating and heavy casting
section.

• A continuous injection on these points to a high level can be controlled to

certain extent with water-cooling.
 GATING AND RUNNER SYSTEMS

GATING

• Opening through which molten metal is forced in to the cavity.

• Position of Gating depends on the casting.

• Gating Influences production speed, the size of the die, cooling, wear and
overflow sizes
GENERAL RULES

• Preferably only one gating should be provided. In case of more gating,

care should be taken that the individual metal streams entering the cavity
do not interfere.
• The cavity should be filled from one direction to another. Care should be
taken to avoid the formation of several jets in the incoming stream.
• It is preferable, especially on large castings to provide the gating point
somewhere in the middle. This will shorten the distance the metal has to
travel through the cavity.
• Care should be taken while deciding the place and direction of gating
that no air pockets can develop during filing period.
• On a correct gating the metal entering the cavity should press the air to
the air vents.
• On thin-walled castings the best surface finish can be obtained generally
with thin gating and high injection speeds.
• On thick walled components, sound and pressure tight castings can be
obtained only with thick gating, slow injection speed, but high pressure.
• The metal stream should fill the cavity with the least possible obstruction
i.e. Direct hitting on cores should be avoided as far as possible.
• The gating points should be so arranged that easy breaking of gating is
ensured without spoiling the corners of the casting.
 GATING THICKNESS

Component Weight

Upto 100 100 – 1000 1 to 5 kgs

gms gms
Zinc Alloy 0.3 – 0.6 0.5 – 1.2 0.8 – 1.8
Aluminium Alloy 0.5 – 1 0.8 – 1.8 1.5 – 3.5
ADVANTAGES AND DISADVANTAGES OF THICK AND THIN GATING

Advantages Disadvantages
Thick Gating Sound Casting. Difficult breaking of
Pressure tight longer die casting.
life. More flow marks
especially on thin walled
casting.
Thin Gating Better surface finish. More shrink and air holes
Better control for More soldering
direction of flow. Shorter Die life.
IMPORTANT POINTS TO BE CONSIDERED DURING GATING DESIGN:

1. The travel of small individual streams should be as short as possible. On long

travel, the alloy may cool on the die wall to an extent that fusing at the meeting
points are hardly possible.

2. Small passages should be fed direct from runner with hot metal, otherwise deep
flow marks may occur.

3. The meeting points should be preferably on thick sections where the die
temperature can be maintained hot.

4. It is also desirable that meeting points are close on areas where overflows can be
provided. This way it can be avoided that trapped air prevents the joining.
GATING CALCULATIONS

W
A= dxtxv

Where,
A = GATING AREA

W = WEIGHT of CASTING in Gms.

d = DENSITY OF METAL
(Al = 2.6, Zn = 6.8)

t = CAVITY FILL TIME in SEC

v = VELOCITY THROUGH GATE.

APPROXIMATE VALUES OF GATE VELOCITIES

ZINC - 30 – 50 m / sec

ALUMINIUM – 20 – 60 m / sec

MAGNESIUM – 40 – 90 m / sec

BRASS - 20 – 50 m / sec

Cavity Fill time for Different Wall Thickness

WALL THICKNESS in MM CAVITY FILL TIME in SEC

1.5 0.01 - 0.03
1.8 0.02 – 0.04
2 0.02 – 0.06
2.3 0.03 – 0.07
2.4 0.04 – 0.09
3 0.05 – 0.10
3.8 0.05 – 0.12
5 0.06 – 0.20
6.4 0.08 – 0.30
RUNNER

• Channel which leads metal from sprue bush to the cavity.

• Generally Machined in One half of the die.

• Rectangular shape in section.

• Width: Depth = 2:1 to 3:1

• Sidewall machined in an angle of 2º to 5º

• Runners to be short and straight to the cavity.

• Abrupt change in direction tends to develop turbulence.

• Blind Runner Additional local heating by the provision of blind runner.

GATING THICKNESS TO RUNNER THICKNESS - 1:6 to 1:10

GATING AREA TO RUNNER AREA - 1:3 to 1:4

RUNNER CROSS SECTION DESIGN
 OVERFLOWS AND AIRVENTS
OVERFLOWS

• To Maintain even Die Temperatures

• Maintain uninterrupted metal flow in to the cavity.

• Reception of lubricant remains and foamed metal

• The depth of overflow to be three times the section of casting and width about
double of the depth.

AIR VENTS

• Position of Air vents to be in place where the metal fills last.

• Often they are provided after I Trial after knowing flow of metal.

• Depth of Air vents to be 0.1 mm to 0.15 mm

• Increase of existing air vents to be done only in width and not in depth.

• Along Ejector pins 0.02 mm of Air vents can be provided.

• On intricate castings, venting can be provided on fixed cores, between joints of inserts
and along moving cores.
CHILL VENT
DIE- CHILL VENT ASSY.
 Thermal analysis of Die cast dies
Temperature- Die

The die temperature is one of the most important process

parameters besides the specific pressure, metal velocity and the
alloy type. The recommended working die temperatures are as
follow.
Alloy --- Zn Al
Die temp ◦C --- 150 – 200 180 - 300

The correct and constant die temperature is a basic

prerequisite for a satisfactory and trouble free production runs
and enhances the die life.
The amount of heat in KJ/hr. to be dissipated can be
calculated with the aid of the following formula.
Q =q.n.G
Q - The quantity of heat to be led off in KJ/hr.
n - Number of shots per hour.
q - The quantity of heat to be led off at every shot.
 for Al and Mg alloys, q = 607 KJ/Kg
for Zn alloys, q = 201 KJ/Kg.

G – Shot weight in Kg.

For the layout work of the cooling channels, the following values can
be taken as a basis for the heat dissipation.
Cm length of channel

Cooling channel at spreader Ø13-15- 502 KJ/hr

Cooling channel at sprue or runner Ø 9-11- 377 KJ/hr
Ø 8 - 293 KJ/hr
Cm length of channel
Cooling channel in the area of die cavity Ø13-15- 251 KJ/hr
Ø 9-11- 188 KJ/hr
Ø 8 - 146 KJ/hr
Cm length of channel
Cooling channel in holding block Ø13-15 - 125 KJ/hr
Ø 9-11 - 92 KJ/hr
Ø8 - 75 KJ/hr
 MANUFACTURING OF DIES

CHARACTERISTICS OF DIE STEEL

• Structural Soundness and Uniformity.

• Good Machinability

• High resistance to Heat checks

• Sufficient strength and hardness to resist deformation during various operations.

• High resistance to the erosive and washing action of the die cast alloy.

• Sufficient toughness to resist cleavage cracking.

• Low Coefficient of thermal expansion.

• Dimensional stability in heat treatment

 Composition of Die steel –H13

C Si Mn Cr Mo V
Typical
Analysis 0.39 1.0 0.4 5.2 1.4 0.9
%
MANUFACTURING OF DIE INVOLVES

• Inserts and Cores Pre machining using Machining Softwares like UG and
CIMATRON etc.

• Inserts and Cores Heat treatment.

• Post machining of Inserts and cores.

• Electrodes pick up using Softwares like CIMATRON, PROE, UG, etc.

• Sparking of Electrodes in EDM Machine.

• Polishing of Inserts, Cores

• Final Assembly and try out

HEAT TREATMENT

Various stages of Heat Treatment Process are,

• Stress Relieving of Material.

• Hardening

• 1st tempering

• 2nd Tempering

• 3rd Tempering

Normal Specification of Hardness for Various Die Parts.

Inserts and Cores - 46 – 48 HRC

Sprue bush - 46 – 48 HRC
Filling Sleeve - 47 – 48 HRC
Ejector pins - 44 – 46 HRC
Core pins - 46 – 48 HRC
 DIE CASTINGS ALLOYS
ALUMINIUM ALLOYS

• The outstanding characteristics of Aluminium are its lightness.

SALIENT FEATURES OF ALUMINIUM

• Retention of a High Polish for long periods of time.

• Excellent Corrosion resistance.

• Freedom from Dimensional changes.

• Retention of properties at subnormal temperatures.

• Pressure tightness characteristics to Maintain even Die Temperatures

SELECTION OF ALUMINIUM ALLOYS FOR DIE CASTING
The factors that influence the Alloy Selection for Casting are,

• Mechanical Property Requirements.

• Service Requirements.

• Casting Process.

• Availability of Alloy.

• Economics.

GENERAL EFFECTS OF ALLOYING ELEMENTS

SILICON :

• Improves Fluidity and castability of molten metal.

• Reduces external Shrinkage.

• Reduces the coefficient of thermal expansion and improves weldability.

• Freedom from Dimensional changes.

COPPER:
• Reduces internal shrinks.

• Increases hardness.

MAGNESIUM:

• Increases strength and ductility.

• Increases corrosion resistance.

• Improves machinability.
IRON:

• Reduces Shrinkage.

• Minimize soldering.

• Normally Iron contents of 0.8 – 1.20 is desirable.

MANGANESE:

• Reduces shrinkage.
CHROMIUM:

• Reduces Stress cracks or stress corrosion.

• Improves strength at higher temperatures.

ZINC:

• Improves machinability.

• Zinc content of 4.5 % and higher causes brittleness in alloy.

TIN AND LEAD:

• Used for better machinability in alloy.

• But combination of these two elements in excess of 0.50% causes brittleness in

die casting.
 DIE CASTINGS ALLOYS
ZINC ALLOYS

SALIENT FEATURES OF ZINC

• Excellent Physical & Mechanical Properties.

• Very High Production Rates.

• Machining & Finishing Costs Low.

• Low Die Cost.

• Close Dimensional Tolerance and uniformity.

• Low Material cost because of moderate alloy cost and minimal scrap loss.

• Good Corrosion resistance.

 GENERAL EFFECTS OF ALLOYING ELEMENTS

ALUMINIUM :

• Aluminium composition below 3.5 % in Zinc results in poor Castability

• Impact Strength Decreases with an increase in Aluminium above 4.5%

COPPER :

• Increases Tensile strength and Hardness.

• Zinc components under high temperature looses Impact strength & Dimensional
Stability with Mazak –3. In that case Mazak – 5 is suitable.

MAGNESIUM:

• Magnesium presence helps to prevents subsurfaace network corrosion.

• Magnesium contents grater than 0.06% reduces Impact strength and tend to
Heat Crack.
IRON:

• Increase in Iron content increases Hard Spots in Casting and affect

Machinability.

CADMIUM:

• Cadmium in Zinc alloy should be kept below 0.05%

TIN & LEAD:

• Both Tin & Lead sould not be present above the permissible limits as they are
impurities

APPLICATIONS FOR ZINC DIE CASTING:

• Automobile Industry - Radiator, Carburetors and Fuel Pumps

• Electrical Industry - Washing Machines, Micro Phones, Thermostat Housing
• Hardware Industry - Furniture, Padlocks, Blind Hardware, Plumbimg
Fixtures.
• Generai Industry - Coplings, Mandrels, Hoists.
CHROMIUM:

• Reduces Stress cracks or stress corrosion.

• Improves strength at higher temperatures.

ZINC:

• Improves machinability.

• Zinc content of 4.5 % and higher causes brittleness in alloy.

TIN AND LEAD:

• Used for better machinability in alloy.

• But combination of these two elements in excess of 0.50% causes brittleness in

die casting.
 PRACTICAL APPLICATION OF VARIOUS DESIGN

a) SLEEVE EJECTION
b) UNDER CUT CASTING - 4 CAVITY
c) RACK AND PINION ARRANGEMENT
 CASTING DEFECTS AND RECTIFICATIONS
DEFECTS AT FOUNDRY FLOOR

INCOMPLETE FILLING:

Cause:

• No sufficient metal.

• Low injection pressure or slow plunger speed.

• Cold metal or low die temperature.

• Trapped air also prevents filling.

Rectification:

• More metal in sleeve

• Providing air vents.

• Increase in die and metal temperature.

SCRATCHES AND MARKS ON THE CASTING:

Cause:

• Unevenness of cavity will be reproduced on the casting.

• Soldering of alloy on die steel.

• Tool less taper.

Rectification:

• Cleaning and polishing of die.

• Remove possible undercuts or increase taper.

SOLDERING:

Cause:

• Hot metal hits direct to die walls.

• Soldering of alloy on die steel.

Rectification:

• Reduce metal temperature.

• Change direction of metal flow.

• Increase hardness of inserts.

• Replace inserts with more suitable die steel. Remove possible undercuts or
increase taper.
FLOW MARKS:

Cause:

• Spraying of metal with high injection speed..

• Low injection pressure or thick gating.

• Uneven die temperature.

Rectification:

• Spraying of metal with normal injection speed.

• Increase in Injection Pressure.

• Even die temperatures.

HARD SPOTS:
Cause:
• Oxides enclosed in molten metal.

• Segregation of alloy elements in low metal temperature.

Rectification:
• Clean metal with flux.

• Check metal composition and increase metal temperature.

SPONGY STRUCTURE ON CASTINGS:

Cause:
• Oxides enclosed in molten metal.
• Segregation of alloy elements in low metal temperature.
Rectification:

• Clean alloy with flux.

• Change and apply less lubrication.
COLD SHUTS:

Cause:

• Various metal streams cool too much before they meet again.

• Trapped air prevents proper fusion.

• Oxide film develops at the ends of metal stream, which makes fusion difficult.

• Low injection Pressure.

Rectification:

• Change of gating direction.

• Increase injection pressure.

• Increase in die temperature

• Improve air venting.

SHRINK CRACKS:

Cause:

• Internal stresses are greater than strength of casting while cooling.

• Delayed ejection or core pulling.

Rectification:

• Adjust working speed.

• Change component design. (Avoid sharp corners)

• Control die metal temperature.

SURFACE DEPRESSIONS:

Cause:

• Local over heating on die.

• Subsurface porosity.

Rectification:

• Adjust die metal temperature.

• Change in gating position.

• Increase in pressure.
 DEFECTS REVEALED AFTER MACHINING

SHRINK HOLES:

Cause:

• Metal solidifies in some sections much earlier than in others.

• Less injection pressure.

Rectification:

• Change position of gate.

• Improve on die cooling

• Increase in injection pressure.

BLOW HOLES:

Cause:

• Air trapped in cavity.

• Gas enclosed in alloy.

• Oversize sleeve for small casting.

Rectification:

• Improve in air venting.

• Change direction of metal flow.

• Reduce injection speed and clean metal with flux .

MICRO POROSITY:

Cause:

• Lubrication mixes with metal and develop gas.

• Air is trapped in to the metal when injected with high velocity

• Air trapped in cavity.

• Gas enclosed in alloy.

• Oversize sleeve for small casting.

Rectification:

• Keep die clean.

• Use little lubrication.

• Clean molten alloy and reduce injection pressure.

 INFRASTRUCTURE FOR GOOD CASTINGS

• Die Casting Machine with Auto Ladle, Auto Sprayer and Auto Extractor.

• Holding and Melting Furnaces.

• Die Heating and Cooling Equipments

• Trimming Tools

• Stress relieving of the Dies after every 20,000 Shots.

• Impregnation of Casting

• Die Maintenance at regular Intervals.

Die Maintenance
 Die Maintenance
¾Stress relieving at frequent intervals.

¾Soldering materials to be removed .

¾Nitriding operation to be carried out
¾0.03mm – 0.5mm thickness.

¾Cleaning and storing of the die after a run.

¾ Normally, cleaning is done at 60˚C.

 Welding Of Dies
• Welding methods
– Arc Welding
– TIG Welding

• Welding Consumables
– Shielded metal arc welding, coated electrodes
– TIG Filler rods.
 Tool preparation for welding

¾Clean the Tool by Grinding.

¾Prepare Joint.
 Welding Procedure

–Maintain the temperature to 620 -

710˚F.
Build up weld
 Examine weld

¾ Clean and Inspect the tool.

¾ Grind away the final layer of weld metal before
any heat treating.

Temper Tool
¾ Temper the tool to Temperature 50 - 70˚F below
the third tempering temperature.

.
Failure of Die casting Dies in
service and Preventive
Measures
¾ Die casting dies fail when a stress or
combination of stresses in the die become
greater than the strength of the steel.

¾ There are two kind of stresses involved

i. Stresses which are produced while the die is
being made, such as from machining, grinding,
EDM, faulty heat treatment or mistakes in
design.
ii. Stresses which are produced while the die is in
operation, such as thermal stresses or
mechanical stresses.
 Reasons for the failure of
Diecast Dies
¾Gross cracking or cleavage cracking
( Thermal Shock )
¾Die breaks into two or more pieces, often
through Thick sections after only a few
stress cycles.
¾The stress may be caused by heat
treatment, sudden temperature change
((i.e) turning Cooling water onto a hot die )
or by a severe temperature gradient
Heat checking (Thermal Fatigue)
¾ Dies Undergo alternate heating and
cooling during the manufacturing process.
¾ The alternate expansion and contraction
of the die surface promotes conditions
which favour fatigue at or just below the
surface.
¾ Cracks are initiated and grow slowly with
stress reversal
 Mechanical Damage
(Wear or Erosion )

¾This may be gradual wear by the abrasion

of molten metal or may be caused by
casting ejection and moving die parts
 Soldering
¾This is a diffusion effect where the molten
aluminum or zinc forms a metallurgical
bond with the tool steel.
¾Once there is direct metal to metal contact
between the tool and the molten alloy,
welding will occur.
¾ High temperatures and high pressures will
encourage the effect.
 How to Prolong Die Life.
STEEL Selection for Dies

¾Premium grade H13 steel is

most commonly used die Steel
for die casting dies.
 Design Factors

¾The design of a die casting die is

determined by the shape of the finished
component
 i.Not Enough Steel
¾ Die casting dies have cracked , sometimes
catastrophically, after very short runs
because not enough steel was used.
¾ When the die is in machine it is subjected
to many stresses , the principle one being
locking pressure, injection pressure and
thermal stresses.
¾ The steel will flex during this cycle and the
amount of flexing depends upon the
thickness of the die. The thinner the die,
the greater the flex.
ii. Avoid sharp corners.

Sharp corners and machine marks are

stress raisers.

iii. Avoid Sharp lettering

The letters and numbers should be

designed to provide the largest possible
radius. If not, the die is tend to crack
through the bottom of the sharp crevice.
 Cooling lines

¾ The cause of the gross cracking may

sometimes be found in the construction
of the cooling lines.
¾ The cooling lines must be smooth and
free from machining marks.
¾ Sharp machining marks are stress
raisers.
Improper seating of Insert causes
cracking
¾ Another frequent cause of early cracking in
corners and sharp radii is the improper seating
of a die insert into its holder or the improper use
of shims.
¾ There must be 100% contact between the
bottom surface of the die insert and the housings
or unequal pressures will be exerted.
¾ Only the edges of die inserts are touching,
resulting in an uneven application of force and
excessive deflection, which causes cracking.
Improper Seating
Do Not Use shims
 Shrink fitting may cause cracking
¾ Occasionally die inserts are shrink fitted
into a pocket.
¾ This practice often causes very great
stress in the insert and housing.
¾ These stresses plus the stress occurring
during the casting process will cause
cracks in the corners or radii of the die
and / or holder.
¾ Shrink fitting is not a recommended
practice.
 Heat Treatment for Optimal
Performance
¾H13 is one of the toughest of the tool
steels used.
¾To achieve maximum properties, it has to
be heat treated correctly.
¾Since the die cannot be tested for strength
and toughness, after manufacture, all care
shouid be taken to adopt the correct heat
treatment procedure.
 Pre-Heating Dies.
Pre-heating of die
¾ Reduces the production time before
castings are produced with good surface

¾ Reduces the difference in temperature

between the die steel and the inflowing
metal
 Stress relieving of Dies in Service
¾By stress relieving, the crack rate will be
reduced.

¾ In order to stress relieve a polished die

surface, a temperature of 50°C below the
final tempering temperature used in the
initial heat treatment is recommended.
 Restricting EDM Damage
¾ Finish the EDM operation by fine
machining (i.e low amperage, high
frequency)

¾ Remove the resolidified layer by

polishing.

¾ Retemper the die around 10°C below

previous temperature
 Preventing Soldering
¾ Soldering is caused by the chemical
interaction of the casting alloys and the
die material during filling and
solidification,

¾ To prevent this soldering.

¾ Keep the alloy within specification, particularly
the iron content.
¾ Keep average gate velocity below 48 m/sec.
¾ Control metal and die temperature.
 Preventing Erosion
¾During die casting, the molten metal is
injected into the die, and under certain
conditions, it leads to a reaction between
the molten metal and the die steel, which
can cause erosion of the steel.

¾Actually, the phenomenon can be

regarded as a combination of erosion and
corrosion.
Salient features of Critical Dies
SLEEVE EJECTION
UNDER CUT CASTING - 4 CAVITY
¾An interesting design with angular
ejection.
¾Such dies have the advantage to cast
small parts with undercuts or threads.
¾The impression is made in a tapered
insert, that is fitted into a tapered cavity in
the moving plate.
¾The insert is split ,in order to part whilst it
is pushed forward to eject the casting.
¾An additional advantage of this method is,
that the outside of the component does not
require to be tapered.
RACK AND PINION ARRANGEMENT
¾ Untercuts on castings can demand movable
core to be withdrawn in angles towards the
movable die plate.
¾ Before the casting will be ejected, the ejector
cylinder of the machine is pushing with rod D the
plate A.
¾ At this time the rack C, which is fixed with the
plate A is rotating the pinion G and consequently
retracts the core H.
¾ At the time the plate A has Completed the stroke
Q, the Core has cleared the undercut, and the
casting can be ejected.
¾ The pins E and F Ensure that the core and the
ejector pins will return to their starting position.
Thanks