DIE CASTING

DIE CASTING TRIMING DIES #1

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The trim die is a tool that trims the runner, overflows, and flash from the casting. The trim dies are single or multiple cavity tools, made in the same configuration as the die casting die.

Depending on the shape of the casting, the trim die may be a simple open-and-close trim die or it may include as many slides as the die casting tool. In some cases multiple station trim dies will be used for successive trimming operations.

Trim dies require as much attention to detail in design as the die casting tools and the use of quality materials should be specified to extend their productive life.

DIE CASTING TOOLING INHERITED #1

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In some instances a customer may transfer a die casting die from one die caster to another. This generally will raise some operational questions for the receiving die caster of which the customer should be aware.

The die may need to be put into a different type of die casting machine. This may require some modifications to the die’s ejector system as well as to the shot sleeve, i.e. the entry for molten metal.

The die’s gate and runner system may also need to be modified to suit the new machine conditions. It may be necessary for any residual oil in the hydraulic system of the die to be sent out for sampling to assure that it does not contain any contaminants.

The die must be evaluated by the customer and the die caster’s tool room superintendent to assure that there are no visual problems with the die. They should also determine whether the die arrived with any required limit switches and hydraulic cylinders.

Upon this review an adaptation cost can be established and agreed upon before the receiving die caster has invested a large amount of time and expense in preproduction work.

At the end of this section, will aid in addressing questions regarding transferred or “inherited” tooling.

Die or tooling ownership and replacement is often a point of discussion.

DIE CASTING CAVITY AND INSERT MATERIALS #1

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The grade of tooling materials to be used in the construction of a die casting die should be

specified as high quality, at a minimum, and preferable premium quality. These requirements are based on the extremely high temperatures and pressures used in die casting production.

Tooling grade requirements will vary depending on the tooling component, the alloy being die cast, the critical character of the cast part design and the long-term production quantities desired. Every aspect of the proposed product’s design and production specifications must be discussed with the die caster before tooling material can be selected. The following are typical tooling lowest requirements:

Die and Cavity Materials

The zinc alloys, which cast at the lowest temperature in the nonferrous family, cause the least wear on their tooling and thus permit the use of non-premium die material, such as P-20, in cases where part designs are relatively simple. Purchasers are cautioned, however, to be aware of the unwise investment in non-premium grade tooling for zinc parts if there is any possibility that production quantities may reach higher levels than originally anticipated. At higher production levels, such tooling may expire and the cost of replacement dies will far outweigh an original investment in premium material.

Aluminum, magnesium and ZA die casting dies require high quality tool steel, as above.

If part designs have very critical features or if high production runs are being contemplated,

however, premium grade tooling will always be the wisest investment.

For Al, Mg, ZA-12, and ZA-27 die cast parts, H13 Premium or Superior Grade tool steel

is recommended whenever part design features are intricate and specifications tight, and when

production volumes will be high. In such cases, non-premium grade tooling will nearly always

result in costly premature die failure.

Since copper alloy die castings are cast at the highest temperatures of the nonferrous alloys,

only H13 high grade tool steel is recommended for brass die casting dies.

Metal certifications for the material grades listed, provided by quality tooling material suppliers,

will be made available for inspection by the die caster. The H13 Premium or Superior Grade should meet the tool steel standard.Special Quality Die Steel and Heat Treatment

Acceptance Criteria for Die Casting Dies.

Die Cavity Insert Materials

The materials recommended for use as tool steel for die cavity inserts parallel the recommendations

for die cavities, above, with some additions.

In addition to H13 Premium or Superior Grade, the maraging and speciality tool steels* are

used for die inserts needing higher hardness to improve their resistance to the heat checking

(thermal fatigue cracking) or crazing of the insert’s surface caused by thermal cycling of the

die from the high temperature molten alloy and die spray/die cooling. The fine cracks that may

result can produce corresponding veins on castings.

In high wear (erosion/washout) and temperature areas, especially if internal cooling and/or die

spray is difficult, small cores and inserts in aluminum die casting dies can eventually break or

wash away due to the velocity of the aluminum entering the cavity. Tungsten- and molybdenum based alloys are occasionally used successfully in these areas to resist these conditions. Although these materials show superior physical properties compared to conventional steels at high working temperatures, care must be used in machining them. Also, their increased cost must be considered in the overall cost of the die and number of shots required (life of the die).

DIE CASTING TOOLING #1

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For the proper design of production tooling, pressure tightness, secondary machining and

surface finishing specifications must be understood in detail. Areas of the casting subject to

machining must be fully discussed at the outset, so that the die can be designed to reduce to an absolute minimum the presence of porosity in those areas. Cosmetic surface requirements for the casting will require specific steps in finishing the cavities of the die.

These are among the types of questions that the customer should be prepared to discuss with the die caster while reviewing the supplementary checklist at the end of this section.

The Engineering and Design sections provide detailed treatment of the tolerancing implications of various casting design features, as well as guidelines which apply under differing casting conditions.

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#1 DIE CASTING MACHINING PREPLANING

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While most die castings are produced to near-net-shape, and many to net-shape, the close tolerances possible with die casting and the repeatability of the process suits die cast parts to economical high-precision secondary machining operations.

A die casting can be designed to accurately adapt to machining fixtures by casting in locator holes or casting a flush locating datum surface. Die castings can be drilled, tapped, reamed, punched, or have nearly any type of machining operation performed on them.

Machining operations, including gaging and any other secondary operations that may be required, can be performed by the die caster. Properly designing the part and the die for optimum quality and economy in secondary machining will have an important impact on reducing final part costs. Detailed discussions should be held with die caster engineering personnel to establish such machining parameters as the precise location, extent, and depth of the machining required; the surface finish required; and any other specification necessary to result in a quality component.

Decisions on special machining equipment ownership, maintenance and replacement must also be discussed. Such matters are outlined in the Commercial Practices section of this manual.

# DIE CASTING INTRO

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The die casting die, or mold, is a closed vessel into which molten metal is injected under high pressure and temperature, then rapidly cooled until the solidified part is sufficiently rigid to permit ejection from the mold.

For longevity of operation in this environment the die casting die must be built from high-quality tool steel, heat-treated to the required hardness and structure, with dimensions of the die and cavity machined to exacting specifications. The two die halves run in a die casting machine that is operated at the required temperatures and pressures to produce a quality part to net-shape or near-net-shape customer specifications.

The customer’s product design requirements directly affect the size, type, features, and cost of the required tooling. The items involved in the tooling decision include the number of cavities, number of core or slide requirements, weight of the die, machining, finish requirements, polishing and plating to name just a few. A convenient checklist of die construction considerations, intended for use in discussion with your custom die caster, appears at the end of this section.

Explanation of the most important terms related to die design are given in the following sections of this chapter. A complete glossary of die casting terms appears at the end of this volume.

The discussion in this section provides a guide to aid the die casting specifier in understanding the requirements of the die caster that will be necessary to produce the optimum die casting, by the most economical production methods.

The various alloys available for die casting, from aluminum to zinc, require unique and special features in the die that produces them. Because of these differences, the descriptions and parameters described in this text are generic. Where possible, options are listed but should be used only as a general guide, with the final decisions discussed between the customer and the die caster.

VENTILATION AND VACUM IN GATING

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Although the die castings can be expected to show high strength and integrity, some product requirements may call for additional measures in the design section, die design and production stage on-line.Designers are trying to avoid concerns porosity would be wary of techniques such as eliminating thick wall sections in their designs.For custom designs, engineers should always consult with a die caster experienced before design parameters locked in.Given the final part design, die casters will follow certain guidelines die design, and flow simulation, combining the gating die, overflowing and ventilation configurations for correct air evacuation of the die cavity and reduces the porosity to acceptable levels. where the pressure shortness no specification casting, the process can be designed such that the residual porosity enter only non-functional, internal areas of the casting. Porosity is received in non-critical areas.While not a substitute for sound products and die design, vacuum system can also be used to improve die filling, reducing gas porosity, and improve the mechanical properties. A vacuum system designed to evacuate the ambient air from the die cavity during casting and creating a negative pressure or vacuum. die should be built specifically to receive the vacuum system, so the discussion received porosity level should be held well in advance of die design

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Tooling And Wall Thickness

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Casting may be defined as the production of a desired shape by introducing a molten material into a previously prepared cavity and allowing it to solidity. The metals most frequently cast are iron, steel, aluminum, magnesium, some copper alloys, and certain zinc alloys.

Although the craft is an one, modern casting methods frequently involve precise science and highly skilled engineering. An example is the one V8 engine block cast from aluminum or gray iron, with cylinder chambers and water jackets formed by the many intricate cores set in the mold and holding wall thicknesses within close dimensional accuracy.

Casting is the fastest method for producing complex shapes from raw materials that can be temporarily liquefied by heat or chemical means. Sand casting accounts for some 95% by weight of all metal cast. The fluid material is poured or forced into a shaped cavity called a mold or die. After it has solidified, the casting is removed from the mold. In sand casting the mold is destroyed after one use, but molds for many materials are reuable.

The materials to be cast, the volume of production, and the requirements of the functional design all affect the selection of the mold material an design, and largely determine the other tooling required. For nonmetallic castings, the moet.lds are usually made from gray iron or steel, cast, machined from blocks, or formed from sheet.

Good casting design dictates the use of as uniform a wall thickness as possible, or one that tapers slightly from the thinnest section remote from the gate to the heaviest section at gate. In addition, alloy fluidity dictates the minimum practial wall thickness for each die castable metal.

Minimum Wall Thickness For Die Casting

Surface are in2 : Up to 3.9

Tin, Lead, Zinc : 0.0236-0.0394

Aluminum, Magnesium : 0.0315-0.0471

Copper : 0.0589-0.0787

Surface area in2 : 4.0-15.5

Tin, Lead, Zinc : 0.0395-0.0589

Aluminum, Magnesium : 0.0472-0.0707

Copper : 0.0788-0.0982

Surface area in2 : 15.6-77.5

Tin, Lead, Zinc : 0.0590-0.0787

Aluminum, Magnesium : 0.0708-0.0982

Copper : 0.0983-0.118

Surface area in2 : Over 77.6

Tin, Lead, Zinc : 0.0788-00982

Aluminum, Magnesium : 0.0983-0.118

Copper : 0.119-0.157

Formation Of Technology Basics

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Forming Technology Developments

The history of the formation of metal began in prehistoric times that estimated in the span of time between the years 4000 to 3000 BC The development of metal formation begins in the manufacture of accessories or decorations royal, shield for war purposes, household appliances and so on. Materials metallic material is generally made of bronze and brass. Process for the manufacture of equipment that is carried out is done manually by a process of heat and cold. Metal forming processes for a wide range of equipment is done by experts who have specialized skills metals. Experts metal has a hand job skills (handy craft) obtained from generation to generation. The process of formation of profile shapes is done entirely by hand using the skills. Auxiliary equipment used include various forms of hammers, foundations and models forming a simple mold. Profile shape plates produced from this formation process have high artistic value, particularly in the form of engraving that is displayed on the product. Profiles are shown to have meaning and value of art by displaying forms of, flowers, symbols, human civilization as well as profiles of animals. Some of the results of historical relics found household appliances such as forms cup / saucer, a variety of dishes. Product plates and cups have special designs and carvings that have meaning and value of art. Archaeological field survey results illustrate that household products are used for different kingdoms with products issued for ordinary people. Usually these products have specific characteristics, ranging from design and engraving or embellishment on the product. Patterns or profile shapes worked for jewelery or accessories for this kingdom has a high artistic level, it can be seen from some historical relics found in several historical museums in France and other historical towns. The development of metal forming technology is characterized by the discovery process of the formation by using the tools forming by using a pressure hydraulic system, also using the runway, punch, swage, dies as a tool to form the desired profiles. If at first the formation process is done manually on top of the foundations of forming with a hammer, then now is the process of formation is done with a variety of methods. The method used in metal forming process including the process of bending or kinking, squeezing, rolling, spinning, deed, drawing, stretching, crumping, blanking, press and so on. Each process has its own formation ability, for example for the bending process, the process is able to bend it straight and neat plates used for office equipment such as file cabinets, lockers, cabinets of data and so on. Plate rolling process is also very widely used for decision-making of pipes, tanks, pressure vessels such as boiler or boilers and others. This rolling products also can be done manually or with a motor control. Propulsion motor control is easier in the process of rolling, rolling pelatpelat particularly thick with high level of accuracy. The rapid expansion also occurs in the process of formation of the pressure or press. Press process is performed using hydraulic power using a swage or mold with a pressure rubber (rubber) forming. This process can be done in a cold state, especially for the working of the formation of thin plates. The results of this press products can form a hard profiles, with the resulting shape with no defects. Process pressure (press) is widely used for the hydraulic body formation-body car with the term now full press body. Plates sheets are experiencing this formation work as press produces plates become more stiff (rigid). Plate products produced are also experiencing rapid development, it is since the discovery of plate rolling process which produces plates that have formability, weldability and capable machine. Plate products resulting from the process of rolling this multilevel mempuyai microstructure elongated shape and flat, so that the plate is the result of rolling or bending elastic properties memunyai good to do the process of formation. Plates quality sheet has the characteristics of good formability. These properties appear if the plates undergo a process of formation of the side plate experiencing stretching does not cause cracks. These cracks can cause damage or tearing of the plate components are formed. Characteristic properties of weldability can also be shown if the plate undergoing a process of welding the cracks or crack does not occur in the transition area. The transition area is an area that is susceptible to damage because this area is an area that experienced a change of heat and cold. The term welding technology is the Heat Affect Zone (HAZ), which in this area microstructure formed erratic changes. Due to changes in the microstructure of this, then there is a change of the mechanical properties of the plate material. Changes in mechanical properties, especially on the nature of violence and tension luluhnya. Plate material products produced not only for the purposes of its creation only diproduk but plate products are used for special purposes can also be generated. Plate products for special purposes is usually for military purposes are also used for banking keperluaan. Plate products for military purposes can be seen from the manufacture of steel tanks used for war purposes. Tank Steel produced has a bullet-proof characteristics, so that the plate material used must be resistant to various kinds of gunfire. Bulletproof vests used by the security forces are also coated with a material bulletproof plate. Bulletproof plate material used to coat the front of the chest or has a very thin thickness when compared with the plates used for Tank Steel.

Basic Engineering Establishment

Metal forming technique is a process that is done by providing a change in the shape of the workpiece. These shape changes can be done by giving the external force causing plastic deformation. This metal forming applications can be seen in several examples such as rolling (rolling), bending (bending), forging (forging), extrusion (extruding), withdrawal of wire (wire drawing), the withdrawal of the (deep drawing), and others. Steps being taken in the process of formation of a construction include:

1. Design tools according to function and usefulness.

2. Analyze the construction of the loading plate

3. Make the design drawings

4. Determine the type of plate material

5. Determine methods of grafting and reinforcement

6. Determine the method of assembly

7. Creating a tool construction working drawings

8. Creating a stretch image

9. Perform initial cuts (pre-cutting)

10. Perform cutting plate material

11. Conducting the process of formation

12. Determine the tools or models

13. The method of assembly

14. Measurement of the dimensions of the construction

15. The test construction

16. Finishing

Adult formation technology is widely used for various purposes. Construction is usually distinguished by the formation of the desired dimensions.

Basic Metal Casting

The process of casting (casting) is one of the techniques of making a product where the metal melted in a crucible then poured into the mold cavity which is similar to the original shape of the cast product to be made. Casting can also be interpreted as a manufacturing process that uses liquid metal and molds to produce parts with a form that approximates the shape of the final geometry of the finished product. Casting process itself can be divided into two kinds, namely traditional casting (traditional) and non-traditional (non-traditional).

Traditional techniques consist of:

1. Sand-Mold Casting

2. Dry-Sand Casting

3. Shell-Mold Casting

4. Full-Mold Casting

5. Cement-Mold Casting

6. Vacuum-Mold Casting

While non-traditional techniques are divided into:

1. High-Pressure Die Casting

2. Permanent Mold Casting-

3. Centrifugal Casting

4. Plaster Mold Casting-

5. Investment Casting

6. Solid-Ceramic Casting

There are four factors that affect or are characteristic of the casting process, namely:

1. The flow of molten metal into the molding cavity

2. There was a heat transfer during solidification and cooling of the metal in the mold

3. Effect of printed material

4. Freezing of molten metal from the condition

Classification is based on the age of the casting mold, there are casting with disposable (expendable mold) and no permanent mold casting (permanent mold). Expendable sand molds included in the mold. Therefore can only be used one time casting alone, after which the mold is destroyed when making the casting. In mold making, the types of sand used was silica sand, zircon sand or green sand. While the adhesive between the grains of sand can be used, bentonite, resins, furan or water glass. as follows:

1. Cavity (mold cavity), is the room where the molten metal is poured into the mold. The shape of the cavity is equal to the workpiece to be casted. Cavity mold made using a pattern.

2. Core (core), its function is to create a cavity in the casting. The core is made separately with mold and assembled at the time of the mold will be used.

3. Gating system (system inlet), an inlet of the mold kerongga descending channel.

4. Sprue (channel down), an inlet from the outside to the vertical position. This channel can also be more than one, depending on the desired casting speed.

5. Pouring basin, the grooves on the mold whose main function is to reduce the speed of the liquid metal goes directly from the ladle into the sprue. High speed metal flow may occur in the sprue erosion and the transport of liquid metal impurities originating from the furnace kerongga mold.

6. Raiser (enhancer), a useful reserve of liquid metal in the mold cavity to fill back in case of shrinkage due to solidification. The metals that can be used to perform the casting process, namely: Cast iron, white cast iron, gray cast iron, cast iron maliable, nodular cast iron, cast steel and others. Metal smelting is the most important aspect in casting operations as a direct effect on the quality of the cast product. In the smelting process, first charge consisting of metal, alloying elements and other materials such as flux and slag forming elements inserted into the furnace. Flux is the inorganic compound that can "clean up" the molten metal by removing gases dissolved participate and also elements of impurity (impurities). Flux has beberpa usability depends on molten metal, such as aluminum alloys are cover fluxes (which prevents oxidation of the aluminum surface of the liquid), Cleaning fluxes, drossing fluxes, refining fluxes, and dry wall fluxes. Smelting furnaces used in the foundry industry is an electric arc furnace, induction furnace, furnace crucibles, and a cupola furnace.

Four Factors that Affect

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There are 4 factors that affect or are characteristic of the casting process, namely:

1. The flow of molten metal into the molding cavity

2. There was a heat transfer during solidification and cooling of the metal in the mold

3. Effect of printed material

4. Freezing of molten metal from the condition.

1. Cavity (mold cavity), is the room where the molten metal is poured into the mold. The shape of the cavity is equal to the workpiece to be casted. Cavity mold made using a pattern.

2. Core (core), its function is to create a cavity in the casting. The core is made separately with mold and assembled at the time of the mold will be used.

3. Gating system (system inlet), an inlet of the mold kerongga descending channel.

4. Sprue (channel down), an inlet from the outside to the vertical position. This channel can also be more than one, depending on the desired casting speed.

Basic Metal Casting

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Traditional techniques consist of:

1. Sand-Mold Casting

2. Dry-Sand Casting

3. Shell-Mold Casting

4. Full-Mold Casting

5. Cement-Mold Casting

6. Vacuum-Mold Casting

While non-traditional techniques are divided into:

1. High-Pressure Die Casting

2. Permanent Mold Casting-

3. Centrifugal Casting

4. Plaster Mold Casting-

5. Investment Casting

6. Solid-Ceramic Casting

IMPORTANT POINTS to DIE CASTING

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Die casting mould integrates such know how and technology as casting, mould cooling, and further, cast finishing methods.

Die cast products are used in various field, including areas related to automotive engines, house ware, toys, life style tools. In the future, die cast products will need to be ever more precise, durable, and economical with shorter delivery times. The key to these improvements is mould design, including casting methods, and casting technology.

Design of Die Casting

It has been well established that in a simple die casting die the injected stream travels across the cavity and impinges on opposite wall. It then spreads out along the cavity wall and finally backfills the entire cavity. In complex dies or those with cores, the flowing mass is more turbulent. This concept of cavity filling is basic to the proper design of these dies.

Gate Location and Size

For a given casting there are many workable gating designs, each more or less approaching the prevailing conditions. In general, a gate is usually placed on an edge from which it can be cleanly sheared, or where its trimming will not impair the casting surface. But gate location also affects the character of the metal flow, hence porosity and surface finish.

One authority advocates a gate at the smallest cross section of the die cavity so that the surface of the casting increases with increasing distance from the gate. This technique creates a better heat balance within the die ; the hotter metal contacts the die surfaces of smaller area and transfers less heat to the die. As the metal flows farther, it cool and transfers less per unit area to the die. Thus, the total heat input to the die block is more uniform throughout the cavity.

Vents

Porosity is most likely to occur where vents are too small or so poorly located that they became blocked by the inflowing metal. To prevent this, some vents should be located as close to the gate as possible to allow air to escape from that part of the cavity which fills last.

Test have shown that venting has an important bearing on the injection speed and casting quality. They indicated that the speed of the entering jet is seldom equal to that of a free jet. When the vents were sealed, the jet velocity was reduced by 50%, and increased injection pressure will not increase filling time unless adequate is provided.

Vents should not exceed about 0.008 in. thickness if fins are to be avoid, but commercial practice uses vents up to 0.016 in. deep. Ejection pin, slides, insert clearances, and the parting line all add to the total cavity venting are. Some designers use a vent area of at least 50% of the ingate area.

Runner

Runner design and locations can be varied to meet the needs of conservation or dissipation of heat to maintain thermal equilibrium and appropriate die temperature gradients, Shapes of runner cross sections vary from round to trapezoidal to elliptical; from wide and flat to narrow and thick. If the heat transfer ate of the runner system high, high surface area to volume ratio, the metal is cooled somewhat by the time it reaches the gate. This is advantage for a casting of thick cross section but is poor practice for a thin walled casting because the metal will lose more heat traveling within the cavity, and incomplete fusion and deep striation are likely. In such case, the heat transfer between the runner and cavity can be altered by using a runner more nearly circular in cross section.

In practice most die casting runners are trapezoidal, about two times as wide as they are deep. As they approach a round or square cross section, internal porosity is more likely to appear.

Sprue Pin

In edge gate cavities, which are typical of cold chamber machines, the sprue is merely a small appendage to the main runner and has little influence on metal floe or thermal equilibrium within the die . In center gate dies for zinc, however, the sprue may have considerable influence on the thermal balance within a die block. Heat transfer from the sprue depends upon the contact area between the sprue pin and the cast metal. A slender sprue pin present a small heat absorption mass and consequently, because of friction, the sprue pin tip may reach temperatures equal to or greater than the injection temperature of molten alloy. This impedes solidifications at the gate. Therefore, it is better to use a well splayed sprue of large diameter in conjunction with a blunt conical sprue pin. Thus, an adequate cross section can be maintained with a relatively thin walled sprue. This design allow the sprue o water cooled, so a better die block temperature gradient can be maintained because a large proportion of heat dissipated from the injected metal is absorbed by the spue pin an less passes to the adjacent die cavity.

Materials

Die casting materials must be resistant to thermal shock, softening, and erosion at elevated temperatures. Of lesser importance are heat treatability, machinability, weldability, and resistance to heat checking. The performance of die materials is direcly related to the injection temperature of the molten alloy, the thermal gradients within the die, and the production cycle. Tool steels of increasing alloy content are required as the injection temperature of the molten alloy and the thermal gradients within the die increase, and the production cycle becomes shorter. Dies for use with zinc can be prehardened by the manufacturer in a range of Rc 29-34. The higher melting alloy require hot work tool steel.

hopefully the above can make inputs, and technical development of the world is more excited, thank you for your attention.

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DIE CASTING INTRODUCTION

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Generally one can say the diecasting process consists of 4 main region:

+ die casting machine
+ casting alloy

+ die

+ periperal equipment around the diecasting machine to mechanise the proses.

Considerable new developments have taken place during the past years in the regions of diecasting machine,alloys and peripheral equipment,however quality demands on the castings also dicatate increased.The ever increasing considerable effort has been spent in this area.As a proof,one may of die construction.

For the diecasting of suitable light or heavy metal alloy we have the following machine types available:

+ the horizontal cold chamber system

+ the horizontal cold chamber system for centre gating

+ vertical cold chamber system

+ the hot chamber system

THE PRESSURE DIE CASTING

A. Planing Stage

Casting Pressures for Die Casting Alloy

Standart Part :

Al+Mg to 400 bar

Zn 100-200 bar

Ms : 300-400 bar

Technical Part :

Al+ Mg 400-600 bar

Zn : 200-300 bar

Ms : 400-500 bar

Pressure Tight Part :

Al+ Mg 800-1000 bar

Zn : 250-400 bar

Mg : 800-1000 bar

Electro Plating Parts :

Zn 220-250 bar.

B. Design Stage

Fs (kn) = A (cm2) x p (bar ) /100

F (kn) = 1,1-1,25 x (Fs+F1)

F1(kn) = tangential x Fk(kN)

A= Project Area (cm2)

F1 = Slide Force (Kn)

p = Spec Casting Pressure (bar)

DIE STEELS

Working Life

Insert Piece :

Al 100.000

Zn 300.000-500.000

Ms Brass 35.000

Small Piece :

Al 50.000

Zn 150.000

Brass 18.000

Shot Sleeve :

Al 80.000

Zn 500.000

Ms Brass 70.000

Plunger :

Al 20.000

Zn 100.000

Ms Brass 20.000

Nozlee :

Zn 250.000

A. Heat Treatment

Recomendaions for the Hardening of Die Casting Dies

Die Plate :

Zink-Alloys 43-45 HRC

Al-Alloys 44-46 HRC

Al-,Mg-Alloys 44-46 HRC

Cu-Alloys 39-40 HRC

Insert :

Zink -Alloys 43-45 HRC

Al-Alloys 44-46 HRC

Al-Mg-Alloys 44-46 HRC

Cu-Alloys 39-40 HRC

Split Insert/Machining After/Heatreatment :

Zink-Alloys 41 HRC

Al-Alloys 43-45 HRC

Al-Mg-Alloys 43-45 HRC

Cu-Alloys 34-36 HRC

Round Core :

Zink-Alloys 46 HRC

Al-Alloys 46 HRC

Al-Mg-Alloys 48 HRC

Cu-Alloys 43 HRC

Cavity Core :

Zink-Alloys 43 HRC

Al-Alloys 44-46 HRC

Al,Mg-Alloys 44-46 HRC

CU-Alloys 36-37 HRC

Sprue Buhs/Speader :

Zink-Alloys 48 HRC

Al-Alloys 48 HRC

Al,Mg-Alloys 48 HRC

Cu-Alloys 39-40 HRC

Slide /Wedge Lock/Guides :

Zink-Alloys,Al-Alloys,Al-,Mg-Alloys =Case Hardening

B. Diecasting Dies Built From Standart

DIE TEMPERATURE CONTROL

A. Practical Hints

GATING TECHNIQUE FEED SYSTEMS

A. General Rules

B. Centre Gatint System For Horizontal Cold Chamber Machine

C. 3-Plate System With Stripper plate Built In Die

D. 3-Plate System With Stripper Plate Built In Machine

E. System Loss And Gating Calculations

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DIE TRIAL

A. Entry Inspection

B. Testing

DIE MAINTENANCE

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