Die Casting Mold Parts

Inox Cast Die Casting Mold Parts

Inox Cast is a certified manufacturer and supplier of die casting mold parts. We have full capabilities in providing customers with a wide range of die casting mold parts designs. Inox Cast guarantees you that we can provide you the highest quality parts for your needs.

As a professional manufacturer, we make sure that we are equipped with advanced manufacturing technology. Thus, you can assure that we can provide you different designs of die casting mold parts for your requirements.

All our die casting mold parts are widely used in different industries and applications. These are very useful in automotive, medical, machinery, aerospace, plumbing, electrical, and more. Inox Cast offers you an outstanding solution for your application.

We are also customizing die casting mold parts based on your specifications. We manufacture different types of die casting mold parts with different sizes, dimensions, shapes, and styles based on your specifications.

We can also personalize your orders with your logo to promote your brand. Just send us your details so we can give you a free quote.

Inox Cast also manufacture die casting mold parts using premium quality raw materials. It also has various surface treatments like polishing, surface finish, etc. to ensure high-quality. All products are manufactured with superior quality at an affordable price.

We have more than 20 years of experience in the industry. Thus, you can assure that we can provide solution based on your needs. Our R&D team is expert in prototype designing, development, and production of die casting mold parts.

If you need help in finding the right die casting mold parts for your business, Inox Cast is ready to help you. We offer 24/7 assistance and immediate response to your inquiry. Make Inox Cast as your supplier and manufacturer!

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Die Casting Mold Parts: The Ultimate FAQ Guide

I know you would like to learn more about die casting mold parts.

The best part, this guide has all information you need.

Keep reading to learn more.

What Are Die Casting Molds?

To better understand what die cast molds are, we will break down the definitions into digestible parts as below:

• Molds – These are hollowed-out blocks that are filled with either a liquid or any desired raw material.

The filled material will, in the end, assume the shape of the mould.

• Casting – It is the manufacturing process in which liquid raw material is poured in to the molds.
• Die casting – Finally, die casting is the automated process of forcing molten metal through molds.

Hopefully, you now have a basic understanding of die casting molds. We can now proceed to a more compact definition of die casting moulds.

Die casting molds typically consist of two halves mounted on a movable machine plate.

The design of these molds is such that the two halves create the hollow required for pressing the liquid melt during the casting process.

die casting mold

Importantly, the molds are made from heat-resistant high-grade steel to prevent them from melting during the casting process.

Generally, the die casting process involves application of high pressure between the two halves. For this reason, the die casting molds are equipped with latches.

Conclusively the main types of metal that you can cast include zinc, aluminum, magnesium, copper, lead, and silicon.

What Are The Main Die Casting Mold Parts?

In the previous section, we gave you a detailed explanation of die casting moulds.

Now, we will explain the various parts of die casting molds to exhaustively cover this topic.

die casting mold parts

Draft

This is perhaps an essential part of the die casting molds.

In simple terms, the draft is the amount of slope, angle or taper added on to the surface of the die casting mold making the base narrower than the opening.

Notably, molds are easily damaged if you are using a die casting mold having walls perpendicular to the surface of ejection.

Reason being, the metal formed will stick to the walls resulting to damage if excess pressure is applied.

Also, it is important to note that the drafts are located in the inner walls of the die.

This is because during die casting, the castings usually shrink towards the core.

In summary, the draft or draft angle is key to ensure that the castings come out smoothly and in one piece.

However, coming up with the draft angle is not a walk in the park and pretty much requires specialist to come up with the correct dimensions.

Fillet

In a scenario where two surfaces of the casting are likely to meet at a sharp angle, a curve is added. This curve is what we refer to as the filet.

Fillets, just like drafts, function to protect the castings from damage. The main role of the fillets is to prevent high pressure in the castings.

Simply put, fillets eliminate undesirable corners and hard edges resulting to a smooth and strong casting.

Parting Line

Parting line is where two different parts of a mold come together. Commonly, it indicates the difference between the outside and the inside parts of the die.

By looking at the location of the parting line, you can determine which part is the ejector and which is the cover.

The parting line affects both the quality and the life of the die cast by allowing the smooth flow of the metal.

Bosses

Bosses act as mounting points and standoffs for the various die casting parts. Importantly, bosses should be adequately thick to support the weight of the various components.

Engineers and designers usually add a hole at the center of the bosses to make the wall thickness uniform.

Additionally, bosses usually are narrow in nature with a well thought draft angle.

Ribs

Ribs are important in ensuring the stiffness and strength of a component. The design of ribs is usually given high consideration mostly in areas of the die casting characterized by high stress.

With advancements in technology designers and engineers are resorting to thinner and deeper ribs.

Holes and Windows

Holes and windows are essential in die casting molds as they affect the ease of ejection of the final molding.

Also, these two parts allow for the creation of sizeable drafts.

To prevent improve material flow and eliminate unwanted castings on the holes, extra features such as overflows, cross feeders and flashes are added.

Support Plate

The main role of the support plates is to support the frame of the mold and allow for mold installation.

Together with other plates, the support plates constitute the mold base.

Ejector Plate

The ejector plate drives the ejector all the ejector pins uniformly and with the same force.

The calibrated and uniform operation of the ejector plate ensures that the casting is not damaged.

Also, the ejector plate reverts the ejector pins in readiness for the next shot.

Ejector Pin

The ejector pin also constitutes the ejection part of the die casting mold. The main role of the ejector pin is to push the casting of the die half.

A die casting mold needs to have enough ejector pins to adequately distribute the force exerted by the ejector plates.

Ejector Retaining Plate

Ejector Die

The ejector die hosts the runner (the path from the shot hole to the die casting mold cavity) and the ejector pins.

Typically, the ejector die is attached to a movable platen.

Spreader

Core Insert

The core insert is held in place by the core back plate.

The core insert forms part of the ejection system, i.e., you can rotate the core inserts to eject the threaded components of the die casting mold.

Cavity Insert

Cavity inserts can be simply described as the two equal parts of the mold cavity. Replacing and bolting cavity inserts in to the two die halves is relatively easily.

Cover Die

Unlike the ejector die, the cover die is usually attached to a stationary platen in the front part of the die casting mold.

Sprue Bushing

The sprue bushing vertically connects the mold’s face to the machine’s nozzle. As such, it offers an ideal passage of the molten metal to the mold cavity.

Also, the sprue bushing controls the flow of the molten metal into the mold.

Considering their role, sprue bushings are mostly made from either copper base alloy or hardened steel.

Pockets

Pockets or metal savers are strategically placed holes or open spaces on the die. The pockets makes the die cast  lighter without tampering with the its structural integrity.

How Does Hot-Chamber And Cold-Chamber Die Casting Molds Parts Compare?

The hot-chamber and cold-chamber die casting molds mainly differ in terms of their molten metal delivery process.

Hot-chamber die casting molds usually deliver the molten metal to the die via a gooseneck where as the cold-chamber die casting mold transmits the molten metal to the die via a shot chamber.

hot chamber die casting

Simply put, the cold-chamber die casting mold is horizontally aligned while the hot-chamber die casting mold is vertically aligned.

The die casting mold parts are more or less similar in both of the casting machines. However, the parts slightly differ in operation and design.

Below, we have simplified the difference, between the two die casting molds parts, in table form.

cold chamber  die casting

How Does The Die Casting Mold Work?

Usually, the die casting mold operates in five basic steps within one cycle. One cycle is short and can last not more than two seconds.

Below is a detailed explanation of the five key steps to help you grasp the working principle of the die casting mold.

Die Preparation

Preparing the die will first require the die to be cleaned. The die is opened and then cleaning commences.

Cleaning is usually done after every injection cycle to aid in the removal of the metal.

After the cleaning, the two halves of the die are lubricated to facilitate ejection during the molding process.

However, lubrication is not mandatory after every cycle.

Importantly, the larger the part and the more the cavities, the more the lubrication time.

After cleaning and lubrication is done, the two die halves are tightly clamped together.

Tight clamping ensures the die remains intact during the injection stage. This finalizes the preparation stage.

The time for the preparation stage is dependent on the size of the die casting mold.

Injection

The injection stage commences with the transfer of the molten non-ferrous metal from the furnace into a chamber.

After the transfer, the molten metal is injected into the die under high pressure of between 1000 to 2000 psi.

The time required for the molten metal to fill all the cavities of the die is referred to as injection time, which lasts less than 0.1 seconds.

The minimal/fast injection time prevents early solidification.

Cooling

Once in the die cavity, the high pressure is retained but the liquefied metal will start to cool. It is in this stage that the formation of the final shape of the casting occurs.

The cooling time of the casting will depend on the:

Wall thickness of the metal

The metal’s thermodynamic properties

Geometrical complexity of the die

Ejection

After the cooling time elapses, the die halves are opened to eject the castings.

During ejection, adequate force should be applied by the ejection mechanism. This is because the casting shrinks and sticks to the die cavity during cooling.

Trimming

Although not compulsory, this stage ensures that the final casting comes is smooth with no undesired extension.

Typically, trimming is done using a trimming press or you can manually use a saw. You can opt to recycle the trimmed parts.

Which Types Of Lubricants Do You Use On Die Casting Mold Parts?

Initially, solvent based lubricants were the most popular lubricants applied on die casting mold parts. These lubricants were easy to apply but were characterized by carbon buildup on the cavity walls.

Gradually, the die casting industry has shifted to the use of water-based lubricants. The commonly used lubricant under this category is water-in-oil emulsions.

Water-based lubricants are not only healthy and environmentally friendly but are also safe. However, the water used should be adequately treated to prevent any potential surface defects.

What Is The Future Of Die Casting?

We live in a rapidly changing world characterized by advancements in science and technology. Improvements continue to be implemented in the field of die casting.

The current die casters have the capability of producing castings of various shapes, sizes and thickness. Nowadays, most castings are durable and strong.

Also, with today’s die casters you can easily customize the dimension of the castings.

With the increasing efficiency of die casting the most manufacturers are sure to integrate it in their production process.

How Do You Maintain Die Casting Mold Parts?

Maintenance of die casting mold should be done daily. Below are some important maintenance practices that will both improve efficiency and save on cost.

• Having professionals disassemble and clean your die casting mold will help prevent any improper unloading and loading.
• Adequately coating all the threads, screw bearing surfaces and bolts with grease when assembling the parts.
• Using special cleaning equipment such metallographic sand paper to clean the sealing surface.

Storage also forms part of the maintenance practices on die casting mold parts. Below are some main storage considerations you can make:

• Always ensure you clean and reassemble the die casting mold before storage.
• Ensure the die casting mold is store ins a dry, clean, and well-ventilated room. The storage room should be free of corrosive substances.
• Storing the die casting mold on a rack will allow for easy access and secure positioning.

What Causes Wear In Die Casting Mold Parts?

The die casting process involves rapid temperature changes, from extremely hot (during injection) to extremely low (during cooling).

These uneven temperature changes results to thermal fatigue which wears out most parts of the die casting mold.

die casting mold

Notably, thermal fatigue creates visible cracks on the surface of the mold.

In summary below are the main causes of wear in die casting mold parts:

• Dynamic load cycle – After a certain number of cycles, fatigue will be generated resulting to cracks.
• Oxidation – Oxidation propagates the cracks caused by the thermal fatigue.
• Erosion – Finally, the molten metal’s high kinetic energy damages the molten surface.

Although wearing occurs overtime, there are some instances of premature rapid wear. You can reduce the intensity of wear in two main ways:

• Increasing the hardness of the mold
• Ensuring low chemical reactivity between the molten metal and the mold.

What Is The Best Material For Making Die Casting Mold Parts?

The best material for the mold parts that are in contact with the molten metal is tool steel (X38CrMoV51). This type of steel is specifically designed for molds and has high resistance to:

• Wear
• Annealing
• Dynamic load
• Corrosion
• Thermal fatigue

How Frequently Should You Replace Die Casting Mold Parts?

How regular you should replace your die casting mold parts depends on three main factors:

Material Used To Manufacture The Die Casting Mold.

If the mold material is strong and durable, the mold parts will not require frequent replacement. In such a scenario, the mold parts will take long to wear

The Life Span Of The Die Casting Mold

Various die casting molds have different casting cycles. Typically, the lifespan of most die casting molds is between 100 000 to 120 000 casting cycles.

After the life span or the stipulated casting cycle, you will either have to repair or replace the mold parts.

Maintenance

Lubrication takes the center stage in the maintenance of die casting molds.

Regular lubrication will prevent molten metal from attaching itself to the mold’s surface.

Lubricating the molds after every cycle will reduce the number of times you will replace the mold parts.

How Does Die Casting Mold Parts Affect Quality Of The Final Die Cast Products?

The various parts of the die casting mold work harmoniously to produce the best quality of die cast products.

For instance, if the draft is not well aligned, the final die cast product might be difficult to remove. Applying too much pressure to remove the cast product might damage it.

On the whole, each part will affect the die cast product quality as discussed in the preceding section this guide.

For all your die casting needs, inox is here to help – contact us now.