With our in-house tooling shop, which can help customer offer complete solution from tooling design, manufacturing, modify, maintenance to tooling end management.
Die Casting Tooling is crucial to the success of die casting production. Generally talking and reviewing with our customers to assess the feasibility of part design for tooling and correct if exits deficiency before the tool is built. Then modifying mold features on the front end will not only help to improve the final part but also enhance the quality of mold. During this design phase, we can evaluate in advance where the tool can put removable inserts that can save time and decrease maintenance for our customer.
|1||High Precision CNC Machine||4||Max 1210*1050*810/Min. 600*450*430|
|2||High Speed CNC Machine||9||Max 1800*800*750/Min. 850*520*520|
|3||CNC Machine||6||Max 1500*800*700/Min. 800*550*580|
|4||DMU monoBLOCK 5-AXIS CNC Machine||2||Max 935*850*650/Min 735*650*560|
|5||EDM Machine||5||Max1800*900*1000/Min 450*350*220|
When someone asks me “what is draft angle?” or “why do I need a draft angle on my aluminum die casting part?” The technical answer is, all aluminum die castings require a draft angle on the walls of die cast parts perpendicular to the parting plane or parallel to the slide interfaces. Since I have selling die cast parts for over 10 years, I find simple answers and provide simple calculations for my customers. What does that mean to the typical engineer (any engineer other than tooling or mechanical) or professional buyer? I try to give examples that most people can relate to, because most people do not have a need to concern themselves with how things are made, only what is made, and will it be what they need. I ask, “Have you ever noticed on a cupcake the bottom diameter is smaller that the top diameter?” or “Have you noticed that a cake pan has sides that slope in toward the middle of the pan?” That would be an extreme example of a draft angle. Aluminum die castings would stick inside the die casting tool, molds, or die casting die if there was not enough draft angle in the tool and part. The typical draft angle for an aluminum die casting part is two degrees per side. The calculation for that is simple if a person is familiar with die casting production part design, but is not familiar to most people.
Tooling: Dies and Molds for Die Casting
Die cast tooling called insert die, die casting dies, or die casting molds, comes in one part each cycle. Sunrise Metal only uses cold chamber die casting machine tooling styles, sizes, and values. Die cast tooling comes in single cavities (one part each cycle) or multiple cavities (more than es or molds for aluminum die cast parts).
Die cast tooling comes in various forms:
1) Die Cast Tooling Inserts
2) Prototype Die Cast Tooling Inserts
3) Unit Die Tooling
4) Complete Class “A” Die Cast Die or Mold Tooling
5) Die Cast Family Mold Tooling
6) Trim Dies for Die Cast Parts
Our In-House Die Cast Tooling Capabiities include:
a. Die casting dies.
b. Die casting molds.
c. Die casting inserts.
d. Die cast tooling modifications.
e. Die cast tooling repairs.
f. Diecast tooling and trim die manufacture.
If you got any questions, please do not hesitate to send us a message. We reply within 24 hours.
DIE CASTING MOLD
Die Casting Mold is the most essential and unique hardware parts used by a Die-Casting machine.
It helps to shape a product in a Die-Casting process. It consists of two hardened tools, steel dies, which, if combined, forms a cavity.
The dies of the Die-Casting Mold can be more than two because it depends upon the complexity of the final die-casting product design.
WHAT DOES DIE CASTING MOLD MEAN?
Industrial die-casting molds are very diverse. The variety of these die casting molds depends upon the vast range of die casting products.With all the differences that exist in the die-cast molding. In general, it can be summarized in four different ways, and which are the following:
However, the most essential & reliable type of industrial molds is found in individual casting molds.
Die casting depending on type/design of Mold. the material used in die-casting, and what characteristics that piece of metal has.
To fulfill the exact requirements, different casting methods have been used.
Mostly, these methods are characterized by the final required product, its use, and the customer’s actual requirements.
WHAT ARE THE ADVANTAGE OF DIE CASTING MOLDS IN PRODUCING COMPONENTS?
The use of die-casting molds has many advantages in producing components. Including:
And in advance to die-casting molds, there is no need left for processes like crushing, grinding, and drilling.
WHAT ARE THE DESIGN BENEFITS OF DIE CASTING MOLDS?
Die Casting Molds to ease us in manufacture/production of the die-casted products in the following ways:
WHAT ARE THE HIGHLIGHTS THAT MAKE A SERIOUS DIE CASTING MOLD?
Aluminum Die Casting is the most prudent and productive innovation, and die casting molds can likewise spare us half of the expense of the crude material.Here are a few highlights that make a serious die casting mold:
WHAT IS THE LIFE EXPECTANCY OF THE DIE CASTING MOLD?
On the off chance that you conclude that the aluminum die casting is the correct choice for your creative needs.At that point, you ought to need to comprehend the life expectancy and upkeep that aluminum die-casting molds require.
Its life is difficult to pinpoint since it’s gradually reliant on a lion’s share of elements.
A portion of the basic variables from them are:
According to the standers our industry follows, the lifespan of the aluminum die-casting molds is between 100,000 to 300,000 shorts.The lifespan of the zinc die-casting molds is between 200,000 to 350,000 shorts.The lifespan of the magnesium die-casting molds is between 300,000 to 700,000 shorts.
WHAT IS THE DIE CASTING MOLDS STRUCTURE?
We are seeing a massive number of molds being developed every day.And more products, especially aluminum products, are made using molds by industrial die casting, which specially use most advanced molds.The primary and general structure of die casting molds consists of two separate parts.
That is moving Mold is responsible for separating the part to remove the final product at the end of the die casting process.
An overview of the basic process is described below:
WHAT ARE THE ADVANTAGES OF UTILIZING DIE-CASTING MOLDS?
We are going to mention some of the most numerous and industrial/customer beneficial advantages of Die-Casting Molds,the following are the advantages the industries and customers can have from die-casting mold usage:
WHAT IS THE HISTORY OF THE DIE CASTING MOLDS?
The use of die-casting molds started in the mid-19th century when the US unveiled the process of making die-casting molds.The initial version of the Mold was designed by experts to press non-ferrous molten metal alloys.
However, which was way much harder than the metal to produce the piece.It was first to make the aluminum products/parts. With two pieces of the mold surface, they cut between the molds when the Mold was cooled and afterward, extract a bit.
Due to problems like hard opening, locking of the die, stamping, die removal after a few products, etc., many modifications were made and became the today die-casting Mold.
Now, die-casting is mainly used to make parts. Die casting molds are mostly used to make parts that have a thickness of 1.5 to 15 mm, and high-pressure melt die-casting machines must mold all.
Today, the majority of die casting molds are being manufactured by using stainless steel of varying volumes and thicknesses.
WHAT ARE THE THREE TYPES OF CASTING FOR MOLDING?
Die Casting Molds – or – High-Pressure Molds
Gravity Die Casting Molds – or – Low-Pressure Molds
Sand Molds that are known as Sand Molds too
Among them all, Die Casting is well-known and is widely used in the industry.
The Die Casting Molds usage is increasing day-by-day and producing various industrial parts.
WHAT IS THE DIFFERENCE BETWEEN DIE-CASTING MOLDS AND CASTING MOLDS?
Casting Mold is a general term/mechanism.On the other hand, Die Casting Mold is a type of it that is also known as permanent metal mold and mostly used in Pressure Casting Machines.The ultra-unique and accurate production of Die Casting Mold are through High-Pressure Die Casting.
HOW IS DIE CASTING MOLD PROCESSING THROUGH THE DIE CASTING MACHINE?
The Die-Casting Mold operates within the die-casting machine and injected into the die.That means a hole for the die and through channels/structure, high-pressure molten metal, into the die.
The Die Casting Molds comprise of two essential parts.These two parts can be easily separated from the Mold when the melt has been cooling down and shaped into a mold.
WHAT ARE THE QUALITIES OF THE DIE CASTING MOLDS?
The type of part going to be produced by these molds determines the characteristics of die casting molds.However, some of the important characteristics of the die casting molds are the following:
HOW DO YOU MAKE A DIE CASTING MOLD WORKS?
The Die Casting Molds are mostly used in the manufacturing process. however, these molds also can be used for the accurately dimensional and textured surface part production.
Forcing the molten aluminum at a high-pressure into the mold dies is a way to accomplish it.
There are some subsequent procedures in die-casting molds manufacturing which are used by the die-casting mold process:
WHAT UNIQUE VALUES DO DIE CASTING MOLDS HOLD?
The quality of the die-casting Mold designs is determined by the properties of die-casting, economic efficiency, and values the die casting mold holds.The following are the unique values that the die casting mold must focus:
WHAT FACTORS AFFECT THE QUALITY OF THE DESIGN OF THE DIE CASTING MOLDS?
When it comes to the development of the high-quality die casting mold, many influences contribute to the success of the process by including the following:
WHAT ARE THE DEVELOPMENT ADVANTAGES OF DIE CASTING MOLDS?
The picked alloy, (for example, aluminum alloy) for die-casting molds relies upon a financial plan, weight, and aluminum properties.Many die castings molds products development advantages are the following:
WHAT IS MEAN BY THE DIE CASTING MOLD RELEASE AGENT?
Incorporation for the die casting release agents during the process became vital to ensure the ejection of the part from the die are free of any defects.
Enterprises utilize most vigorous and top-notch release agents and their precise application to accomplish a top of the line uniform item nature of die casting.Following are some types of die casting mold release agents:
HOW MANY TYPES OF DIE CASTING MOLD RELEASE AGENTS ARE USED BY INDUSTRIES?
In general, industries offer two types of die casting mold release agents:
These release agents are the best option for standard die casting as they provide a release agent as well as a medium helps in cooling down the mold.
These release agents are additionally an extraordinary alternative if your need is to paint or plate a segment.
They help to give the necessary release agents as well as add to an expanded die casting surface temperature.
However, these release agents do not offer the same level/compatibility of cooling as compared to water-based.
WHAT ARE THE FEATURES OF THE DIE CASTING RELEASE AGENTS?
The primary concern with the die casting process is the porosity of die casting mold release.But our industry helps reducing the porosity on a vast majority of levels, start from the beginning of product design.Furthermore, our experts design proper venting in order to minimize the porosity.
Here are some essential benefits of high-pressure die casting mold release agent:
Benefits of low-pressure die casting mold release agents:
Benefits of die casting mold release agent for forging:
WHAT ARE THE DIE CASTING MOLD RELEASE AGENT BENEFITS FOR THE CUSTOMERS?
Die-casting mold release agents are considered as only planned such that gives the clients with the accompanying advantages:
WHAT ARE THE INDUSTRIAL ADVANTAGES OF USING DIE CASTING MOLD RELEASE AGENTS?
Some essential industrial advantages of using Die Casting Mold Release Agents are the following:
Our industry also ensures:
HOW DO DFM AND REFINING WORK FOR DIE-CASTING MOLDS?
Draft: It’s a certain angle of tooling core to be quickly released from die-casting Molds during the process of die-casting aluminum.It helps providing a draft-sample for die-casting molds die proper ejection,if we don’t do this, there are going to be occur potential die-casting molds manufacturing risks.
Fillet: It’s around the juncture of two surfaces that met at a sharp corner/edge.When the die-casting parts are designed, the designer must put fillets on the pieces to remove undesired edges/corners.
Nonetheless, likewise for stress fixation thought.
Pillar: It’s intended to help some deadlocks surface.For the most extreme quality of the die casting mold, the thickness of the pillar must be equivalent to the all-inclusive wall thickness.Figure 22.2 & Figure 22.3 (Graphical representation of the universal wall thickness for Die Casting Molds)
Otherwise, there are high chances of it being cracked.
Rib: It’s designed to strengthen the walls and surface of the die-casting mold so the output-part will be strong enough to handle any type of situation.We generally like to our customers to make the thickness ribs between half to 80% of all-inclusive wall thickness.It assists with lessening shrinkage of the parts during the aluminum die casting process.
Holes and Windows: By adding proper draft on the holes/windows feature during die-casting manufacturing.
However, these features will help to grip the die steel during solidification.
WHAT ARE THE WAYS TO ENSURE THE QUALITY OF DIE-CASTING MOLDS DESIGN?
Our industry has a rich involvement with die casting mold design.We consider every detail about die-casting mold so that there will be no mass-production problem.The following fine design checklist will be our industries preferred.
WHAT IS THE DIE CASTING MOLD FLOW SIMULATION?
The die casting mold flow-simulation can accurately and correctly predict a cast component’s quality before the product development phase.This flow simulation result is a reduction in the sampling of pre-production costs.Furthermore, as optimized and refined flow-simulation leads to time/energy, material, and die-casting mold cost saving.Our engineering team utilizes die-casting mold flow simulation software to analyze the die casting feasibility.Be that as it may, it additionally predicates any potential and high-chance deformity; even the die casting mold isn’t commenced.
This activity (flow simulation) is helpful and valuable in anticipating where the shrink is, twisting area, and other inconspicuous dangers.In light of this flow simulation information, our specialists can see the air/gas ensnarement, problem areas, and other potential tops of the line design dangers.after the die casting design is improved, our specialists use the simulation software for existing instruments attached to die casting machine parameters.
Additionally, to see the aluminum/metal move through the gating, running framework, and die casting mold cavity.
They are making subtle input changes into the die-casting molds flow-simulation software.That also help providing a rapid feedback need-to-make changes into the process, to the dies, or equipment.Through this, problem-solving time is reduced, and more importantly, the results are immediate.
Furthermore, it helps our industry to reduce defects and scrap rates proactively.
WHAT ARE THE SIX STEPS OF DESIGNING AND MAKING DIE-CASTING MOLDS?
When the die casting mold design is done in the wake of concluding.It needs to out-source die-casting mold base, steel (For cavity, core, lifter, or slider), ejection pins, and other die casting mold embellishments.
We are getting the die casting mold embellishments effectively and rapidly.It is vital to achieving a high-end quality product and our industry located in China.This is a benefit because of its most mature supply chain in China and helps us get our products on time.
With the assistance of the CNC machining process, it needs to expel 95% of additional material from die casting mold core.
It also removes the same amount of extra material from a cavity, or sliders (usually keep between 0.3 to 0.5 mm for precision manufacturing for EDM process).
Die-casting mold tool have a need to withstand high-level temperature during die-casting process.
Total-steel of the die-casting mold (for cavity, core, and slider) have a need to be hardened by HRC between 48 to 54 degrees depends on die casting mold life.
At last, the opportunity has arrived to get the tempered exactness creation like EDM, milling, CNC machining, wire-cutting, and the remaining.
However, total amount of dimensions/features need to be machined accurately on a sufficient shrinkage-rate.It’s also considered as the primary manufacturing process for a die casting mold making.
If every die casting mold part has been made, our industry needs to get the surface of die casting parts polished.Our experts prefer this because to obtain a high-end and a perfect part surface.
It takes a ton of work to complete this process accurately.
This would be the last advance to get the entirety of the mold parts fitted together precisely.Furthermore, check out if everything assembled correctly, utterly, and adequately.
Our industry can make accurate die casting mold parts, and it’s easier to get the die casting mold assembled and working.
HOW DOES DIE CASTING MOLDS ARE REPAIRED AND MAINTENANCE?
Basically, to confirm the life-long die casting mold quality, our industry tests the die casting mold life range.If it’s between 100,000 to 300,000 shorts for aluminum die casting Mold, then it’s perfect, and we use it.
In case if there is any die casting mold problem, our industry provides technical support or replacement service.
However, for production mold, life-long repair, maintenance, and renewal are the alternative options.
We take care of our tools and die casting molds so our clients will never have a problem when they order aluminum die casting products.
WHAT PARTS DOES DIE CASTING MOLD IS CONSISTING OF?
The structure of the die casting mold’s die can be divided into the following parts according to the functionality they provide:
Die Casting Molding parts
Movable fixed die casting mold core
Die casting molding inserts
Die Casting Mold base parts
Movable fixed die casting mold clamping plate AB plate
Supporting plate Die casting mold leg
Gate sleeve Diverter cone Horizontal runner Inlet Outlet
Overflow Tank Exhaust Tank
Die casting mold ejector Fixing plate
Ejector plate Reset lever
Die Casting Mold Guide Parts
Guide Post Middle Guide Post
Guide Bush Middle Guide Bush
Core-pulling slider Oblique Guidepost
Detent block Spring
Cooling System Heating System Reinforced Column
WHAT MATERIALS ARE USED FOR THE DIE-CASTING MOLDS?
Die Casting Molds are made of the following type of steel:
H13 Heat-Resistant Steel: For the front and rear die casting mold cores, die casting core pulling cores, gate sleeves, shunt cones.
45 # Steel: For AB Plates, slider, inclined guidepost.
T8, T10: Guidepost, guide sleeve, thimble, reset lever.
A3 Steel: Front and rear die casting mold clamps, pallets, ejector plates, mold feet.
WHAT IS THE HEAT TREATMENT HARDNESS OF THE DIE CASTING MOLD CORE,AND WHAT ARE ITS CONSEQUENCES OF BEING TOO SOFT AND TOO HARD?
The maximum hardness of the core heat treatment should be HRC between 45 to 48.If the treatment is too soft (less than HRC43), then the die casting mold core can be readily crushed.They are also can be deformed, and sticky during the production for the die casting mold.
And if the treatment is too hard (higher than HRC50), then the die casting mold core can be easily cracked, and some parts have hardness after nitriding reaches HRC 58 – 60.
WHAT ARE THE FACTORS FOR CHOOSING DIE CASTING MOLDS FOR AN ALUMINUM DIE CASTING MACHINE?
The following are the crucial factors for choosing to die-casting molds for a die casting machine:
WHAT IS THE FUTURE OF THE DIE-CASTNG MOLDS IN DEVELOPMENT?
Die Casting Molds are sold to the users in the hands of the service.
Die Casting Molds must flow into the hands of downstream users.
Also, it must be marketable with the advancement of industrialization to speculate on the development of the industry.The following are six aspects that will be the directions of the development of the die casting mold in the future.
An intelligent Die Casting Mold that serves to emerge strategic industries as a kind of energy-saving.Furthermore, environmentally friendly die-casting Mold that serves the energy conservation and environment protection industries.
Ultra-precision die-casting Mold with sensing functions as service of the new generation information technology (IT) die casting industries.
An ultra-precision die casting mold for medical equipment serving the biological industries.
An original die casting mold for the service of high-end equipment manufacturing industries.
Die-casting molds for the new energy industries.These die casting molds mainly include new blade molds, spindle molds, and motor molds for megawatt wind turbines.
Die Casting Mold for new energy automobile industries.
The die casting mold industries should adjust their production scale and product structure promptly.
Also, keep pace with the production times, and better grasp the future development trend to adapt to the die casting products market demand in the new era.
IS DIE CASTING MOLD IS DIRECTLY RELATED TO PRODUCT QUALITY?
Yes, because to get a high-quality die casting part, it’s imperative to control the surface temperature of the die-casting mold.
Bumpy temperatures of die-casting molds can lead to an unsteady die-casting dimension.
Also cause die-casting deformation within the production phase.
Furthermore, resulting defects in die-casting molds. These defects can be heat-pressure/sticking, surface-depression, cavity shrinkage, and thermal gas/medium bubbles.
When the difference in die-casting mold temperature is massive.
It’ll have different effects on the die casting production-cycle variations, such as filling-time/cooling-time or spraying-time.
WHAT IS THE IMPORTANCE OF SURFACE TEMPERATURE CONTROL OF DIE-CASTING MOLDS?
The surface temperature control of the die casting mold is crucial for the production of supreme and high-quality die casting parts.Uneven/inappropriate die casting mold temperatures can lead to unstable die casting parts dimensions.
There is a high chance of traces when stacked on low-temperature of the front/end melt and can results severely.Out industry uses the improved methods to maintain the surface temperature of the die casting Mold because it’s the most critical part of the whole die casting process.
Check if the wall-thickness is too thin, and the more delicate-area filled accurately and directly.
shape should be filled naturally and need to be checked calculate the distance, the closed area, blocked area, rounded corners are too small to fill, and also pay attention to identify whether ribs or cold sports lies or not.
WHAT DEFECTS DIE CASTING MOLDS HAVE TO FACE AND HOW TO PREVENT THEM?
In the die casting mold item process, the die casting mold is more than once exposed to warm.The die-cast molding surface, and its internal deformation cause micro-cracks to occur.
Be that as it may, the die casting mold must be adequately preheated toward the start of the die casting process.The die casting mold additionally should be kept up inside a specific working temperature extend during the die casting process to dodge the beginning period break disappointment.
Under the activity of die casting infusion power, the die casting mold will split at the most vulnerable point.Mostly the scribing marks on the die-cast molding surface are without polishing, or the fine-cracks will start to appear first at the clear corners of the die-cast molding.
Afterward, when the grain boundary has a brittle phase, it can be easily broken.The break engenders quickly during the weak crack, which is a dangerous factor to the disappointment of the die casting mold.
For this reality, scratches, electric machining marks, and so on, on the die casting mold surface must be polished well.However, it is in the pouring system; furthermore, the die casting mold material used is required to have a high-level strength.
Also, excellent and exceptional plasticity, impact toughness, and fracture toughness.
WHAT IS THE MOST SIGNIFICANT FACTOR OF DIE CASTING MOLDS?
Mold temperature is considered the most significant factor that affects the Die Casting Molds.When it comes to the aluminum die-casting process, temperature proved a critical factor for it.
Die-casting temperatures and die-casting mold temperatures, these both have a crucial effect on the final die-casted product.
Die Casting Temperature:
As the die casting temperature expands, the solvency of hydrogen gas (could be some other) in the aluminum composite increments.
This makes it very difficult to precipitate during the process of die-casting aluminum, affect aluminum mechanical properties, and also affect the die-casting Mold.
Aluminum compounds increment oxidation with expanding temperature. Oxidized considerations will in general fall apart the properties of the aluminum-alloys.
Besides, the iron substance of the metal/aluminum increments as the temperature increments.
This leads to a decreased & unique amount of fluidity and deteriorates that effects the performance of aluminum products.
Die Casting Mold Temperature:
The die casting mold temperature has an exceptional level of influence on the lifeline of the die-casting mold.
Intense temperature of die-casting molds can cause new cracks.When die-casting mold temperature is too low, the shrinkage stress caused by the aluminum alloy increases, and the casting is prone to cracks.
At the point when the die casting mold temperature is excessively high, it’s beneficial to get a smooth surface of the casting, but at the same time, it’s inclined to shrinkage misery.
WHAT DOES IT MEAN BY DIE CASTING MOLD BASE?
It represents the functional units of the mold’s die. Its primary task is to fix the cavity of the mold in case of any defect.
During the production process of die-casting, the die-casting base handles the absorbed forces by that process and ensures the integration of aluminum die-casted components.
The die-casting mold base is manufactured/made through the machining by large steel blocks. This way, we can achieve an exceptional amount of stiffness and strength.
The Die-Casting Mold Base is commonly all around dimensioned.
WHAT ARE THE WAYS TO EXTEND THE LIFESPAN OF DIE CASTING MOLDS?
The best ways to extend the lifespan of Aluminum Die-Casting Molds are following:
By applying these two techniques, the heat checking will slow down immensely, ultimately extending the lifespan of the tooling.
Furthermore, you’ll have to factor in the extra costs of these coating and decide whether it’s productive and beneficial, extending the lifespan of the Aluminum Die-Casting Molds or not.
When it comes to the heat treatment of the die casting mold, there are several critically important aspects to consider.
Including the heat treatment furnace used, the number of tempering applied to the die blocks, and the productive-rate used during the heat treatment process.
WHAT ARE THE TOP PRODUCTS MADE THROUGH THE DIE-CASTING MOLDS?
The top products made through Aluminum Die-Casting Molds are divided into four sections:
Automotive Parts: Engine, Body & Chassis Components, Safety Parts
Marine & Ship Parts: Maritime Satellite Communication, GPS Positioning System, Hunting Underwater System
Telecommunication: Radar & Frequency Control System, Antenna, Transmitter
Instrumentations & General Industry Parts: Ultrasonic Scanner, Flow Control System, Textile Industry, Some Applicants & IT