Die casting is a metal casting process in which molten metal is pressed with great pressure into a mould cavity. A mould cavity is made using two toughened steel dies. These dies would've been machined into shape, and work similar to an injection mould. Most of the die castings are made from non-ferrous metals such as copper, zinc, aluminum, magnesium, pewter, tin, and lead-based alloys. A cold or hot chamber machine will be used varying on the type of metal that is being cast.
There is a myriad of geometric characteristics to think about when making a tangential model of a die casting. These geometric characteristics include the draft, fillet, parting line. bosses, ribs, and holes or windows.
A draft depends on how much of taper or slope is distributed to cores and any parts of the die cavity. This allows for a smooth ejection of the casting from the die. If the die cast surface is lined up with the opening direction, then this means that they require draft. The draft is put in place to ensure the right ejection of the casting from the die. A fillet is a slightly curved turning point of two different surfaces. This is because the two surfaces would have intersected at a very sharp edge or corner, fillets are added to die castings to remove corners and edges that they do not desire.
A parting line is the point at which two sides of a mold meet. Depending on the area of the parting line determines the side of the die that will be the cover, and which is the ejector. Bosses are an addition to die castings. Their purpose is to act as a mounting point and stand-off for different that will have to be mounted. It is necessary for bosses to have the same wall thickness for the best integrity of the die casting. Ribs are also an addition to die castings. Their purpose is to provide extra support for the designs that will need maximum strength.
When adding windows and holes to your die casting you should take some serious consideration of these characteristics. This is because they will hold on to the die steel in its process of solidification. Holes and window features are added to cancel out this affect.
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