Die casting tools / die casting molds
Die casting tools are used for the manufacture of metallic castings. In this case, more specifically, the mold cavity , the die casting mold ( cavity) , the forming member during the casting process. The mold cavity is at the core of die-cast tool. It is a negative image of the casting determines the shape and the manufacturing process. It usually consists of special materials or high-strength hot-work steels according to DIN EN ISO 4957th
A cast mold can , depending on the tool steel and the molten metal can be performed up to 1,000,000 casting operations . They thus fall into the category of permanent molds . Permanent forms are preferable to lost molds for economic reasons. Only if a casting permanent mold would not release, remedy is to be a lost form . But the technology of die casting tools has made great strides in recent decades . As a result, the production possibilities of permanent mold castings have improved tremendously. Why can now make even the most complex castings permanent mold .
Die casting tools are made in several stages and by different processing methods. A die-cast tool consists mostly of metal blocks . Delivered as a blank , they are first brought into shape by machining process . The blanks are predominantly made by milling , turning, grinding or EDM according to the specifications . After editing predefined areas follows . These areas can be improved , for example by polishing , etching or coating. In addition to the custom-made parts are die casting tools also from several standard parts. They are appointed from standard parts catalogs and arrive at the assembly of the individual components used.
The die casting process is one of the primary shaping manufacturing process. To the archetype cutting manufacturing processes include all manufacturing processes in which a formless substance a solid body is made. They usually come right after the breakdown of the raw material and are thus still far from the diverse heritage working method . In die casting, the amorphous material is a metal melt, which is , after curing, to form a solid casting.
When die-casting method, a molten metal melt is shot into the closed mold halves of the die under high pressure. In the die the molten metal hardens. After curing of the liquid metal , the die casting machine moves apart the two mold halves, the ejector push the casting from the mold.
As a rule, allows the die-casting process divided into four steps :
1. Schließen der Formhälften (Vorfüllphase)
2. Einschießen der Metallschmelze (Formfüllphase)
3. Aushärten der Metallschmelze (Nachdruckphase)
4. Öffnen der Formhälften (Auswurfphase)
Construction of a cast mold
Die casting tools always consist of two mold halves. A distinction is made between the mold halves Angus side and ejector . In the gate side of the die-casting mold is located on the machine side piston pushes the molten metal into the die casting mold and thus fills the cavity. On the opposite side of the ejector , which ejector is located , which press the molded cast part from the mold after casting .
A pressure die-casting die is generally of the following components :
Angus chuck page
Mold frame Angus page
Angus side mold plate
Mold ejector plate
Ejector mold frame
In addition, components such as :
Slider ( optional)
Advantages of die casting tools
The use of die casting tools bring a number of advantages. Mostly , the advantages of die casting tools, or the cast to wear in larger batch quantities .
• High efficiency
• Strong output ( output)
• Short production cycles
• Enormous dimensional
• Long service life of the casting tool
• Good resistance values of the components
• Smooth surfaces accessible
• Thin-walled castings feasible
• complex component geometries feasible
• High process stability through automation
Disadvantages of die casting tools
The downside of using die tooling is significant in the high cost. They are particularly relevant for small numbers to bear.
• High cost
• Complex production of the die
• machine -heavy production process ( investment costs)
• Put the machine required to print mold
• vent to prevent air pockets ( optional)