Review on Die Design for Die Casting

This introduction paper is based on the paper "Review on Die Design for Die Casting" published by "Journal of Emerging Technologies and Innovative Research (JETIR)".

1. Overview:

• Title: Review on Die Design for Die Casting
• Author: Pratibha Walunj, Aditya Rokade, Pradeep Tuljapure, Sujit Survase, Sagar Wagh
• Year of publication: 2019
• Journal/academic society of publication: Journal of Emerging Technologies and Innovative Research (JETIR)
• Keywords: Die, Die casting, Design, Maintenance

2. Abstract:

Pressure Die Casting is one of the significant ways of manufacturing nonferrous metal casting. This is used widely for manufacturing on large scale. In this process a permanent mould or die is used to cast the component. This document givessummary about die designing required for pressure die casting.Brief information related to gating system, die material, maintenance has been described in this paper.

3. Introduction:

In the die casting process, parts are formed by forcing molten nonferrous metals under pressure into metal moulds called dies. The mould cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mould during theprocess.Mostdie castingsare made from non-ferrous metalsspecifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys as they possess good mechanical properties and absence of creep is required. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Die castings are extensively used for manufacture of intricate engineering components. Typical applications are housings for automotive assemblies and electrical motors/pumps, and structural parts for electronic equipment. Design of parts for die casting is critical for obtaining good castings. It involves providing proper gating systems and design for uniform metal flow, uniform wall thickness, bosses, avoidance of side cores, provision for inserts, providing generous drafts, and keeping minimum machining allowance.
Die casting is categorized two types namely- Hot Chamber and Cold Chamber as shown in Figure 1&2. Metals like Zinc, tin and lead alloys are casted in hot chamber die casting having melting point below 390°C whereas aluminum alloys are casted in cold chamber die casting machine. Aluminum dissolves ferrous parts in the die chamber and hence preferred to be used in cold chamber die casting. Continuous contact of molten metal is avoided by using a ladle for introducing molten metal directly to the machine.

4. Summary of the study:

Background of the research topic:

Die casting is a significant manufacturing process for nonferrous metal parts, where molten metal is forced under pressure into a reusable metal mold (die). It is widely used for large-scale production of complex engineering components.

Status of previous research:

The paper draws upon established knowledge in die casting, referencing prior work on die design principles, material selection, gating systems, and common practices in the industry. It refers to existing standards and literature for aspects like material properties (e.g., EN8, H13 steel), design calculations for gating and overflow, and defect analysis.

Purpose of the study:

This document givessummary about die designing required for pressure die casting. Brief information related to gating system, die material, maintenance has been described in this paper.

Core study:

The core of the study revolves around the essential elements of die design for die casting. This includes a detailed look at the die itself (Figure 3), materials used for dies, considerations for die design such as core placement and ejector pin strategy, specific design calculations for overflows, gates, runners, and shot sleeves/sprues. The paper also covers die manufacturing methods like Wire EDM, die testing, common defects in dies, and maintenance procedures.

5. Research Methodology

Research Design:

The paper is a review article, summarizing existing knowledge and practices in die design for die casting. It compiles information from various sources, including academic publications and industry standards.

Data Collection and Analysis Methods:

Data is collected from existing literature, including textbooks (Ref., Ref.), technical articles, and online resources (Ref., Ref., Ref., Ref., Ref., Ref., Ref., Ref., Ref., Ref., Ref.). The analysis involves synthesizing this information to provide a comprehensive overview of die design principles and practices.

Research Topics and Scope:

The research focuses on die design for pressure die casting. The scope includes:

• Types of die casting (Hot Chamber, Figure 1; Cold Chamber, Figure 2).
• Die components and structure (Figure 3).
• Die material selection, considering failures like thermal fatigue, mechanical erosion, and chemical attack.
• Specific die materials (Carbon steels, low-alloyed steels, high-alloyed steels, chrome steels, tungsten steels, EN8, H13 Tool Steel).
• Principles of die designing, including core placement, ejector pin considerations, vents, sprue/runner/gate design, overflow design, and shot sleeve/sprue design.
• Die manufacturing, with a focus on Wire Cut EDM.
• Die testing methods.
• Common defects in dies (heat checking, cracks, erosion).
• Die maintenance and inspection.
• Applications, advantages, and disadvantages of die casting.

6. Key Results:

Key Results:

The paper outlines critical aspects of die design for die casting. Key considerations in die material selection include resistance to thermal fatigue, mechanical erosion, and chemical attack. Various steel types like carbon steels, alloyed steels (EN8, H13) are discussed based on their properties and applications. [A. Material for Die:]
Designing the die involves strategic placement of fixed and movable cores, design of loose cores for undercuts, and careful positioning of ejector pins. [B. Designing of Die] Vents, sprue, runners, gates, and overflow wells are crucial for casting quality and must be designed with considerations for air escape, metal flow, and thermal balance. [B. Designing of Die, Design: 1. OverflowDesign:, 2. Gate design:, 3. Runner design:, 4. Shot sleeve and sprue design:]
Wire Cut EDM is highlighted as a preferred method for die manufacturing due to its precision and ability to create complex parts with minimal residual stress. [C. MANUFACTURING OF DIE] Testing of dies, often using non-destructive methods, is important for ensuring long working life and identifying potential issues early. [D. Testing of Die:] Common die defects include heat checking, various types of cracks, and erosion, often stemming from thermal stress fatigue. [E. Defects in Die's] Regular maintenance and inspection are vital for prolonging die life and ensuring consistent casting quality. [F. Maintenance]

Figure Name List:

• Fig. 1. Hot Chamber Die Casting
• Fig. 2. Cold Chamber Die Casting
• Fig. 3. Exploded View of Die

7. Conclusion:

The die casting process offers several advantages, including excellent dimensional accuracy, high production rates, smooth cast surfaces, and the ability to cast thin walls and intricate parts. [Advantages of die casting] Inserts can be cast-in, and secondary machining operations can often be reduced or eliminated. [Advantages of die casting] However, it also has disadvantages such as potential microporosity, limitations in casting hollow shapes and very large products, unsuitability for high melting temperature alloys, and high initial investment costs. [Disadvantages of the die casting process] The process is generally limited to high-fluidity metals. [Disadvantages of the die casting process]

8. References:

• http://ijesc.org/
• https://www.google.co.in/search?q=hot+chamber+and+cold+chamber+die+casting+ppt&safe=active&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiqjbL-5OrgAhUMQY8KHdqyDycQ_AUIDigB&biw=1396&bih=686#imgrc=
• P L Jain," Principles of FOUNDARY TECHNOLOGY" 4th edition, TATA McGraw-Hill
• O P Khanna," Foundry Technology", Dhanpatrai Publication.
• http://www.custompartnet.com/wu/die-casting (die exploded view reference)
• E. RAGAN, J. DOBRÁNSKY, P. BARON, T. OLEJÁR, MATERIALS ON DIES FOR PRESSURE DIE CASTING
• http://www.astmsteel.com/product/en8-carbon-steel-080m40-bs-970/
• https://www.hudsontoolsteel.com/technical-data/steelH3
• https://www.americanwireedm.com/edm-services/edm-machining
• The Die Care and maintenance Task Force of NADCA Die Materials Committee
• https://www.linkedin.com/pulse/10-maintenance-principles-die-casting-mould-jane-ai
• https://en.wikipedia.org/wiki/Die_casting
• http://www.industrialmetalcastings.com/casting_die_casting.html
• https://link.springer.com/chapter/10.1007/978-1-4684-7120-5_10

9. Copyright:

• This material is a paper by "Pratibha Walunj, Aditya Rokade, Pradeep Tuljapure, Sujit Survase, Sagar Wagh". Based on "Review on Die Design for Die Casting".
• Source of the paper: [DOI URL not provided in the paper, Journal URL: www.jetir.org (ISSN-2349-5162)]

This material is summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
Copyright © 2025 CASTMAN. All rights reserved.

Summarize:

This paper, "Review on Die Design for Die Casting," provides a comprehensive overview of the key aspects involved in designing dies for pressure die casting of nonferrous metals. It covers the fundamentals of the die casting process, including hot and cold chamber methods (Figure 1, Figure 2), and details the critical considerations for die design such as material selection (e.g., H13 steel, EN8), gating and runner systems, overflow design, and the use of cores and ejector pins (Figure 3). The paper also touches upon die manufacturing techniques like Wire EDM, methods for testing dies, common die defects and their causes (e.g., thermal fatigue), and essential maintenance practices to ensure die longevity and casting quality. Finally, it lists the applications, advantages (e.g., dimensional accuracy, high production rate) and disadvantages (e.g., microporosity, high initial cost) of the die casting process.

Key questions and answers about the research:

This paper reviews the essential elements of die design for pressure die casting, covering material selection, gating systems, and maintenance. [Abstract] The purpose is to provide a summary of die designing requirements for this manufacturing process. [Abstract] Key results include guidelines for die material selection based on failure considerations, detailed design principles for various die components like gates and runners, and an overview of manufacturing, testing, and maintenance procedures. [A. Material for Die:, B. Designing of Die, C. MANUFACTURING OF DIE, D. Testing of Die:, F. Maintenance]

Q1. What are the primary failure considerations when selecting die materials?

A1. The primary failure considerations are thermal fatigue (causing heat checking), mechanical erosion (dies should resist wear but not be too brittle), and chemical attack (decarburization leading to pitting). [Review on Die Design for Die Casting, Section A. Material for Die:]

Q2. What is the purpose of an overflow in die casting design?

A2. Overflow is needed in most aluminum die-casting applications to reduce non-metallic inclusions and air entrapment and help balance the thermal effect during the die filling. [Review on Die Design for Die Casting, Section B. Designing of Die, Design: 1. OverflowDesign:]

Q3. How is the gate area (Ag) typically determined in gate design?

A3. The gate area (Ag) is determined by the formula: Ag = Fill rate / gate velocity mm². [Review on Die Design for Die Casting, Section B. Designing of Die, Design: 2. Gate design:]

Q4. Why is Wire-Cut EDM a preferred method for die manufacturing?

A4. Wire-Cut EDM is chosen over other methods because it creates minimal residual stress, which helps extend the life of the part by avoiding premature failure, making the manufacturing process efficient. [Review on Die Design for Die Casting, Section C. MANUFACTURING OF DIE]

Q5. What are the two basic kinds of stresses that cause aluminum die-casting dies to fail?

A5. The two basic kinds of stresses are those created during the manufacturing of the die, and those produced during the exploitation process (use of the die). [Review on Die Design for Die Casting, Section E. Defects in Die's]

Q6. What are some common defects found during the inspection of castings after shakeout?

A6. The most common defects are misruns and cold shuts, which can be caused by cold dies, low metal temperature, dirty metal, lack of venting, or too much lubricant. Other possible defects include gas porosity, shrinkage porosity, hot tears, and flow marks. [Review on Die Design for Die Casting, Section F. Maintenance, Inspection]