Solutions for:
Poor Die Design
Many of the problems which are experienced in the day to day operation of die casting dies can be traced back to the original die design process.
There is now a large body of scientific knowledge about the Die Casting process which makes it possible to calculate and predict all the important process parameters.
However, many of the people who are given the task of designing the die do not have this specific knowledge. The result is that many dies are designed without first calculating all the required process parameters.
So, while on the surface, these dies may look like they will do the job, in practice there are many shortcomings.
In some companies, the die design is left entirely to an external toolmaker. While the staff in some toolmaking companies have been fully trained in Die Casting technology and process design, many are not. So the dies are designed only from a cavity-making perspective.
In the worst cases, dies are designed primarily to reduce the toolmaker’s costs. Die blocks and cavity inserts end up too thin, cooling channels are inadequate or in the wrong location, and runner systems are designed to speed up the machining process. No wonder they cause problems in production.
Cheap tooling is a poor investment for a Die Caster. A small cost up front results in large costs for the life of the part.
When casting reject-costs become very high, it is not uncommon to see blame being apportioned in the wrong direction: to operators, to machine condition, to die maintenance, to metal quality or even to the die spray!
A better idea is to go back to the original die design and review it.
- Were the process parameters properly calculated?
- Was the process design completed?
- Was the die design adequate?
If you need help in improving die and process design, contact HotFlo! by email today.