When it comes to designing diecastings, everybody wants to do everything that they can to take advantage of the entire die casting process. Manufacturers want to take advantage of the process because it will help increase their profit margins, the better the diecastings are the better the end results are. Not only will designing better diecastings help save money, but it can also speed up production. The better the die castings are designed the more efficient they will be which can mean faster turnaround times, not to mention fewer mistakes.
Here are some tips that you can follow when designing your diecastings.
- Rather than having 90-degree angles on all of the corners, what you want to do is maximize the radius of the corners. In other words, round them off a bit rather than making them 90 degrees.
- Try to avoid using huge, plain surfaces for your die casts. If you need to do a large area for your die cast try to break it up with some type of texture, such as stippling or ribs.
- The wall sections should be equal; meaning no thin or thick parts, if that is possible.
- To help keep costs down concave notches should be avoided; they are also very difficult to do. Rather than using concave notches try using convex finger grips.
- Walls that are located around the corners of the die should never be thin.
- Raised and depressed lettering can be done with dies. Ione thing to keep in mind though is that depressed lettering is costs more than raised.
- Rather than trying to core, a hole all the way through casting drill spots is a lot easier.
- Try avoiding any kind of sharp corners when casting the part because the sharp corners are a lot harder to maintain. Instead, try to add some roundness to the corners.
- You can usually modify the cavities of the dies to help get rid of any binding that might occur due to any shrinking over the cores.
- If at all possible, keep all of the deep cavities on one side of the mold.
- When using any kind of contours you want to remember that some of them are easier to deal with than others. For example, rounded tops or even two forty-five degree angles are easier to deal with rather than a 45-degree angle with a rounded top on the upper corner.
- If sections have been cored to make a uniform wall you will want to add some type of ribs to give the casting some extra strength.
- Another problem manufacturers run into is flashing in the tread inserts. To prevent this from happening all one has to do is leave some kind of space in between the surface of the casting and the threads.
- With many castings, you run into the fact that two corners must fit together, to help the corners fit together properly you will want to leave a relief.