Die Casting Tools
HOSHI TOOL provides comprehensive high-pressure die-casting solutions tailored to your requirements. By leveraging cutting-edge technology, we help clients bring their designs to life cost-effectively.
Our advanced die-casting services offer exceptional customization, efficient production, reduced expenses, and enhanced durability and corrosion protection. With automated systems in place, we streamline the process to maximize efficiency and meet budgetary needs, even for the most complex parts.
What Is Die Casting Tools?
Die casting is a precision metal forming process in which molten metal is injected into a mold cavity under high pressure. Once cooled and solidified, the metal takes the shape of the mold, producing a part with precise dimensional accuracy and functional properties. Die casting molds operate in controlled cycles to consistently yield high-quality alloy components.
This process is widely employed across various industries, including lighting, automotive, aerospace, heavy machinery, furniture, engines, and motorcycles. Its unique material properties and scalability make it ideal for mass production. Below are key insights into the die casting process to enhance your understanding of this advanced manufacturing technology.
1. Die Casting Dies Structure
The casting shape is molding after the die casting cavity and the moving core are closed. The molding system includes core, cavity, sliders, inserts, and inserts pins.
The mold base included various steel plates, frames, and other structural parts. The function is to combine and fix the various parts of the mold and enable the mold to be installed on the die casting machine.
Ejector function to eject the casting parts from the mold, including ejection and returned parts, and the guiding parts. Used same material as forming parts to make the ejector pins and easily damaged parts.
It is connected with the molding part and the pressure chamber to guide the metal material into cavities in a certain direction. It directly affects the speed and pressure of the molten metal molding part. It is composed of a sprue, a runner, an inner gate, etc.
The overflow system is a channel to remove the air from the pressure chamber. and generally includes venting slots and overflow slots. Sometimes, In order to improve the venting conditions, installed vent plugs in deep cavities.
There are other components such as bolts and pins for fastening and positioning parts for positioning in the mold.
For smaller die cast parts with relatively simple geometric switches, molds of standardized modules are often used.
Compared with aluminum alloy, magnesium alloy has lower hot melt, and its iron content is also very low. Therefore, the mold has a longer life.
2. Advantages Of Die Casting
Die castings offer exceptional impact resistance, making them ideal for heavy machinery such as trucks and automobiles. They provide precise dimensional stability, essential for transportation in varying temperature conditions, unlike plastic, which is prone to deformation.
Die cast components, including robotic arms and engine covers, exhibit superior durability, maintaining structural integrity even under extreme temperatures. Their high corrosion resistance makes them suitable for marine, chemical, and defense applications exposed to harsh environments.
Additionally, die casting is the only method capable of achieving the required strength for thick-walled components, such as furnaces, aerospace parts, and large vehicles.
3. Why Choose Hoshi As Your Partner In Die Casting?
4. Deeply Understand The Die Casting Process By Video
5. RFQs About Die Casting Tools
Aluminum alloy die casting, Zinc alloy die casting, Magnesium alloy die casting are the three main die casting tools.
The temperature of the aluminum alloy melt is usually around 1202~1292℉. The mold life of aluminum alloy die casting molds should be focused on whether mold sticking and early dry cracking of the mold cavity occur. At present, General used aluminum alloy die casting mold steels included: 4Cr5MoSiV1 (H13), 4Cr5MoSiV (H11), 3Cr2W8V, and new steel grades Y10 and HM3.
The melting point of zinc alloy is 752~806℉, and the surface temperature of the zinc alloy die-casting mold cavity will not exceed 400°C. The materials generally used to manufacture zinc alloy die-casting molds are alloy structural steels 40Cr, 30CrMnSi, 40CrMo, etc., alloy mold steels 5CrNiMo, 5CrMnMo, 4Cr5MoSiV, 4Cr5MoSiV1, 3Cr2W8V, CrWMn, etc.
The melting point of magnesium alloy is 1202℉. Die-casting has a good molding feature. The tensile strength of magnesium alloy castings is equivalent to that of aluminum alloy castings, generally up to 250Mpa, up to more than 600Mpa. The most commonly used is H13 steel or materials with similar properties. After machining, the cavity part is quenched and annealed to make the hardness within the range of 46-48HRC. Only the cavity part and special parts of the mold need to use H13 steel, and these parts generally account for 20-30% of the weight of the entire mold. The other parts of the mold are made of low-carbon steel and medium-carbon steel.
For smaller die cast parts with relatively simple geometric switches, molds of standardized modules are often used.
Compared with aluminum alloy, magnesium alloy has lower hot melt, and its iron content is also very low. Therefore, the mold has a longer life.
Stable machine, stable material supply, no pores, and residue.
The core and cavity are at the specified temperature during the heat treatment process to ensure that the material is in the best performance. It is important to choose the right die casting steel for the cavity and core because the production is always in a high-temperature environment.
The metal material has no impurities and the temperature is suitable, then the surface of the die casting will be smoother
The gate, slag strap, and ejector design in the mold are reasonable, and the casting process is smooth, without excessive pressure and material waste
Rough and precision punching.
Deburring, clean the hole.
CNC, EDM, WEDM.
Surface corrosion protection.
Sandblasting, oil blasting, electroplating, and even positive oxidation.
After the tool is running for a period of time and before storage, check the important dimensions and the mold components may damage that need to be repaired or replaced.
After confirming all tool components are no damaged, they must be cleaned up completely. Check whether there is residual material in the cavity, whether the material runner is clean, and whether the parting surface of the mold, top block, and sliding block working surface are strained.
The surface of the cavity should be carefully inspected. If there is rust or water rust, it should be polished again.
After the cavity is cleaned, to prevent rust, apply anti-rust oil.
Before the mold is placed in the storage place, remove the residual cooling water in the mold and the residual oil in the oil pipe, and then use the locking plate to fix the moving plate and the fixed mold to prevent it open.
Mold storage is required to be in a flat, dry, clean place that is convenient for lifting and handling. The storage should be classified, and similar molds should be placed together.
More dangerous when casting in workshop，more requirements in terms of safety in production，more insurance and protection
All other types of casting except die casting are not suitable for thin walls
Heavier than plastic products, more shipping costs, and packaging costs
More demanding on the environment，dirtier and messier workshops, exhaust and effluent discharge not easily dealt with
No complex die structures can be used, for the same product, plastic molds can complete more structures, die-casting molds need secondary processing, CNC, WEDM
More cost than plastic, like materials, tools, transport, environment, and secondary processing
