Die Casting Design Guide: Tips & DFM Analysis

According to the implication of design evaluation written by J.A. Barton, design can account for 70% of the cost of a product. 80% of the quality problems are unwittingly designed into the product itself. Effective design plays a crucial role in die casting success. By understanding key principles, you can create high-quality, cost-effective parts.

Brief Overview of Die Casting

Die casting is a manufacturing method that uses a die casting machine, attaches a mold to it, melts mainly non-ferrous metals, and press-fits them with both parts intact. The aim is to produce products with high precision and excellent texture at high speed. Products created using the die-casting method are technically and economically suitable for mass production of products with complex shapes and thin wall thickness.

What is the DFM Process in Die Casting?

DFM Process In Die Casting

Effective design for manufacturability (DFM) plays an important role in die casting success. it is a design that prioritizes functionality. One purpose of DFM is to approach a design that is easy to manufacture. The second purpose is to find hidden risks and unreasonable waste and generate them.

There are five major approaches to DFM. Well, the process is, but first of all, the question is whether it is a large-activity process or not. The shape is designed to be easy to manufacture in a large-activity process. Well, the second point is where DN discussions often take place.

The third point is materials. Well, I think this will be an opportunity to reconsider whether or not you are choosing the right materials. Also, the forth point is where crucial discussions are often held. What is the working environment in which it will be used?

We will discuss the materials, surface finish, etc. Also, the last standard is the final standard. Yes, and since it is DFM for die casting, we will focus on large activity, but when it comes to defects in large activity, 40% of that is product design and another 40% is mold design. That means that 80% of the work goes into some kind of design.

Potential Surface Finishing Issues in Die Casting Design

Issue Cause Solution
Flashing Metal leakage between mold halves
  • Improve parting line design
  • Increase clamping pressure
  • Adjust injection parameters
Cold Shuts Incomplete metal filling
  • Increase injection pressure
  • Redesign for uniform wall thickness
Blistering Trapped air pockets
  • Improve venting in the mold
  • Slow down injection speed
Texture Issues improper mold surface texture
  • Polish mold surfaces
  • Adjust cooling parameters
Inclusions Foreign material trapped in the metal
  • Improve metal cleanliness
  • Refine filtration process

Key Factors in Designing Die Casting Parts

Key Factors in Designing Die Casting Parts

Wall Thickness
A consistent wall thickness ensures even cooling and solidification for maximum structural integrity and mechanical properties, as well as reduced material usage and cycle times that lead to cost-cutting benefits for production processes. Thinner walls could potentially reduce material usage as well as cycle times significantly impacting cost effectiveness.

Parting Line
A parting line refers to the point at which two different sides of a mold come together, making its positioning critical in shaping both aesthetics and functionality of final product. Proper positioning requires strategic thought.

Draft Angles
Draft angles are gradually tapering surfaces inserted into molds to assist castings’ easy removal from them, decreasing risks during removal while improving quality in final product. Proper draft angles reduce damage caused by unintentional release while increasing production rates overall.

Ejector Pins
Ejector pins are used to push finished castings out of molds and require careful design in terms of placement, size and number in order to prevent defects such as marks or indentations on finished parts.

Fillets and Radii
Fillet corners (rounded corners) and radii can significantly boost casting strength by relieving stress concentrations within a mold and contributing to its flow of molten metal within it. These features also contribute to smooth metal transference within it.

Undercuts 
Die casting parts that feature undercuts can only be accessible along a parting line by using advanced tooling solutions like side-actions or split molds; otherwise they become difficult and more costly to produce.

Holes & Windows
When creating die cast parts with holes or windows, proper consideration must be given to factors like their size and location in order to preserve structural integrity. A suitable tooling design must also be established in order to achieve precision results.

How To Design A Successful Die Casting Project?

To get a perfect die casting design project, you must be innovative and expert in understanding the material choice. The first thing to do is define what you want to achieve with your part and determine the stresses it will go through. This will help in material selection as it ensures that appropriate materials (aluminum, zinc, magnesium, etc.) are used for their right density, strength, and anti-corrosive properties.

As mentioned above, DFM is the second most important thing in die casting design. That entails designing a part specifically for die casting including its capabilities and limitations. Subsequently, Die casting simulation software can be a powerful tool here. This way, tests such as virtual trials of designs can display the vulnerable areas of the part.

Lastly, working closely with a reliable die casting company is extremely important. A professional die casting parts manufacturer ensures that a part is fully functional and follows design parameters accurately.

Work with CFS Foundry for Die Casting Design and Manufacturing

Being the best die casting manufacturer in China, CFS’ die-casting products are now in demand in a wide variety of fields. We have both cold chamber die casting and hot chamber die casting capabilities to make both aluminum castings and other non-ferrous metal castings. To maintain quality, we ensure all the parts are 100% inspected before delivery. Any RFQs on die casting project, pls feel free to contact us!

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