Transcript Chapter 5
Chapter 5 Overview
Casting die
is the other major component
Casting die has four functions:
• Hold molten metal in shape of desired casting
• Provide means for molten metal to get into the
space where it is held in desired shape
• Remove heat from molten metal to solidify it
• Provide for removal of the solidified metal
5-1
Chapter 5 Objectives
Identify the
four types of casting dies
Identify the three major casting die modules
Identify the purpose of each major die
component
5-2
New Terms
Cavity
• The void or empty space in the die that fills with metal to make
the casting
Gate
• The smallest restriction in the alloy flow path, located at the
edge of the casting
OEM
• Acronym for Original Equipment Manufacturer
Overflows/lifters
• Small pockets of alloy located around the edge of the casting
5-3
New Terms cont.
Runner
• Die cast alloy distribution system within the casting die
Shot
• All the injected material
Vacuum vent
• Helps get the air out of the die cavity.
Vent
• Path from the die cavity to outside the die
5-4
Die Ownership
The OEM owns the
tooling required to make
the die casting
• If GM opted to purchase casting from a custom
producer, the custom producer would buy
casting die from a toolmaker and then sell the die
to GM
• If GM opted to manufacturer the casting in its
own plant, GM would buy the die from a
toolmaker directly
5-5
Types of Dies
Single cavity die
• Produces one
casting at a time
Multiple cavity die
• Produces more than
one casting at a time
Family die
• Produces a number of different parts
Unit die
• OEM owns the unit die and the custom die caster owns the
mold base or unit die holder
5-6
Unit Die System
Advantages
• Lower tooling costs
• Shorter lead times
• Potentially lower
piece part costs
Disadvantages
• Reduced flexibility in part design
• Limited size
• Possible problem moving tooling from one vendor to
another without additional tooling costs
5-7
Mold base
Steel envelope that is designed to hold all the other
die components together
Usually made from a pre-hardened steel such as a
P-20 or AISI 4140
5-8
Stationary half mold base
Acts
as container for stationary die cavities
Provides means for attaching stationary die
half to machine
Couples injection system to the die
Provides a means for aligning to two die
halves
Has several components
5-9
Stationary Half Mold
Base Components
Clamp slots
Guide pins
Pryslots
Mounting/clamp plate
5-10
Moving half mold base
Acts
as container for the die cavities
Couples ejection system to the cavities
Provides means for aligning the two die
halves
Components include:
• Guide bushings
5-11
Ejector box
Provides a
means for mounting moving half
mold base to moving machine platen
Supports moving half mold base against
machine closing force and force of injection
Couples machine ejector system to die
ejector system
Has several components
5-12
Ejector Box Components
Parallels/rails
Clamp plate
Support pillars
5-13
Ejector system
Inside the ejector box
Provides one of four critical die functions, to
‘provide for removal of the solidified metal’
Has several components
5-14
Ejector System Components
Ejector pins
Return
pins
Ejector plate
Ejector return plate
Guided ejection
5-15
Die Cavity
Cavity
blocks
Core pins
Slides
Casting
Carrier
Wedgelock
Cam pin
Cooling lines
Heaters
Core pin
5-16
Die Cavity cont.
Several
cavity features share same
terminology as the die cast shot
•
•
•
•
•
Sprue
Runner
Gate
Overflows
Vents
5-17
Miscellaneous Components
Biscuit block
Sprue bushing
Sprue post
Stop buttons
Quick eject cam
and pins
5-18
Summary
Casting die
is the other major component
• Has four functions
Castings can
be manufactured by the OEM or
purchased from a custom producer
4 casting die forms: single cavity, multiple
cavity, family and unit
A typical die contains 3 modules: stationary
mold base, moving mold base and ejector box
5-19
Summary cont.
Unit dies are
not complete dies; have certain
advantages and disadvantages for the OEM
There are many components to casting dies
•
•
•
•
•
•
Mold base
Stationary half mold base
Moving half mold base
Ejector box
Ejector system
Die cavities
5-20