Variables for Die Castings Draft
The first tip that I'd want to provide is about adding draft to a component that has already been created. A minor taper is applied to the internal and external walls of a part, normal to the separation line, which is referred to as "adding draft." This helps to mitigate the consequences of shrinking and makes it easier to remove the casting from the cavity. Adding draft to a part makes it easier to cast the component. According to the alloy and process options, optimum draft angles are typically in the range of 14 degrees to one degree per side. Ensure that your technical representative is aware of any important areas where draft must be kept to a minimum. In many circumstances, it is possible to achieve a draft that is close to zero in specific areas. When building your component, try to keep draft in mind at all times and use liberal draft in non-critical sections from the beginning.
Fillets and Radii are two terms that are used to describe the shape of a filter or a radius.
Also, remember to incorporate fillets and radii into the design of your component. Make advantage of generous fillets and radii wherever it is possible, especially in non-critical locations. In the event that a fillet or radius is not possible or acceptable in a particular place, make a note of it on your component drawing. Filets and radii help to reinforce the component, increase metal flow, and make the application of following finishes more straightforward.
Ribs and Bosses are two of the most important words in the English language.
It is common practice to incorporate ribs and bosses into part design to boost the strength of a component's structural integrity. To the greatest extent practicable, they should be integrated using fillets and radii to eliminate harsh edges. Because the majority of ribs and bosses have non-critical side surfaces, it is important to apply draft in the appropriate manner.
Designing Pockets in Solid Portions If the part being built needs to be lightweight, one option that is frequently employed is to build pockets in solid sections. Besides reducing the weight of the part, this also reduces cycle time and lowers the cost of manufacturing the part. Make certain to apply the appropriate draft and radii once more.
When developing a die cast component, consider all of the advantages and disadvantages of the process as a whole. Consider including features that will incur little or no additional expense. Logos, surface textures, integrated fasteners (rivets, studs), embossed component numbers, and other design elements are examples. Even greater adaptability is possible with the 4-slide die casting method. Your technical specialist can assist you with all of these options and more as necessary.
Increasing the efficiency of material flow
Finally, I'd want to provide some suggestions for assisting with the flow of metal into the cavity, which will ultimately result in the production of the final part. It is easier for the metal to flow through a cavity if the corners and sections are smooth and uniform. This results in faster filling without the production of metal flow turbulence. I am aware, however, that a uniformed part is not always a possibility for everyone. Long "windows" or slots in parts can significantly limit the flow of metal, whereas circular holes help the metal to flow more freely.
I hope you have found these suggestions to be helpful. We have a page dedicated to part improvement on our website if you would want to learn more about these possibilities and others that I did not include. It includes a plethora of information on how to improve the design of components.