14 Design For Die Casting PDF

PEMP
PDN 505
Session 14
Design for Die Casting
Lecture delivered by
Prof. M. N. Sudhindra Kumar
Professor MSRSAS-Bangalore
Sudhindra MSRSAS
M.S Ramaiah School of Advanced Studies - Bangalore 1

PEMP
PDN 505
Session Objectives
At the end of this session the delegate would have understood
DFM for Die Casting Parts
How to design die cast components
Commandments of Die casting design
Sudhindra MSRSAS

PEMP
PDN 505
Session Topics
1. Dont design castings!
2. Do Practice simultaneous engineering
3. Know Effectiveness of casting design
4. Design for Function & Assembly
5. Rib the part to add strength and stiffness & Reduce
weight
6. Design For Metal-flow
7. Design For Uniform Wall thickness
8. Design with as thin a wall thickness as possible
9. Let walls intersect at right angles
10. Know How to design a Boss?
11. Be generous with drafts
Sudhindra MSRSAS
12. Think Avoidance of side cores

13. Think simplicity (Two-piece die)
PEMP
PDN 505
Session Topics
14. Think of shop man
15. Dont be too smart with Sliding core
16. Know Limitations of Cast Threads
17. Design Inserts to Cost
18. Limit machining Allowances to a minimum
19. Specify explicitly location of ejector pins
20. Design For Flash and Gate Removal
21. Think of Die-sinking costs
22. Leave the Letters Raised
23. Know the limitations of cored out holes
24. Design for Assembly
25. Know limitations of dimensions & Tolerances
Sudhindra MSRSAS

PEMP
PDN 505
Introduction:
There is a Japanese methodology called OET(On Error

Training). Once a colleague commits a mistake &
corrects it, he calls all his co-workers & shares his
negative experience.
This session is a compilation of design rules how to
design die cast components & how not to design.
Sudhindra MSRSAS

PEMP
PDN 505
Introduction:
Die cast component design may be thought of as ~ 80%
science & some 20% art(= Design for aesthetic appeal /
Beauty), like in the design of cylinder head fins of a
motorcycle.
We are only covering the science part in this session.
The remaining 20% art-part may sometimes have even
80% impact on the visual appeal to the customer. That is
beyond the scope of this session.
Sudhindra MSRSAS

PEMP
PDN 505
1. Commandment: Dont design castings!

The first Commandment in Design for Castings is-
Dont design castings!( Dont waste your time making detailed
views of the drawings.)
Make sketches & discuss with the founder who is going to make
the casting for you, on matters of
Position of parting plane
Functional features,
Achievable accuracies...
Sudhindra MSRSAS

PEMP
PDN 505
2. Do Practise simultaneous engineering
Practicesimultaneous engineering-
Discussion of the details of the casting by part-
designer with the die-maker is required for
maximum effectiveness of the design of the
casting.
Sudhindra MSRSAS

PEMP
PDN 505
3. Know Effectiveness of casting design:

Easy to cast without filling problems
Easy to machine without the disadvantages of
either too less or too much material to remove by
machining
The most economical in cost by reducing
Cost of the die
Cost of component
Sudhindra MSRSAS

PEMP
PDN 505
Sudhindra MSRSAS

PEMP
PDN 505
QUALITY PARADOX
100% For a PDC Die 100%
Flexibility & Knowledge /

Opportunity Expertise of our
to improve own casting !
design Cost of Change !
quality of a
new Casting
Sudhindra MSRSAS
0% 0%
Concept Detailed Time
FMEA Die Mfg. Trial Production
Design Design
PEMP
PDN 505
4.Design for Function & Assembly
Part designer should

Study overall function of the product
Consider the possibility that several functions
can be incorporated into one casting with
integral features
Design for attachment and assembly
Typified by the chassis for Xerox high
speed electronic printer
Sudhindra MSRSAS

PEMP
PDN 505
Example of multi-functional casting design:
One-piece chassis for a high-speed electronic printer replaced 82

separate components and fasteners in the forerunner assembly.
Drilling and tapping have been eliminated by incorporating cored
holes, which receive thread-forming screws for fastening. (Courtesy
Sudhindra MSRSAS
Diablo Systems, a Xerox company.)

PEMP
PDN 505
5. Rib the part to add strength and stiffness &

Reduce weight:
Ribs are mainly incorporated into a die

casting to reinforce it structurally, with a
minimum increase in weight, replacing
heavy sections that would be otherwise
necessary.
Sudhindra MSRSAS

PEMP
PDN 505
Think Ribs:
Ribs are
fairly easy
to
incorporate
into an
existing
hardened
die
Sudhindra MSRSAS
Ribbing of various forms used to stiffen

the wall of a die casting.

PEMP
PDN 505
Examples of strong light weight components
Aluminum die castings for two-wheeler engines show how good

design can provide ribs where needed for strength and cored holes
for fastening while maintaining fairly constant wall thickness.
Sudhindra MSRSAS
(Courtesy Aluminum lndustrie Vaasen.)

PEMP
PDN 505
Examples of large light weight components
These die-cast aluminum components for a weight scale

Sudhindra MSRSAS
demonstrate intelligent use of ribbing to promote strength and

stiffness. (Courtesy Aluminum Industrie Vaasen.)
PEMP
PDN 505
Where & How to Design Ribs?
Box shaped components are strengthened by incorporating internal

Sudhindra MSRSAS
ribs that run the full depth of the part.Corners are reinforced by
radiusing to avoid corner fractures in the casting
PEMP
PDN 505
Where & How to Design Ribs?
Where there would normally be a heavy section

adjacent to a cored area, introduce further coring to
Sudhindra MSRSAS
create ribs, thereby removing mass & obtaining uniform

wall thickness
PEMP
PDN 505
Poor Design Of Rib
Acute-angle intersections cause the die

to overheat in the area between the ribs.
Multiple intersections of radial ribs
should be avoided; otherwise, the
Sudhindra MSRSAS
intersection will contain porosity.

PEMP
PDN 505
Typical case of how ribs

should not be designed
Sudhindra MSRSAS
Number of ribs intersecting = 6!

PEMP
PDN 505
Slightly improved design of ribs:
Number of intersections = 4
Sudhindra MSRSAS

PEMP
PDN 505
Optimum Rib design:
Much improved rib design(Only 3 ribs

intersect at each point)
Sudhindra MSRSAS

PEMP
PDN 505
Procedure for design of Reinforcing Ribs
Designer may under-design initially,

test sample castings, then add strength if necessary
by removal of die steel until the
optimum combination of mechanical properties
and casting-material conservation is
reached.
(Preferable to over-designing and having to
lighten the die casting later by welding the die,
Sudhindra MSRSAS
which is a costly, life-limiting procedure.)(E.g..)

PEMP
PDN 505
6.Design For Metal-flow:

Avoid
Abrupt section changes
Sharp corners
Walls at an acute angle to one another
(Disturb the continuity of metal flow and
promote porosity and surface
irregularities)
Blend differing sections into one another with

Sudhindra MSRSAS
radii as generous as possible.

PEMP
PDN 505
Design For Metal-flow:

Sudhindra MSRSAS

PEMP
PDN 505
Why More Radii?

Radii
Sharp external corners are undesirable because
they become a localized point of heat and stress
buildup in the die steel that can cause die cracking
and early failure.
Therefore, radii and fillets should be as generous

as possible, preferably at least 1.5 times wall
Sudhindra MSRSAS
thickness for both inside and outside radii.

PEMP
PDN 505
Sharp corners cause

uneven cooling, while
rounded corners
permit uniform
cooling with much
less stress; Rounded
corners that maintain
uniform wall
thickness provide the
T best results
Sudhindra MSRSAS

PEMP
PDN 505
Why to avoid sharp corners?

Sudhindra MSRSAS
Sharp edges on cores are difficult to maintain because they are points of heat
concentration,
with resulting premature erosion of the die material.
PEMP
PDN 505
7.Design For Uniform Wall thickness
The easiest die casting to make and the soundest

in terms of minimum porosity is one that has
uniform wall thickness.
Sharp changes in sectional area or heavy sections

over 6 mm thick should be avoided if possible.
When a heavy section seems to be indicated, its

Sudhindra MSRSAS
underside should be cored out.

PEMP
PDN 505
Importance of Uniformity of wall thickness
Less Problems
Sudhindra MSRSAS
More Problems

PEMP
PDN 505
8. Design with as thin a wall thickness as possible:

Sudhindra MSRSAS
*Fine-grained dense structure, devoid of porosity, thus making the skin the strongest
part of wall thickness (?)
PEMP
PDN 505
Max Strength/Weight is achieved with 0.8 - 1.3 W.T
Strength
Weight
Ratio
Sudhindra MSRSAS

PEMP
PDN 505
9.Let walls intersect at right angles:

Sudhindra MSRSAS
Intersection of two walls should be at right angles to

avoid sharp corner hot spots
Fig.20 M.S Ramaiah School of Advanced Studies - Bangalore 34
PEMP
PDN 505
10.Know How to design a Boss?

Sudhindra MSRSAS
To avoid surface shrinks, relocate the boss and connect it to the wall with a short rib.
The ribs should be no wider than the thickness of the casting wall

PEMP
PDN 505
11.Be generous with drafts:
When the draft angle is abnormally small, even the slightest depression in the drafted
Sudhindra MSRSAS
surface of the die will prevent ejection causing drag marks in the surface of the casting

PEMP
PDN 505
12. Think Avoidance of side cores:

Sudhindra MSRSAS

PEMP
PDN 505
12. Think Avoidance of side cores:

Sudhindra MSRSAS

PEMP
PDN 505
13.Think simplicity (Two-piece die)

Sudhindra MSRSAS
If possible, the part should be designed so that it can be made in a simple two-piece die.

PEMP
PDN 505
14.Think of shopman :
Through-wall cored holes for tapping should be countersunk on both sides to avoid
deburring; Holes for tapping should be cored rather than drilled. A drilling operation is
Sudhindra MSRSAS
eliminated, and the tap will cut into dense material for a higher-quality thread.

PEMP
PDN 505
15.Dont be too smart with Sliding core
Should never be designed to intersect the opposite die half, since imperfect die closure
Sudhindra MSRSAS
(possibly the result of flash at the parting plane not being fully removed) would result
in a damaged die
PEMP
PDN 505
16.Know Limitations of Cast Threads:

Sudhindra MSRSAS

PEMP
PDN 505
16.Know Limitations of Cast Threads:

It is possible to die-cast internal threads in
zinc parts only by using techniques that
involve either unscrewing the casting from
a threaded core or rotating the core out of
the casting during ejection.
Sudhindra MSRSAS

PEMP
PDN 505
Design of bush type inserts:(To resist both

axial and rotational forces).
Insert with knurled circumference (Positive

location within the die must be provided to
Sudhindra MSRSAS
prevent insert movement during the casting

cycle)
PEMP
PDN 505
Design of bolt type inserts:
Insert with recess & longitudinal grooves

Sudhindra MSRSAS

PEMP
PDN 505
Design of bolt type inserts:
Insert Machined & U/C square

(insert's threads must be kept away
Sudhindra MSRSAS
from the casting face)

PEMP
PDN 505
Design of bush type inserts:
Insert with locally machined flat

Sudhindra MSRSAS

PEMP
PDN 505
Design of bush type inserts:
Insert with drilled anchor holes

Sudhindra MSRSAS

PEMP
PDN 505
17. Design Inserts to Cost

Sudhindra MSRSAS
Decision based on Cost comparison for inserts

PEMP
PDN 505
18.Limit machining Allowances to a minimum:

Sudhindra MSRSAS
Deeper cuts could open up unsightly subsurface porosity and

possibly affect function
PEMP
PDN 505
19. Specify explicitly location of ejector pins:
If an area to be machined covers ejector-pin

locations, their impressions should be
0 to 0.4 mm depressed-so that they are
removed in machining.
Sudhindra MSRSAS

PEMP
PDN 505
20.Design For Flash and Gate Removal

With complex castings having massive core
slides, the cost of complete removal by a
combination of die trimming and hand operations
can be as much as, or even considerably more
than, the cost of the raw casting !
Sudhindra MSRSAS

PEMP
PDN 505
20.Flash and Gate Removal:

Sudhindra MSRSAS
Avoid an angled junction of an external wall with the parting line.It is preferable to add a
minimum-draft shoulder at the parting line, so that most of the gate material will come
away in trimming.

PEMP
PDN 505
20.Simplify Flash and Gate Removal

Sudhindra MSRSAS
Trimming tool to match intricate geometry would be expensive and hard to maintain.
Advisable to add a shoulder between wall detail and parting line to allow for use of a single
trimming die or a lathe-turning operation to remove gates and flash.
PEMP
PDN 505
21.Think of Die-sinking costs:(?)

Sudhindra MSRSAS
If the casting is designed with convex features in outside walls,it is a straightforward job
to mill the corresponding concavities into the steel.
PEMP
PDN 505
22. Leave the Letters Raised :

There are two alternatives.
The easy way is to specify that the
characters be raised in the casting.
This can be accomplished by relatively
inexpensive engraving of the die.
If the characters are to be depressed into the

casting, however, all the background steel on that
Sudhindra MSRSAS
face of the die must be painstakingly removed

around the characters.
PEMP
PDN 505
On Lettering
If the designer wants the economy of raised
characters but does not wish them to
project above the surrounding surface, a raised
pad can be incorporated into the die to
form a depressed area in the casting. Then when
the pad is engraved, the lettering will
come out flush.
Sudhindra MSRSAS

PEMP
PDN 505
23.Know the limitations of cored out holes

The die-casting process can accommodate the
coring in of holes into the body of the
casting at right angles to the parting line.
However, there are core-length limits, depending

on diameter, that should not be exceeded.(Ref.4
page 5.68)
Sudhindra MSRSAS
Long, slender cores may lead to core breakage

PEMP
PDN 505
24.Design for Assembly:

Sudhindra MSRSAS
Zinc only!
Fig.39
PEMP
PDN 505
Sudhindra MSRSAS

PEMP
PDN 505
25.Know limitations of dimensions & Tolerances
The as cast dimensional variations of a die casting

depend on part size.
This dependency is largely due to thermal expansion and
contraction of both the die and the casting. The die
expands at operating temperatures, and the casting
shrinks after it leaves the die.
Variations in die operating temperatures and the
temperature of the molten metal entering the die add to
Sudhindra MSRSAS
the need for a design tolerance on die-casting dimensions.

PEMP
PDN 505
25.Know limitations of dimensions & Tolerances
Tolerances across the parting line and between core

slides and main die blocks must be greater because of
the clearances that are incorporated into these features
in the die to enable them to function at elevated
temperatures.
Recommended tolerances also allow for gradual wear
in die components over the life of tooling. This is a
significant factor.
Another is warpage.
Sudhindra MSRSAS

PEMP
PDN 505
Some case-studies of Problems encountered

during die casting of engineering components
Sudhindra MSRSAS

PEMP
PDN 505
Outside view of Motor Body Housing Casting

~ 180 dia; ~100mm deep; 800gm
Support
pin
locations
10
Sudhindra MSRSAS
Problem: Non-filling of window portions

PEMP
PDN 505
Inside view of Motor Body Housing Casting
Nominal Wall
thickness ~
2 mm
CI Insert
for bearing
Sudhindra MSRSAS
Problem: Non-filling of window portions

PEMP
PDN 505
Motor Body Housing Casting
Original
runner
location near
heavy sections
Sudhindra MSRSAS

PEMP
PDN 505
Motor Body Housing Casting
Fully filled
windows
after the
addition of
Sudhindra MSRSAS
extra runner
PEMP
PDN 505
Housing
Housing ForforHand-grinder
hand-grinder
Sudhindra MSRSAS
Typically asymmetric flow of metal required

PEMP
PDN 505
Housing for Hand-grinder

Sudhindra MSRSAS
Problem:Non filling of semi cylindrical portion : part sticking

to cavity
PEMP
PDN 505
Housing For Hand-grinder
Subrunner
Runner
Sudhindra MSRSAS

PEMP
PDN 505
Design For Die-casting
How did they solve the problem of

Part sticking to the cavity?
Sudhindra MSRSAS

PEMP
PDN 505
Motor Housing Non-drive End (Outside view)

Sudhindra MSRSAS
Dia 180mm; 100mm high;750gm

PEMP
PDN 505
Motor Housing Non-drive End (Inside view)

Sudhindra MSRSAS
2.5mm Wall thickness

PEMP
PDN 505
Motor Housing Non-drive End
Cracks
near the
opening
Sudhindra MSRSAS
Problem: Fin area not being filled at all

PEMP
PDN 505

Cracks
below
opening
Location of
runners near
heavy sections
Sudhindra MSRSAS
Problem: Fins not at all filling

PEMP
PDN 505
Extra sub-
runner just
below
rectangular
Sudhindra MSRSAS
opening
added
PEMP
PDN 505
Fan Casting : Dia ~ 150mm; ~75mm long; gm
16
ejection
pins
170 dia; 30 height; 500gm

Sudhindra MSRSAS
Problem: Fins Breaking; Ejection sticky

PEMP
PDN 505
Fan Casting
Sudhindra MSRSAS
Problem: Fins breaking;ejection sticky

PEMP
PDN 505
Fan Casting
Sudhindra MSRSAS
Draft angle of blades increased from 2 deg to 5 deg

Extra ejection pins 6 nos added
PEMP
PDN 505
Family die for Flange & Bearing Cover
5mm
50dia
thick;
8gm
40dia
Sudhindra MSRSAS
20mm thick; 30 gm

PEMP
PDN 505
Problem:
Only one set of
good parts obtained out of
each shot
Severe Blow-holes
Analysis: Severe unbalanced

Mass-flow; C.f. : 46gm Vs
68gm
Sudhindra MSRSAS

PEMP
PDN 505

Sudhindra MSRSAS

PEMP
PDN 505
Solution: Progressively reducing runner

width Increase radii for improved flow;
Sudhindra MSRSAS

PEMP
PDN 505
Lesson learnt:
For optimum results, the degree of imbalance
between the two sides of a family die should
not exceed + / - 10%
Sudhindra MSRSAS

PEMP
PDN 505
Gear Cover Casting

Sudhindra MSRSAS
140mm dia; 60mm height; 300gm

PEMP
PDN 505
Gear Cover Casting

Sudhindra MSRSAS
Problem: Non-filled area

PEMP
PDN 505
Gear Cover Casting
Sub-
runner
added
Sudhindra MSRSAS

PEMP
PDN 505
Base Casting for Electric Cutter

~300mm X ~ 150mm; 400gm -- Wall thickness 3mm
Sudhindra MSRSAS
Not Filling
PEMP
PDN 505
Initial Gate Position

Sudhindra MSRSAS
Not Filling
PEMP
PDN 505
Fully filled with redefined gatings

Sudhindra MSRSAS

PEMP
PDN 505
Cover for Cutter
Non- Filling
Sudhindra MSRSAS
Dia 240mm;120 mm; 2mm nominal thickness

PEMP
PDN 505
Cover for Cutter

Sudhindra MSRSAS
Wafer-thin wall
PEMP
PDN 505
Cover for Cutter
Solution:
Maintain uniform wall thickness
Sudhindra MSRSAS

PEMP
PDN 505
Conclusion:
20 %
80 %
80 %
20 %
Cause Effect
Sudhindra MSRSAS
Pareto Principle
M.S Ramaiah School of Advanced Studies - Bangalore
Fig. 67 94
PEMP
PDN 505
Have always the simple mind of a student,

because on the simplest of foundations are built
the most wonderful works of nature.
Dr.W.A.J.Chapman
Sudhindra MSRSAS

PEMP
PDN 505
References:
1.Die casting book by Dr.Arthur Street
2.Metals Hand book Volumes 5A,5B,15 SME
3.Principles of Metal Casting By Richard W.Heine
4.Design for Manufacturability By James Bralla
Sudhindra MSRSAS

PEMP
PDN 505
Summary
Die castings are extensively used for manufacture of intricate
engineering components
Die castings are made in alloys of aluminum , magnesium ,
or zinc, and are used where good mechanical properties and
absence of creep is required
Typical applications are housings for automotive
assemblies and electrical motors/ pumps, and structural parts
for electronic equipment
Design of parts for die casting is critical for obtaining good
castings- It involves providing proper gating systems and
design for uniform metal flow, uniform wall thickness,
Sudhindra MSRSAS
bosses, avoidance of side cores, provision for inserts,

providing generous drafts, and keeping minimum machining
allowance

14 Design For Die Casting PDF

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

14 Design For Die Casting PDF

Enviado por

Direitos autorais:

Formatos disponíveis

PEMP

M.S Ramaiah School of Advanced Studies - Bangalore 1

M.S Ramaiah School of Advanced Studies - Bangalore 2

12. Think Avoidance of side cores

M.S Ramaiah School of Advanced Studies - Bangalore 4

There is a Japanese methodology called OET(On Error

M.S Ramaiah School of Advanced Studies - Bangalore 5

M.S Ramaiah School of Advanced Studies - Bangalore 6

1. Commandment: Dont design castings!

M.S Ramaiah School of Advanced Studies - Bangalore 7

2. Do Practise simultaneous engineering

M.S Ramaiah School of Advanced Studies - Bangalore 8

3. Know Effectiveness of casting design:

M.S Ramaiah School of Advanced Studies - Bangalore 9

M.S Ramaiah School of Advanced Studies - Bangalore 10

Flexibility & Knowledge /

4.Design for Function & Assembly

Part designer should

M.S Ramaiah School of Advanced Studies - Bangalore 12

Example of multi-functional casting design:

One-piece chassis for a high-speed electronic printer replaced 82

Diablo Systems, a Xerox company.)

M.S Ramaiah School of Advanced Studies - Bangalore 13

5. Rib the part to add strength and stiffness &

Ribs are mainly incorporated into a die

M.S Ramaiah School of Advanced Studies - Bangalore 14

Ribbing of various forms used to stiffen

M.S Ramaiah School of Advanced Studies - Bangalore 15

Examples of strong light weight components

Aluminum die castings for two-wheeler engines show how good

(Courtesy Aluminum lndustrie Vaasen.)

M.S Ramaiah School of Advanced Studies - Bangalore 16

Examples of large light weight components

These die-cast aluminum components for a weight scale

demonstrate intelligent use of ribbing to promote strength and

Where & How to Design Ribs?

Box shaped components are strengthened by incorporating internal

Where & How to Design Ribs?

Where there would normally be a heavy section

create ribs, thereby removing mass & obtaining uniform

Poor Design Of Rib

Acute-angle intersections cause the die

intersection will contain porosity.

Typical case of how ribs

Number of ribs intersecting = 6!

Slightly improved design of ribs:

M.S Ramaiah School of Advanced Studies - Bangalore 22

Optimum Rib design:

Much improved rib design(Only 3 ribs

M.S Ramaiah School of Advanced Studies - Bangalore 23

Procedure for design of Reinforcing Ribs

Designer may under-design initially,

which is a costly, life-limiting procedure.)(E.g..)

6.Design For Metal-flow:

Blend differing sections into one another with

radii as generous as possible.

Design For Metal-flow:

M.S Ramaiah School of Advanced Studies - Bangalore 26

Why More Radii?

Therefore, radii and fillets should be as generous

thickness for both inside and outside radii.

M.S Ramaiah School of Advanced Studies - Bangalore 27

Sharp corners cause