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Designing Cast Features
Miskolc University
The features of high pressure die castings must be designed to allow three essential
process requirements.
− The mould or die cavity must fill completely with molten metal.
− The metal must solidify with minimum distortion while maintaining the full
integrity of all features.
− The casting must be removed from the die
As molten metal flows through the metal‐feed system into the cavity, it transfers heat
to the mould or die surfaces. In order to avoid casting defects, the cavity must fill
completely before any significant metal solidification occurs; otherwise the casting
will be defective.
The fraction of solid metal that is present when the cavity is initially full depends on
the mass of the casting features in relationship to their surface area, the thermal con‐
ductivity of the mould or die, and the amount of time required to fill the cavity. In
general, high pressure die casting dies exhibit very rapid heat transfer but the ex‐
tremely short cavity fill time allows thin walls to be die cast. Steel and graphite
permanent moulds exhibit very rapid transfer of heat and relatively slow cavity fill
times. They cannot produce castings with walls as thin as possible with pressure die
casting.
Sand and plaster moulds exhibit relatively slow heat transfer rates and slow fill times.
The plaster‐mould process can produce thinner walls than the sand‐mould process,
but not as thin as die cast.
As metal solidifies in the cavity, it shrinks. The shrinkage is compensated in the die
casting process by maintaining high pressure on the metal during solidification. Risers
are provided in permanent moulds and in sand and plaster moulds to feed metal into
the cavity during solidification. The casting must be designed so that it will solidify
progressively from the most massive features toward the in‐gates, allowing molten
metal to feed the features as they solidify. The foundry has latitude to control the
cooling pattern of the casting to some extent by extracting heat more rapidly from
some areas and more slowly from others. It is important to consult with the foundry
as the casting is being designed to ensure a proper solidification pattern.
The design of the high pressure die casting must allow the casting removed from the
die. Features that are parallel to the direction of die opening or pattern removal must
be provided with draft to permit removal.
Features that complicate the mould or die may require additional components; they
should be utilized only when the benefits offset the cost. Additional components
include for example slides and collapsing cores in die‐casting dies.
Designing cast features ‐ 1
CAE DS – High Pressure Die Casting Design
Cast Features
The casting designer should begin by visualizing the mould or die in which the com‐
ponent is cast. The mould or die should be as simple as possible with the parting
surface in one plane. All walls should be of equal thickness and drafts included on all
surfaces that are parallel to die draw or pattern removal. From this starting point, the
designer should systematically:
− Increase or decrease wall thicknesses in various areas, within the limits of the
casting process and alloy, to gain strength or reduce metal content.
− Add reinforcing features such as flanges, gussets and ribs to increase strength
or rigidity.
− Add attaching and locating features, such as holes, bosses and pads.
− Add features that require additional mould or die components to develop fea‐
tures that would otherwise require machining or assembly operations.
− Step the parting surface to develop features that would otherwise require ma‐
chining or assembly operations.
Heavy Masses and Thick Sections
When molten metal solidifies in the die it shrinks, and so liquid metal must be avail‐
able to fill the space created, or a shrinkage cavity will be left. This effect is greatly
increased with thicker sections or local hot spots. The design should aim for uniform
wall thickness throughout the component, avoiding very thick sections, rapid changes
in section and thin sections feeding thicker sections.
Avoiding heavy sections is especially important in die castings which develop
maximum strength when solidification occurs very rapidly. Excessive solidification
time may significantly increase die casting cycle time and also make ejection from
permanent moulds and pressure die‐casting dies difficult.
Transitions between sections of different thickness should be gradual to prevent
distortion and possible cracking as the metal solidifies and cools. Holes in bosses
should be cored rather than cast solid to minimize section thicknesses. Thin sections
with reinforcing ribs of equal thickness or slightly thinner are preferable to thick
sections. Images 1 and 2 illustrate design alternatives for various features to maintain
uniform wall thickness and facilitate casting.
A
B
Image 1. The junctions of the inclined boss and base plate shown at A can be redesigned as
shown at B to achieve nearly uniform wall thickness. With design B, the mould or die structure
is also simpler.
Designing cast features ‐ 2
CAE DS – High Pressure Die Casting Design
A B
One way of reducing heavy sections is to core a cavity in the thickest part. This also
saves material and may speed production. Solidification shrinkage may appear at the
surface as a ʹsinkʹ mark which may be unacceptable on a highly finished component.
Not recommended Recommended
Satisfactory Better
Image 3. Achieving sound castings. Thick sections will solidify last and have excess porosity
inside.
Designing cast features ‐ 3
CAE DS – High Pressure Die Casting Design
Checking Thickness Ratios
As an aid to achieving the required uniformity of section indicated, the following
technique may be found useful: Check the design for changes in section thickness by
comparing the sizes of the spheres which can be fitted into the sections. Do not neglect
the third dimension. If the diameters of the spheres differ by more than 3:1, shrinkage
porosity may occur in the thicker areas. If the diameters of the spheres differ by more
than 6:1, the effect will be severe and casting strength significantly reduced.
Fillets and Corners
External corners of castings are formed in internal corners of the mould or die. Sharp
internal corners of permanent moulds and pressure die casting dies are difficult to
maintain because they are prone to crack due to concentrated stresses. External cor‐
ners should therefore be broken or rounded. Where sharp external corners are
specified on die castings to meet styling requirements, additional maintenance is
required to maintain the die features.
Internal corners of castings are formed by external corners of the mould or die. Sharp
external mould or die features tend to erode or break off as molten metal flows over
them. Sharp internal corners in the casting tend to crack due to thermal or operating
stresses. Internal corners should therefore be relieved with a radius.
Undercuts
Internal undercuts can be formed by gravity casting processes. Loose core pieces are
used in sand‐and plaster‐molding operations. The core pieces are removed from the
casting when it is removed from the mould and reused. Segmented cores can be used
with steel permanent mould operations. In a typical three‐piece core, the centre sec‐
tion is withdrawn first, then the side sections are moved laterally to clear the
undercuts and withdrawn.
Loose core pieces have been used in pressure die casting on a very limited basis. Their
use increases labor and machine cycle time, which significantly increases the cost of
producing the casting. Segmented cores are not used in pressure die casting because
the high pressure that is applied to the molten metal would force it between the core
segments and solder them together. Therefore, internal undercuts are not permissible
in die castings, and should be avoided in permanent mould or sand castings. Image 5
shows four ways of designing to eliminate internal undercuts.
Designing cast features ‐ 4
CAE DS – High Pressure Die Casting Design
External undercuts are usually formed in sand‐and plaster‐molding operations with
loose core pieces. Slides and loose core pieces can be employed in permanent mould
and die casting operations.
Image 6 illustrates a redesign that eliminates an external undercut.
A B
C D
E
Image 5. The housing at A has internal undercuts under the bosses. Design B locates the bosses
outside the housing. Design C uses retractable core members, which break through the bottom
of the casting. Design D eliminates the undercut by extending the boss to the bottom of the
hole. Design E is similar to D on the inside surface but maintains more uniform wall thickness.
A
B
Designing cast features ‐ 5
CAE DS – High Pressure Die Casting Design
Draft Requirements and Casting Precision
Draft is required on surfaces of the casting that are parallel to the direction of die
opening, slide movement, or pattern removal. Adequate draft facilitates ejection of the
casting or removal of the pattern and thereby minimizes foundry costs. Standards for
minimum draft have been adopted by industry organizations in various geographic
areas.
The minimum permissible angle of draft depends on the depth of the feature. How‐
ever, it is unusual to specify the draft for each feature. Draft is usually specified with a
note that covers all features regardless of depth. It is common practice in permanent
mould and pressure die casting to specify external draft at one‐half internal draft. (See
image 7) For instance, if internal drafts are at 1°, external draft is 0.5°.
Image 7. For castings made by permanent mould or high pressure die casting, inside draft
applies to features that shrink onto the die or mould members and external draft applies to
features that shrink away from the die or mould member.
Draft less than industry standard can be specified in some cases to reduce metal
content or eliminate machining operations. When reduced drafts are being consid‐
ered, it is important that the designer work with the foundry to determine the
minimum feasible draft, and identify its effects on the casting. For example, if reduced
draft is specified on a hole in a permanent mould or pressure die casting, ejection
forces near the hole are increased. It may be necessary to increase the structure of the
casting in that area or provide additional ejector pins to develop the required ejection
force without distorting the casting.
Standards for tolerance on surface flatness and feature sizes and locations have been
adopted by industry organizations in various geographic areas. The designer may
specify tolerances closer than industry standard in some cases to eliminate machining
operations. When this is to be done, it is important that the designer work with the
foundry to determine how much reduction is feasible, and the resulting increase in
manufacturing cost.
Reduced tolerances require very close control of casting parameters. The pressure die
casting process includes parameters such as die temperature, molten metal tempera‐
ture, metal injection rate and pressure, and dwell time (time allowed for the casting to
solidify and cool prior to ejection). Similar parameters apply to permanent mould
casting.
Designing cast features ‐ 6
CAE DS – High Pressure Die Casting Design
Very high casting precision can be achieved in die casting by a ʺcut‐and‐tryʺ process.
An initial production run is made, during which the die members that form the criti‐
cal features are deliberately made out of tolerance so that nominal dimensions are
beyond the least material condition (e.g. holes larger than tolerance, bosses smaller
than tolerance). During the initial run, casting parameters are adjusted to bring the
features within the required tolerances. The die is subsequently modified to bring the
dimensions to specified nominal values.
For example, where a hole is to be cast to very close tolerance, the corresponding core
would be made slightly oversize for the initial production run. When the casting
parameters are adjusted, the core diameter would be reduced to the size required to
produce the hole to the specified nominal size. This type of procedure incurs addi‐
tional expense and development time. The cost must be weighed against the cost
savings resulting from the greater precision, such as elimination of finish machining
operations.
Parting Lines and Trimming Operations
Castings are removed from the mould or die attached to metal that solidified in the
runners, risers, sprue, shot cylinder or overflows, depending on the casting process.
The extraneous features are removed from die castings in a trim die, and are usually
sawn off of permanent mould and gravity castings. In either event, there is a slightly
raised line of metal on the casting around the perimeter of the mould or die parting
surface. If assembly or appearance criteria require complete removal, additional work
and expense are required. The additional work can sometimes be reduced or elimi‐
nated by redesigning the casting to locate the parting lines either to a non‐critical
surface or to a feature where it is less noticeable.
Lines also appear at locations where slides interface with other die members. When
flash is generated at these locations, the cost of trim dies and trimming operations are
increased. Similarly increased costs occur when the parting surface is stepped (in
more than one plane) or very irregular.
Image 8 shows how a boss on a cylinder was redesigned to place the parting line in an
area that is more accessible to a trim die.
A B
Excess flash
formation
Image 8. The slide used in the design at A leaves a line on the surface of the cylinder. The
modification at B places the flash where it is accessible to the trim die.
Designing cast features ‐ 7
CAE DS – High Pressure Die Casting Design
Image 9 illustrates a minor design change that simplifies the shape of the parting
surface, reducing the cost of both the trim die and trimming operation.
A
B
Image 9. The scallops in the design at A cause a very irregular trim die. In the design at B, the
scallops are terminated slightly above the base of the knob, requiring a simple circular trim die.
A broken parting plane is very difficult to machine and as a result the die is difficult to
keep closed during the casting cycle. There might be traces of flash on the castings
which are difficult to remove. A simple modification greatly facilitates trimming, and
improves the strength of the component (See image below). Avoid vertical split lines
wherever possible. Example B in the image below achieved this in a part with all the
same design elements as in A.
A B
Not recommended Better, but not optimal
Image 10. Examples of bad and better designs for parting line geometry. Optimal shape
is flat.
Designing cast features ‐ 8
CAE DS – High Pressure Die Casting Design
Design to Assist Die Filling
To produce satisfactory castings, the die must be filled very quickly: 10‐40 millisec‐
onds is typical for castings in the range 50 to 1000g. The higher the standard of surface
finish required, the shorter the fill time must be. Component design should be such
that the molten metal fills the die smoothly and without turbulence to avoid surface
imperfections. Generally the more uniform the wall thickness the easier this is to
achieve.
Not recommended Better
Not recommended Better
Image 11. Obtaining a fast smooth die fill
The design must permit very fast filling without producing turbulence in the metal
flow. Smooth contours and uniform sections assist this. Projections and bosses can be
difficult to fill: buttresses assist flow to such features as well as strengthening the
component.
A long ʹwindowʹ or slot in a component may severely restrict metal flow to part of the
casting. Using a series of round holes may serve to the same purpose whilst assisting
metal flow. (See Image 11.)
Designing cast features ‐ 9
CAE DS – High Pressure Die Casting Design
Designing to Avoid Local Die Overheating
Small protrusions on the die may become overheated. This may lead to defects in the
die casting surface such as surface porosity, drag marks and galling.
A B
Not recommended, Better
sharp internal corners in a casting
will gather heat in the die
A B
Not recommended, Better
very narrow slots between ribs
Image 12. How to avoid hot spots by good component design
Good die design can often help to dissipate the heat developed in vulnerable areas but
the best answer is to design out such features. (A) and (B) provide the same functions
but (B) eliminates right angled corners and so avoids local overheating. Knife edge
projections on the die can cause local overheating and are also vulnerable to mechani‐
cal damage.
Use of Ribs for Strength and Material Economy
Ribs are an excellent way of strengthening a casting without thickening. They should
be rounded and blended and wherever possible arranged to join adjacent sections to
provide mutual strengthening and assist die filling.
Ribs should not be square in section. Blended sections and curved buttresses aid die
filling and give a more uniform stress distribution. This flat plate can be strengthened
and die filling assisted by adding ribs. Shallow, rounded, well distributed ribs are
best, since they are less likely to cause distortion of the casting after ejection from the
die. Avoid thick sections at intersections of ribs or shrinkage porosity may occur at
these points.
Designing cast features ‐ 10
CAE DS – High Pressure Die Casting Design
Not recommended, Better,
flat surfaces and boss, which does not fill ribs aid filling and stiffen the part
properly
Not recommended, Better,
ribs with sharp corners filleted ribs
Not recommended Better
straight ribs round ribs
Image 13. Taking advantage of ribs and buttresses
Designing to Avoid Moving Cores
Complex three‐dimensional shapes are achieved by using moving cores which slide in
the die. However, if the component designer can achieve a satisfactory effect without
these moving cores, the tool will be cheaper and production rates higher.
Some examples of avoiding moving cores are presented in the following images. A
hole can be left ʹopen‐endedʹ (Virhe. Viitteen lähdettä ei löytynyt.) or a hole in a side
of a casting can be produced with two cores from both sides of the mould (Image 15).
The latter can only be achieved where the wall is angled to permit the die halves to
separate, as illustrated in the image below.
Designing cast features ‐ 11
CAE DS – High Pressure Die Casting Design
Requires a moving core Does not require a moving core
Image 14. An open‐ended hole
Designs Using Cored Holes
In many cases, drilling and machining can be completely eliminated by casting accu‐
rately cored holes. Techniques are available for producing small complex shaped
holes without taper. However, to ensure that dies are as strong as possible and require
minimum maintenance in production, some attention to detail is necessary by the
component designer.
Image 16. Some techniques for designing cored holes
Designing cast features ‐ 12
CAE DS – High Pressure Die Casting Design
A blind hole is preferable to a through‐hole, since there can be problems with flash.
Where a through‐hole is required it may be preferable to cast a web at the parting line,
which is removed afterwards with a cutter or during machining.
Where possible, holes should be tapered to assist casting removal from the die. Where
holes are tapered the position of the split line is important, since the overall tolerance
will be affected by both factors.
Blade‐shaped core pins are weak and may easily break in service. Make holes as near
circular as possible and machine details onto a standard round core pin. In the exam‐
ple, the cored hole is required to provide a location on only one of the edges. A
semicircular hole is therefore acceptable and is a better design for tool making.
Surface Finishes
Flat, smooth surfaces are probably the most expensive and least attractive design
feature on a die casting. There are several ways of producing a more attractive ap‐
pearance and reducing the cost of production.
Textures
Some of the many hundreds of surface effects which can be produced by us‐
ing textured dies. As well as enhancing the appearance of the components, the
surface quality is actually improved.
Lettering
Lettering can be used to enhance the surface appearance of the die castings as
well as to convey information. Preferably raise the letters above the surface of
the castings or put them in a depressed panel.
Crowning
Where a plain, highly finished flat surface has to be specified, slight crowning
and rounding of the corners will reduce distortion, aid metal flow and im‐
prove the appearance.
Designing cast features ‐ 13
CAE DS – High Pressure Die Casting Design
Designing Threaded Components
High pressure die casting can produce very fine accurate detail and is therefore capa‐
ble of producing threads on components. The designer must however, ensure that the
casting process is not slowed down and that tooling is kept as simple as possible.
Alternatively, components may be cast with a plain diameter and the threads formed
subsequently.
External threads
Most external threads can be cast provided that they are bisected by the part‐
ing line in the mould main pulling direction or by the parting line in the
moving core pulling direction. Full threads may be cast‐in but these require
the die caster to maintain high standards of tool accuracy. Where the applica‐
tion permits, flats should be incorporated at the parting line so that trimming
is simplified and pitch errors are accommodated.
Internal threads
It is usually cheaper to machine internal threads than to cast them in since the
need to rotate the core to permit extraction slows down the casting rate.
Threads which are either very coarse or steeply pitched are an exception since
they are more easily disengaged. Internal threads consisting of a single turn
can be produced without the need for rotating the core.
A B
C
Image 18. Three different structures for casting external threads. In the structures A and B, the parting line
between mould halves goes through the thread. In the structure C, the thread is divided by the slide parting line.
Designing cast features ‐ 14
CAE DS – High Pressure Die Casting Design
Designs Using Inserts
Inserts may be cast into pressure die castings to increase strength, to provide fixings,
or to provide bearing areas. However, their use increases the component cost since it
slows the production rate and so should be avoided if possible. Inserts should pref‐
erably be driven into the component after the casting operation, since this does not
slow down the casting rate.
Prefer using an insert with a groove or patterned surface. Patterned surface gives
torsional strength to the insert and groove anchors the insert. If properly designed,
inserts provide additional strength and wear resistance. But in the other hand, cast‐in
inserts might weaken the part due to stress buildup.
References
Product design for die casting, Fifth edition, NADCA, USA, 1998
Designing cast features ‐ 15