5-1

Chapter 5 OverviewChapter 5 Overview

Casting die is the other major componentCasting die is the other major component Casting die has four functions:Casting die has four functions:

• Hold molten metal in shape of desired castingHold molten metal in shape of desired casting• Provide means for molten metal to get into the Provide means for molten metal to get into the

space where it is held in desired shapespace where it is held in desired shape• Remove heat from molten metal to solidify itRemove heat from molten metal to solidify it• Provide for removal of the solidified metalProvide for removal of the solidified metal

5-2

Chapter 5 ObjectivesChapter 5 Objectives

Identify the four types of casting diesIdentify the four types of casting dies Identify the three major casting die modulesIdentify the three major casting die modules Identify the purpose of each major die Identify the purpose of each major die

componentcomponent

5-3

New TermsNew Terms

CavityCavity• The void or empty space in the die that fills with metal to make The void or empty space in the die that fills with metal to make

the castingthe casting GateGate

• The smallest restriction in the alloy flow path, located at the The smallest restriction in the alloy flow path, located at the

edge of the castingedge of the casting OEMOEM

• Acronym for Original Equipment ManufacturerAcronym for Original Equipment Manufacturer Overflows/liftersOverflows/lifters

• Small pockets of alloy located around the edge of the castingSmall pockets of alloy located around the edge of the casting

5-4

New Terms New Terms cont.cont.

RunnerRunner• Die cast alloy distribution system within the casting dieDie cast alloy distribution system within the casting die

ShotShot• All the injected materialAll the injected material

Vacuum ventVacuum vent• Helps get the air out of the die cavity.Helps get the air out of the die cavity.

VentVent• Path from the die cavity to outside the diePath from the die cavity to outside the die

5-5

Die OwnershipDie Ownership

The OEM owns the tooling required to make The OEM owns the tooling required to make the die castingthe die casting• If GM opted to purchase casting from a custom If GM opted to purchase casting from a custom

producer, the custom producer would buy producer, the custom producer would buy casting die from a toolmaker and then sell the die casting die from a toolmaker and then sell the die to GM to GM

• If GM opted to manufacturer the casting in its If GM opted to manufacturer the casting in its own plant, GM would buy the die from a own plant, GM would buy the die from a toolmaker directlytoolmaker directly

5-6

Types of DiesTypes of Dies

Single cavity dieSingle cavity die• Produces one Produces one

casting at a timecasting at a time Multiple cavity dieMultiple cavity die

• Produces more than Produces more than one casting at a timeone casting at a time

Family dieFamily die• Produces a number of different partsProduces a number of different parts

Unit dieUnit die• OEM owns the unit die and the custom die caster owns the OEM owns the unit die and the custom die caster owns the

mold base or unit die holdermold base or unit die holder

5-7

Unit Die SystemUnit Die System

AdvantagesAdvantages• Lower tooling costsLower tooling costs• Shorter lead timesShorter lead times• Potentially lower Potentially lower

piece part costspiece part costs DisadvantagesDisadvantages

• Reduced flexibility in part designReduced flexibility in part design• Limited sizeLimited size• Possible problem moving tooling from one vendor to Possible problem moving tooling from one vendor to

another without additional tooling costsanother without additional tooling costs

5-8

Mold baseMold base

Steel envelope that is designed to hold all the other Steel envelope that is designed to hold all the other die components togetherdie components together

Usually made from a pre-hardened steel such as a Usually made from a pre-hardened steel such as a P-20 or AISI 4140P-20 or AISI 4140

5-9

Stationary half mold baseStationary half mold base

Acts as container for stationary die cavitiesActs as container for stationary die cavities Provides means for attaching stationary die Provides means for attaching stationary die

half to machinehalf to machine Couples injection system to the dieCouples injection system to the die Provides a means for aligning to two die Provides a means for aligning to two die

halveshalves Has several componentsHas several components

5-10

Stationary Half MoldStationary Half MoldBase ComponentsBase Components

Clamp slotsClamp slots Guide pinsGuide pins PryslotsPryslots Mounting/clamp plateMounting/clamp plate

5-11

Moving half mold baseMoving half mold base

Acts as container for the die cavitiesActs as container for the die cavities Couples ejection system to the cavitiesCouples ejection system to the cavities Provides means for aligning the two die Provides means for aligning the two die

halveshalves Components include:Components include:

• Guide bushingsGuide bushings

5-12

Ejector boxEjector box

Provides a means for mounting moving half Provides a means for mounting moving half mold base to moving machine platenmold base to moving machine platen

Supports moving half mold base against Supports moving half mold base against machine closing force and force of injection machine closing force and force of injection

Couples machine ejector system to die Couples machine ejector system to die ejector systemejector system

Has several components Has several components

5-13

Ejector Box ComponentsEjector Box Components

Parallels/railsParallels/rails Clamp plateClamp plate Support pillarsSupport pillars

5-14

Ejector systemEjector system

Inside the ejector boxInside the ejector box Provides one of four critical die functions, to Provides one of four critical die functions, to

‘provide for removal of the solidified metal’‘provide for removal of the solidified metal’ Has several componentsHas several components

5-15

Ejector System Ejector System ComponentsComponents

Ejector pinsEjector pins Return pinsReturn pins Ejector plateEjector plate Ejector return plateEjector return plate Guided ejectionGuided ejection

5-16

Die CavityDie Cavity

Cavity blocksCavity blocks Core pinsCore pins SlidesSlides CarrierCarrier WedgelockWedgelock Cam pinCam pin Cooling linesCooling lines HeatersHeaters

Casting

Core pin

5-17

Die Cavity Die Cavity cont.cont.

Several cavity features share same Several cavity features share same terminology as the die cast shotterminology as the die cast shot• SprueSprue• RunnerRunner• GateGate• OverflowsOverflows• VentsVents

5-18

Miscellaneous Miscellaneous ComponentsComponents

Biscuit blockBiscuit block Sprue bushingSprue bushing Sprue postSprue post Stop buttonsStop buttons Quick eject cam and pinsQuick eject cam and pins

5-19

SummarySummary

Casting die is the other major componentCasting die is the other major component• Has four functionsHas four functions

Castings can be manufactured by the OEM or Castings can be manufactured by the OEM or purchased from a custom producerpurchased from a custom producer

4 casting die forms: single cavity, multiple 4 casting die forms: single cavity, multiple cavity, family and unit cavity, family and unit

A typical die contains 3 modules: stationary A typical die contains 3 modules: stationary mold base, moving mold base and ejector box mold base, moving mold base and ejector box

5-20

Summary Summary cont.cont.

Unit dies are not complete dies; have certain Unit dies are not complete dies; have certain advantages and disadvantages for the OEMadvantages and disadvantages for the OEM

There are many components to casting dies There are many components to casting dies • Mold baseMold base• Stationary half mold baseStationary half mold base• Moving half mold baseMoving half mold base• Ejector boxEjector box• Ejector systemEjector system• Die cavitiesDie cavities