Seven Typical Process of Die Casting Making
Step 1: Product DFM & Mold Design
A systematic product DFM is the first step to make a die casting mold. Whatever how perfect your product design might be, however there is always a necessary to perform a DFM analysis for die casting manufacturing. According to our experience, most of time, we helped clients to refine draft angle, adjust thickness of wall, change features for part removal from mold.
After DFM analysis is completed, we will start mold design immediately. Our sophisticated designers utilize Pro/E, UG, Solidworks, Moldflow, Auto CAD for mould design as common, but our dedicated designers would strive for a best solution to improve product quality and efficiency while not increasing manufacturing cost or reducing cost.
During the mold design process, we will define mold layout, gate type, parting line, overflows, ejection system, and mold base. All of these details would be documented with 3D and 2D drawing.
Step 2: Mold Steel and Other Accessories Purchase
We will out-source mold steel and some other accessories locally once mold design is finalized. And get them full inspected for both dimensional and material properties, which enables to have correct material.
Step 3: CNC Machining
Once we got mold steel, firstly we will drill locating holes and CNC-machine mold core and cavity roughly, which means to remove most of extra material and remains about 0.2mm for EDM or CNC final machining. Normally this process takes about few hours.
Step 4: Heat Treatment
Most of time, we need to get our mold core and cavity steel tempered with HRC 38~45 degree. Especially for aluminum die casting mold, which has to withstand high temperature while the mold works.
Step 5: WireCutting/EDM/Milling/Drilling/
While the CNC rough machining and heat treatment are processing, we are simultaneously doing wire cutting to obtain individual sliders, holes, square lifters.
EDM and milling process are also very common way to produce particular mold features, like windows, holes, groove, pillar, etc. This process take much longer time as it works very slow and precision,
Step 6: Mold Fitting, Assembly, and Trial
When every mold component is ready, we will need to get all of components fitted and assembled together.
If mold assembly is finished, it’s time to get the mold tested to validate if there is any mistake or imperfection.
Step 7: Refine, polish, and Texture
When first molded sample(T0) is ready, we need to review and find out if there is anything to improve. If needed, we will record and follow up the imperfections for next around of mold trail.
If the final casting product meets our specification, it’s time to polish and texture the mold. Then the whole process is signed off.