Manufacturing is bigger today than ever before and there is a great deal to know if you are looking more deeply into the processes used these days. For those who are interested in finding out more about die cast tooling, it is easier than you might think. What we want to do here is go over the basics, starting with the definition of the term itself. Then we will go on to see what role the tooling plays in the process, the types of metal used to create it and even the folks who make this part of the manufacturing process so uniquely powerful. Let's get started learning more about how it all works.
What Exactly is the Definition of Die Cast Tooling?
You may have heard it by many names, but die cast tooling is essentially the metal that has a hollow cavity tooled into it that will hold the molten metal shot into it during the die casting process. Both cold chamber and hot chamber machines are out there, but each of them are going to rely on a great die to get the work done. A die is another name for die cast tooling, as are die casting molds, and even insert dies. These all refer to the same die that has been cut with special tools to create the shape of the cavity itself. The shape of that cavity defines the way the finished piece will look once it has cooled within the die.
What Role Does Tooling Play in the Overall Die Casting Process?
Once die cast tooling has been made, it is then put together and usually the two halves of the die will be held together with pins. In addition, huge amounts of pressure will push the die shut before the hot liquid is squirted into the cavity of the die itself. In order for the metal alloy to become liquid, it must be heated to extremely high temperatures. Different alloys respond to those temperatures in different ways, but the bottom line is that once the liquid enters the die's cavities then it must be held there under great pressure for a specific amount of time until the die can be separated to reveal the finished component. As you might imagine, the detailing and accuracy of the tooling will deeply impact how the product not only looks, but also how it functions. Well-designed dies are capable of creating hundreds or even hundreds of thousands of quality parts.
What Kind of Metal is Used for Die Cast Tooling and Why?
This is important to understand because die cast tooling has to be different than the metal which is poured into it since it should not melt during the process. For this reason, steel is generally the preferred type of metal to be used in tooling. Tool steel can be hardened and used for these types of die cast tooling, but you should be aware of the fact that if the casting will be at higher temperature levels then it is wise to consider alloy steels as they will be stronger. Cast iron is simply not an option because the pressure is too great for it to handle without being damaged.
Different Types of Dies in Use Today
Depending on a manufacturer's, or their client's, needs there are a number of different solutions which can be developed that making die casting more efficient and effective. Single cavity components are ideal for small run jobs where high volume is not part of the equation. Multiple cavities can do more faster by having several parts manufactured at one time - this means volume and greater speed of production are both benefits. A unit die can produce different parts at once which works in certain applications, but combination dies can produce several different components at the same time. This last method can work well for parts that have to be assembled. Each of these methods comes with pros and cons you should consider carefully.
Professionals Who Create Die Cast Tooling Serve a Vital Role
There are those who can hand tools and those who use the computer to do tooling. Obviously, the second type is more common today, especially for high precision jobs. These are incredibly valuable people who do a great deal for the companies they serve and they often work on many, many dies throughout their careers.