1. Chapter 5 Overview Casting die is the other major component
Casting die has four functions:
Hold molten metal in shape of desired casting
Provide means for molten metal to get into the space where it is held in desired shape
Remove heat from molten metal to solidify it
Provide for removal of the solidified metal

2. Chapter 5 Objectives Identify the four types of casting dies
Identify the three major casting die modules
Identify the purpose of each major die component
Review course objectives.
Tell participants that all testing will be based on the course and chapter level objectives.

3. New Terms Cavity Gate OEM Overflows/lifters
The void or empty space in the die that fills with metal to make the casting
Gate
The smallest restriction in the alloy flow path, located at the edge of the casting
OEM
Acronym for Original Equipment Manufacturer
Overflows/lifters
Small pockets of alloy located around the edge of the casting
Discuss sand, investment, and lost foam casting.
Use gravity to fill the mold. The mold is destroyed to remove the casting. Mold making is as important part as is making the casting.
Metal flow is slow.
Walls are much thicker than in die casting.
Cycle time longer because of inability of mold material to remove heat.
Discuss permanent mold casting.
A cousin to die casting. The mold is reused, not destroyed. The process uses gravity to fill the casting.
Mold is steel with comparatively good thermal conductivity, hence the release agents used in this process are also insulators. This keeps the casting from freezing periodically and prevents filling.
Machines for this process are smaller than machines used to die cast for similar sized castings.
Discuss centrifugal casting.
Frequently made by jewelers. The choice for low volume castings with a small amount of pressure.
The molds are placed around the circumference of a centrifuge. As the centrifuge spins, metal is poured in at the center and centrifugal force distributes the metal to the molds.

4. New Terms cont. Runner Shot Vent Vacuum vent
Die cast alloy distribution system within the casting die
Shot
All the injected material
Vacuum vent
Helps get the air out of the die cavity.
Vent
Path from the die cavity to outside the die
Discuss sand, investment, and lost foam casting.
Use gravity to fill the mold. The mold is destroyed to remove the casting. Mold making is as important part as is making the casting.
Metal flow is slow.
Walls are much thicker than in die casting.
Cycle time longer because of inability of mold material to remove heat.
Discuss permanent mold casting.
A cousin to die casting. The mold is reused, not destroyed. The process uses gravity to fill the casting.
Mold is steel with comparatively good thermal conductivity, hence the release agents used in this process are also insulators. This keeps the casting from freezing periodically and prevents filling.
Machines for this process are smaller than machines used to die cast for similar sized castings.
Discuss centrifugal casting.
Frequently made by jewelers. The choice for low volume castings with a small amount of pressure.
The molds are placed around the circumference of a centrifuge. As the centrifuge spins, metal is poured in at the center and centrifugal force distributes the metal to the molds.

5. Die Ownership
The OEM owns the tooling required to make the die casting
If GM opted to purchase casting from a custom producer, the custom producer would buy casting die from a toolmaker and then sell the die to GM
If GM opted to manufacturer the casting in its own plant, GM would buy the die from a toolmaker directly

6. Types of Dies Single cavity die Multiple cavity die Family die
Produces one casting at a time
Multiple cavity die
Produces more than one casting at a time
Family die
Produces a number of different parts
Unit die
OEM owns the unit die and the custom die caster owns the mold base or unit die holder

7. Unit Die System Advantages Disadvantages Lower tooling costs
Shorter lead times
Potentially lower piece part costs
Disadvantages
Reduced flexibility in part design
Limited size
Possible problem moving tooling from one vendor to another without additional tooling costs

8. Mold base
Steel envelope that is designed to hold all the other die components together
Usually made from a pre-hardened steel such as a P-20 or AISI 4140

9. Stationary half mold base
Acts as container for stationary die cavities
Provides means for attaching stationary die half to machine
Couples injection system to the die
Provides a means for aligning to two die halves
Has several components

10. Stationary Half Mold Base Components
Clamp slots
Guide pins
Pryslots
Mounting/clamp plate

11. Moving half mold base Acts as container for the die cavities
Couples ejection system to the cavities
Provides means for aligning the two die halves
Components include:
Guide bushings

12. Ejector box
Provides a means for mounting moving half mold base to moving machine platen
Supports moving half mold base against machine closing force and force of injection
Couples machine ejector system to die ejector system
Has several components

13. Ejector Box Components
Parallels/rails
Clamp plate
Support pillars

14. Ejector system Inside the ejector box
Provides one of four critical die functions, to ‘provide for removal of the solidified metal’
Has several components

15. Ejector System Components
Ejector pins
Return pins
Ejector plate
Ejector return plate
Guided ejection

16. Die Cavity Cavity blocks Core pins Slides Carrier Wedgelock Cam pin
Cooling lines
Heaters
Casting
Core pin

17. Die Cavity cont.
Several cavity features share same terminology as the die cast shot
Sprue
Runner
Gate
Overflows
Vents

18. Miscellaneous Components
Biscuit block
Sprue bushing
Sprue post
Stop buttons
Quick eject cam and pins

19. Summary Casting die is the other major component
Has four functions
Castings can be manufactured by the OEM or purchased from a custom producer
4 casting die forms: single cavity, multiple cavity, family and unit
A typical die contains 3 modules: stationary mold base, moving mold base and ejector box

20. Summary cont.
Unit dies are not complete dies; have certain advantages and disadvantages for the OEM
There are many components to casting dies
Mold base
Stationary half mold base
Moving half mold base
Ejector box
Ejector system
Die cavities