Die casting guidelines

Tool & Die Design and Manufacturing

Deluxe Industry strictly controls mold material purchase, mold design and mold manufacturing. We have established a complete mold design process and specifications, using advanced design software and mold flow analysis software such as UG, Pro-E, CAD, flow3D. In the mold manufacturing process, we are equipped with a number of professional surveyors, precision measuring instruments, 100% measurement of each part and each process, our mold accuracy can reach 0.001mm.

Mold & mold components material

Our mold and mold components are usually made from tool steel with a Rockwell hardness of 42-53. If you has special request, we also can give optimized solution. Read more about our rapid tooling service.

Die cast metals

  • The main die casting alloys are: zinc, aluminum, magnesium, brass/copper, stainless steel.
  • Zinc alloy: the easiest to be casted; economic small parts; long life tooling.
  • Aluminum alloy: light weight; dimensional stability; good corrosion resistance; and mechanical properties;
  • Magnesium alloy: the easiest metal to process; excellent strength to weight ratio.
  • Copper/Brass: high hardness; high corrosion resistance and mechanical properties; high wear resistance.

Typical die temperatures and life for various cast materials

  Zinc Aluminum Magnesium brass
Maximum die life [number of cycles] 1,000,000 100,000 100,000 10,000
Die temperature [C° (F°)] 218 (425) 288 (550) 260 (500) 500 (950)
Casting temperature [C° (F°)] 400 (760) 660 (1220) 760 (1400) 1090 (2000)

Die and component material and hardness for various cast metals

component     Cast metal
Tin, lead & zinc Aluminum & magnesium Copper & brass
Material Hardness Material Hardness Material Hardness
Cavity inserts     P20 290–330 HB H13 42–48 HRC DIN 1.2367 38–44 HRC
H11 46–50 HRC H11 42–48 HRC H20, H21, H22 44–48 HRC
H13 46–50 HRC        
Cores H13 46–52 HRC H13 44–48 HRC DIN 1.2367 40–46 HRC
    DIN 1.2367 42–48 HRC    
Core pins H13 48–52 HRC DIN 1.2367 37–40 HRC DIN 1.2367 prehard 37–40 HRC
Sprue parts H13 48–52 HRC H13 DIN 1.2367 46–48 HRC 44–46 HRC DIN 1.2367 42–46 HRC
Nozzle 420 40–44 HRC H13 42–48 HRC DIN 1.2367 H13 40–44 HRC 42–48 HRC
Ejector pins H13 46–50 HRC H13 46–50 HRC H13 46–50 HRC
Plunger shot sleeve H13 46–50 HRC H13 DIN 1.2367 42–48 HRC 42–48 HRC DIN 1.2367 H13 42–46 HRC 42–46 HRC
Holder block 4140 prehard ~300 HB 4140 prehard ~300 HB 4140 prehard ~300 HB

Design geometry

There are a number of geometric features to be considered when creating a parametric model of a die casting:

Draft is the amount of slope or taper given to cores or other parts of the die cavity to allow for easy ejection of the casting from the die.Die castings that feature proper draft are easier to remove from the die and result in high-quality surfaces and more precise finished product.

Fillet is the curved juncture of two surfaces that would have otherwise met at a sharp corner or edge. Simply, fillets can be added to a die casting to remove undesirable edges and corners.

Parting line represents the point at which two different sides of a mold come together. The location of the parting line defines which side of the die is the cover and which is the ejector.

Bosses are added to die castings to serve as stand-offs and mounting points for parts that will need to be mounted. For maximum integrity and strength of the die casting, bosses must have universal wall thickness.

Ribs are added to a die casting to provide added support for designs that require maximum strength without increased wall thickness.

Holes and windows require special consideration when die casting because the perimeters of these features will grip to the die steel during solidification.

Pressure Die Casting Tolerances

Deluxe Industry follows NADCA tolerances. What's more, we can review your design and give solution for high precision if necessary.

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