kineticdiecasting.com

One Tough Job!! Making aluminum parts using the die casting process can really be a tough job. Just imagine pouring raw aluminum and zinc materials into casts, melting metal, and a whole lot more. And did I mention that those steps are just the beginning? Die casting requires more than just pouring metals into a die cast mold.

When the die has finally taken on a solid form, it then must be opened and will then be pinned by the ejector. The gate, runners, sprues and flash, which are collectively known as the scrap, must then be separated from the casting. A special trim die that is in a power press or hydraulic press is often used to do this part of the process. Sawing or separating by hand can also be done but are considered as older methods used also in sand casting which will then require case grinding to smooth out the scrap marks. A much easier way, when gates are thin and easily broken, would be to use tumble shots after which separation of gates should be done. The metal used in the whole process will not be entirely utilized as 15% of it will be not put to use due to many different factors. Remelting it though would make the metal recyclable.

Definitely, the whole die casting process takes on a intricate and arduous labor. And although that is the case, people in this industry still prefer to perform die casting as it produces rapid production rates and gives various other benefits to the whole production process. Besides, the fine finished products that this process yields are very much worth all the hard work that die casting requires.

Die casting tooling is also known as die casting dies, die casting molds or insert die. Die casting tooling also comes in different sizes, values, and styles. Die casting tooling comes either with a single cavity or multiple cavities. The cost for die cast tooling varies for trim dies and cavity inserts.

Die casting tooling can be damaged and wear off from erosion if the cavity inserts are soft. It requires expertise and understanding on how to mold tooling for aluminum. Kinetic Die Casting Company makes die cast tooling.

Die casting tooling insert is the cheapest form of die cast tooling. It requires heat treatment to extend its tooling life. The die cast tooling insert can wear away and be easily damaged due to erosion of the molten metal. There are die casting toolmakers that don’t use enough steel. Therefore it results to low potential life of the inserts.

Inserts must be mounted into a holder that allows the aluminum to inject into the insert. A pathway should be provided for the metal to go in. These holders are commonly called as family die, unit die or mold base.

If you can’t get yourself good quality die casting tooling inserts for your aluminum because it is expensive, try to get a prototype. The prototype insert is can also be used to test and create a design. It is somehow less expensive compared to a hardened cavity insert and it takes less time to produce. However, this tool can be damaged easily and since it is not as good as a steel insert, it can’t be modified.

Kinetic Die Casting owns several Die Casting Tooling Mold Bases that we use to produce aluminum die casting parts. These die cast mold bases are convenient for use for customers who own die casting tooling inserts but not a die cast mold base to use in a die casting machine. Some of the moldbases we own are as small as 12″ by 12″ and are as large as 36″ by 36″. Kinetic Die Casting also owns DME unit dies and MUD bases. DME unit dies are available in many sizes. Kinetic Die Casting primarily uses two DME Unit Die sizes:

Kinetic Die Casting will mount “customer owned” die cast tooling inserts into our mold bases so we can produce aluminum die casting parts. We can mount inserts ranging in sizes from 3″ to 20″ and all sizes in between. If a customer contacts us and they own die casting tooling inserts only, we can make parts for them. We have also made die cast tooling inserts for customers that will fit our mold bases. The tooling inserts are many types, like:

Die Casting Tooling is the greatest cost barrier to producing aluminum die cast Custom Metal Parts. The die cast die mold base is a very large percentage of the die cast tool cost. Kinetic Die Casting uses our die casting mold bases to save money for our customers, so they can get the die casting parts they need.

Kinetic Die Casting has Die Casting Tooling Mold Bases

Die casting tooling is used to make the aluminum plates known as Roof Tile Molds. Aluminum Roof Tile Molds or Roof Tile Plates used by roof tile manufactures. Aluminum Roofing Tile Molds are the aluminum molds that Roofing tile Companies use to make the concrete tiles for roofs on homes. They produce several thousand roof tiles a day using an extrusion process with a concrete slurry. Aluminum Roofing Tile Molds for Concrete Roofing Tile Industry also called Roofing Tilemolds, Tile Molds or Rooftile Plates are usually made in aluminum or steel. Aluminum roof tile molds weigh less and usually cost less than steel.

Concrete Roof Tiles
There are many styles of roof tiles for homes. Many times these styles are called flat profile roof tiles, low profile roof tiles and high profile roof tiles. Some are known as Mission Roof tiles, Villa Roof tiles, Slate Roof tiles, Shake Roof tiles, Roman Roof tiles, Double Roman Roof tiles, Estate S-Tile, Espania Roof tiles, Flat Roof tiles or Barrel Roof tiles.

The die casting tooling made to produce the plate used as molds is very elaborate and can be seen on the Kinetic Die Casting Tooling Page.

Tooling for Die Casting is also known as die casting tooling and die casting molds. The tooling for die casting is constructed from steel and is hardened to 40 plus Rockwell. The steel is cut using mill cutters and using an EDM (Electronic Discharge Machining) process. The die casting mold usually takes more than six weeks to create, many times it may take ten or more for larger or more complex die casting molds or tools.

The area of the die cast tooling that creates the form of the part casting (part) is called the die cavity. The die cavity has the inverse shape of the part casting, like a muffin pan. The cavity is usually inside the “cavity insert” a square block of steel that will fit inside a mold base. There are two inserts for each tool, one for the “hot side” and one for the “ejector side”. These inserts are typically the same size in height and width and can vary in depth, depending on the part cavity depth.

The inserts are mounted in a “Die Mold Base” that is much larger than the set of inserts. The hot side of the moldbase has a hole where the molten metal is injected into the die through a cylinder (shot cylinder) pushed with a shot piston. The ejector side of the moldbase has an ejector plate with pins, known as ejector pins, these ejector pins push the completed part casting out of the cavity.

The cost of the die casting tooling is the responsibility of the customer. Sometimes tooling inserts are sold to a customer to save the cost of making die casting tooling. The cost of the moldbase is born by the die casting company.

(die casting terms)