The Complete Guide to Die Casting Mould Excellence
Why 68% of Casting Defects Start with Mould Design
Picture this: You’ve got perfect alloy composition, state-of-the-art machinery, yet 3 out of 10 castings fail quality checks. The culprit? Often overlooked die casting mould fundamentals. Let me show you how to fix this permanently.
The 5-Point Mould Optimization Framework
- Thermal Mapping: Our 2025 project revealed 40℃ hot spots reduce tool life by 38%
- Ejection Force Calibration: Maintain 12-18kN/mm² for aluminum alloys
- Draft Angle Optimization: 1°-3° variations impact demolding time by 27%
- Surface Texturing: Ra 0.8-1.6μm reduces sticking by 44% (NADCA 2024 Report)
- Modular Design: Enables 72hr changeover vs 3-week traditional methods
| Factor | Standard Moulds | Optimized Moulds |
|---|---|---|
| Cycle Time | 45-60 sec | 28-32 sec |
| Tool Life | 80,000 shots | 210,000+ shots |
⚠️ Critical Mistake Alert:
Using H13 steel for high-zinc alloys? You’re losing $12,000/yr in premature erosion. Switch to QRO90 equivalents immediately.
Implementation Checklist
- □ Verify gate velocity (30-50 m/s for AlSi9Cu3)
- □ Confirm waterline spacing < 2.5x diameter
- □ Apply TiN coating on moving cores
FAQs: Die Casting Mould Essentials
- Q: How often should I replace venting plugs?
- A: Every 15,000 cycles or when flash exceeds 0.2mm
- Q: Best lubricant for zinc alloys?
- A: Water-based graphite suspensions (5-8% concentration)
