Dies are designed to maintain the dimensional integrity of the cavity during the casting cycle. Die casting dies deflect during a casting operation. These deflections affect the quality of the casting operation and the part. Control and prevention of die deflections is therefore extremely important to produce high quality castings. To ensure proper ‘control’ changes in the structural design of the die may be necessary.
Prevention of die deflections can be achieved by proper die design before the die is actually manufactured. It is common practice to compensate at the fabrication stage for thermal growth of the cavity in operation. Structural features are added in the die in order to minimize deflection. The deflections in the die could be estimated at the design stage itself, by the use of computer aided analysis tools and incorporate corrective measures to prevent them…