Die Casting Design and Spec Guide
Die Casting Design and Spec Guide
Die Casting Design and Spec Guide
CONTENTS
Page
Disclaimer
Every effort has been made to assure the accuracy of the data presented in this Design and
10
10
11
12
12
12
Machined Prototypes
12
13
13
14
Customer-CWM Interaction
14
14
Customer Responsibilities
15
15
15
13
12 Post-Casting Operations
16
16
CWM Sales/Engineers
16
16
SPECIFICATION
ALLOY
INGOT
Dross
and
Fines
END-PRODUCT
MANUFACTURER
Component
Remanufacture
and
Servicing
RECYCLING
Fig. 1
Finished
Die
Castings
Internal
Reclaim
FOR
DIE
CASTER
End of
Product
Life
Final
Assembled
Products
END
USER
NADCA
Precision shut-offs,
part of advanced runner
and overflow design, help
minimize any porosity in
the final cast part .
Al 380
Mg
AZ91D
ANSI/AA:
380.0
MECHANICAL PROPERTIES
Ultimate Tensile
ksi
Thermoplastics
Zn 3
ZA-8
AG-40A
Lexan
Torlon
3413
4203L
27.8
46
34
41
54
19
(320)
(230)
(283)
(372)
(130)
23
23
32
41-43
--
--
(160)
(160)
(221)
(283-296)
Elongation
% in 2 in. (51 mm)
3.5
10
6-10
3-5
15
Hardness
BHN
80
75
82
100-106
--
--
Shear Strength
ksi
28
20
31
40
10.5
18.5
(190)
(140)
(214)
(275)
(72)
1.6
43
24-35
2
(4)
(2.2)
(58)
(32-48)
(100)
20
10
6.9
15
(140)
(70)
(47.6)
(103)
(40)
10.3
(71)
6.5
(45)
12.4
(85.5)
1.25
(8.6)
0.7
(MPa)
Yield Strength
ksi
(MPa)
(MPa)
Impact Strength
ft-lb
(J)
Fatigue Strength
ksi
(MPa)
Youngs Modulus
psi x 106
(GPa)
--
--
PHYSICAL PROPERTIES
Density
lb/in3
(g/cm3)
Melting Range
F
(C)
Specific Heat
BTU/lbF
(J/kgC)
Coefficient of
Thermal Expansion
in./in./F x 10-6
( m/mK)
0.099
0.066
0.24
0.227
0.052
0.050
(2.74)
(1.81)
(6.6)
(6.3)
(1.43)
(1.38)
1000-1100 875-1105
718-728
707-759
--
--
(540-595)
(470-595)
(381-387)
(375-404)
0.230
0.25
0.10
0.104
0.27
--
(963)
(1050)
(419)
(435)
12.2
13.8
15.2
12.9
12.1
17
(22.0)
(25.0)
(27.4)
23.2
(22)
Thermal Conductivity
BTU/ft hr F
55.6
(W/mK)
Electrical
Conductivity
% IACS
41.8
65.3
66.3
150
(96.2)
(72)
(113)
(115)
(0.21)
27
n/a
27.0
27.7
23
--
n/a
n/a
__
--
Electrical Resistivity
in.
n/a
( cm)
35.8
(14.1)
1.77
Nominal Comp:
Cu 3.5
Si 8.5
Al 9.0
Zn 0.7
Mn 0.2
Al 8.4
Al 4.0
Mg 0.035 Mg 0.023
Cu 1.0
With mechanical properties, note die casting alloys 380.0, A380.0, 383.0 and 384.0 are substantially
interchangeable. 0.2% offset 500 kg load, 10mm ball Rotary Bend 5 x 107/10 8 cycles
Notched Charpy. AT 68F (20C) ASTM E 23 unnotched 0.25 in. die cast bar Varies with
stress level; applicable only for short-duration loads. Use 107 as a first approximation. At rupture
Izod notched1/8 (3.2mm) ft.lb. (J/M) ASTM D671, 2.5mm cycles.
Btu-in/h-ft2-F
Miniature
Al 380
Mg AZ91D
Zn No. 3
Zn 2, 3, 5, 7, ZA-8
.75 x .75
to 24 x 24
.75 x .75
to 24 x 24
.75 x .75
to 20 x 20
Minuscule
to 4 x 4 x 1
.5 oz.
to 10 lbs.
.25 oz.
to 10 lbs.
.5 oz.
to 8 lbs.
200-800 tons
80-650 tons
150-500 tons
4-Slide Miniature
Yes
No
No
3X to 5X
Life of Part
Life of Part
1X
Table values are approximations. Part sizes shown, for example, in some cases will
require center gating of a part, not always practical with particular part designs.
CWM guarantees the die casting dies it designs & builds for Zinc 3 die casting and miniature die casting for the life cycle of the product component initially placed in production,
excepting die changes and routine die cavity maintenance required during this life cycle.
critical that the customer discuss such specifications in detail in the earliest review meeting.
Location of the castings parting line, as well as its
gate, overflows and vents, must not interfere with
or blemish any of the parts designated cosmetic
surfaces.
Normal, incremental die erosion in production is
inherent in the die casting process. Where there
are cosmetic requirements, special die maintenance procedures to extend the ability of the die
to continue to produce parts to the required highquality surface finish must be discussed. Secondary surface finishing, such as polishing or buffing,
may be complementary to such needs. (Refer to
As-Cast Finish Guidelines on page 10.)
ciently in their housing designs. Heat sinks produced as either die castings or extrusions have
proven most effective in these applications.
The die casting process offers the product
engineer the added advantage of great flexibility in
housing and heat transfer design. An optimized
heat sink can be incorporated into virtually any die
cast housing design.
Unlike a plastic molded housing and extruded
heat sink combination, EMI/RFI shielding is a
built-in function of a thermally optimized die cast
housing.
All forms of extended surfaces for heat transfer
can be die cast: straight fins, S shapes and
pins. Rectangular fins, easily optimized for width,
length and thickness in a die cast design and
readily cast in place with the majority of housing
designs, are the most commonly used.
As with any special part feature, consultation
with CWM engineering is urged well before final
product designs are agreed upon.
6 Tolerancing Guidelines
The extent to which the coordinate dimensioning
guidelines shown here for precision die casting
tolerances can be achieved in production for a
given die cast part design is highly dependent on
part size and configuration, shrink factors, and the
precise feature in which the dimension is planned.
Caution: The design engineer should understand
that precision dimensions in every feature of a
part are not possible in production. Precision
tolerances should only be specified in agreed
upon critical areas, since assuring these tolerances nearly always involves extra precision in
die construction and/or special controls in processing, with additional costs often involved.
Consultation with CWM engineering in the final
part design stage is important to cost-effective
production and part quality assurance.
Note, in some cases and on specific features,
even closer dimensions than those shown can be
held by repeated sampling and recutting of the
die casting die cavity, in combination with the use
of machine capability studies. Such procedures
will incur added sampling and other costs.
Magnesium
Zinc/ZA-8
WALL THICKNESSES
Nominal wall thicknesses that can be die cast are heavily dependent on part
geometry. With small castings, wall thicknesses of 0.030 in. (.762 mm) may be
attained with an optimized part design and alloy selection.
LINEAR DIMENSION TOLERANCES
0.002
(0.05 mm)
0.002
(0.05 mm)
0.001
(0.025 mm)
0.001
0.001
(0.025 mm) (0.025 mm)
0.002
(0.05 mm)
up to 10 in2
(64.5 cm2)
+0.0035
(+0.089 mm)
+0.003
+0.0035
(+0.089 mm) (+0.076 mm)
11 in2 to 20 in2
(71.0 cm2 to 129.0 cm2)
+0.004
(+0.102 mm)
+0.004
+0.0035
(+0.102 mm) (+0.089 mm)
21 in2 to 50 in2
(135.5 cm2 to 322.6 cm2)
+0.005
(+0.153 mm)
+0.005
+0.004
(+0.153 mm) (+0.102 mm)
+0.008
(+0.203 mm)
+0.008
+0.006
(+0.203 mm) (+0.153 mm)
+0.012
(+0.305 mm)
+0.012
(+0.305 mm)
+0.008
(+0.203 mm)
+0016
(+0.406 mm)
+0016
(+0.406 mm)
+0.012
(+0.305 mm)
For projected area of die casting over 300 in2 (1935.5 cm2), consult CWM.
MOVING DIE COMPONENT TOLERANCESadded to Linear Tolerances
Projected Area of Die Casting: inches2 (cm2)Tolerances are plus values only
up to 10 in2
(64.5 cm2)
+0.006
(+.152 mm)
+0.005
(+.127 mm)
+0.005
(+0.127 mm)
11 in2 to 20 in2
(71.0 cm2 to 129.0 cm2)
+0.010
(+0.254 mm)
+0.007
(+.178 mm)
+0.007
(+0.178 mm)
21 in2 to 50 in2
(135.5 cm2 to 322.6 cm2)
+0.014
(+0.356 mm)
+0.010
+0.010
(+0.254 mm) (+0.254 mm)
+0.018
(+0.457 mm)
+0.014
+0.014
(+0.356 mm) (+0.356 mm)
+0.024
(+0.61 mm)
+0.019
(+0.483 mm)
+0.019
(+0.483 mm)
+0.030
(+0.762 mm)
+0.024
(+0.61 mm)
+0.024
(+0.61 mm)
For projected area of a die casting over 300 in2 (1935.5 cm2), consult CWM.
A growing number of design engineers are utilizing GD&T markup on their part engineering drawings. When used properly, geometric
dimensioning can help reduce the cost of a die
cast part by facilitating functional gaging. Product
engineers not already familiar with GD&T procedures are urged to become so. An introductory
discussion, as applied to die cast part drawings,
appears in NADCA Standards, together with more
detailed GD&T references.
Up to 3.00 in.
(76.20 mm)
0.005
(0.13 mm)
0.005
(0.13 mm)
0.005
(0.13 mm)
Additional tolerance,
in. (mm) for each additional in. (mm)
0.002
(0.05 mm)
0.002
(0.05 mm)
0.002
(0.05 mm)
Values shown represent greater casting accuracy involving extra precision in die construction and/
or special control in production. (2006 NADCA Standards, Sec. 4A) Based on CWM recommendations. For some zinc designs, tighter tolerances can sometimes be held, with use of artificial aging.
Thick Gates
& Overflows
0.12 (3 mm)
Thin Gates
& Overflows
0.12 (3 mm)
Metal
Extension in
Cored Holes
Sharp
Corners
Rough within
0.12" (3.0 mm)
Rough within
0.12" (3.0 mm)
Excess Only
Broken Off
Not
Removed
Not
Removed
Within 0.06"
(1.59 mm)
Within 0.03"
(0.8 mm)
Within .015"
(0.38 mm)
Removed
within .010"
(0.25 mm)
Not
Removed
Extension Remaining
Before Trimming
After Commercial
Trimming*
Extension Remaining
Commercially trimmed does not include washing to remove loose material. For very heavy gates and overflows, consult CWM.
(2006 NADCA Standards, Guidelines G-6-5-2006)
10
Table 5 As-Cast Surface Finish Classifications and Final Finish or End Use
Class
As-Cast Finish
1
Utility
Grade
No cosmetic requirements.
Surface imperfections (flow
marks, rubs, surface porosity,
lubricant build-up, etc.) are
acceptable.
2
Functional
Grade
Decorative Coatings:
Lacquers
Enamels
Plating (Al)
Chemical Finish
Polished finish
3
Commercial
Grade
Structural Parts
(high stress areas)
Plating (Zn)
Electrostatic Painting
Transparent paints
4
Consumer
Grade
No objectionable surface
imperfections. Where surface
waviness (flatness), noted by
light reflection, is a reason for
rejection special agreement
should be reached with the
die caster.
5
Superior
Grade
O-Ring Seats or
Gasket Areas
11
Machined Prototypes
12
12 Post-Casting Operations
CNC Precision Machining
When net-shape die casting is not feasible for a
given part design, post-casting precision machining will be used to achieve final dimensional specifications. CNC machining may also be employed
when the unit machining trade-off is less costly
compared to the investment in particularly complex automated die casting die slide components
to achieve net-shape components.
At the same time, post-casting machining of die
castings is a more complex production process
than machining directly from billet stock. This is
especially the case with high-tech die castings in
general & high-tech Mg die castings in particular.
A higher-level of experience in CNC preplanning
and machining center fixture design are critical to
cost-effective CNC machining of die cast parts.
While state-of-the-art machining centers and
equipment can usually provide the greatest cost
advantages on high-volume post-casting projects,
more conventional machining units and cells may
prove more cost-effective on lower-volume work.
As outlined in section 5 of this guide, die caster
engineer consultation and careful preplanning in
the product design stage is critical to quality postcasting machining results. It is essential that all of
the specific machining requirements to be executed after the part has been die cast must be
made clear before a design goes forward: prior to
any CAD metal flow simulations, prototyping, or
the development of die design drawings.
With a depth of experience in machining Al, Mg and Zn alloys, CWMs in-house precision
CNC machining facility, using advanced high-speed centers, assures highest quality results.
13
Customer-CWM Interaction
Successful collaborative engineering hinges on
the timely and accurate exchange of information
on the part of all persons responsible for the conception, design, development, evaluation, production, quality, sales, delivery, servicing, and
eventual disposal of the final product.
This requires close coordination of functions
within the originating company, and both within
the external supplier-producer organization and
between key representatives of the originating
company and the supplier. All key elements in the
development process should be running in parallel, rather than sequentially, and product requirements and concerns considered and
communicated concurrently by all parties.
quality planning which can be expected to influence the final engineered die cast product.
14
Customer Responsibilities
A tightened production timeline places additional
responsibility on the customer to confirm that all
product and design requirements have been
signed off on by all relevant company departments before die design begins, and that a timely
communications channel is in place between
CWM and the key company team leaders.
15 Contract Manufacturing
With most end products, a die cast part is a component of a larger assembly, precision-mated to
15
CWM Sales-Engineers
As an arm of our engineering and sales departments, CWM sales-engineer representatives are located in major design and production centers in the U.S., and in
Canada & Mexico. They can answer your initial questions, provide copies of CWM
printed literature, arrange for a Design-for-Die Casting Seminar at your company
or your visit to CWMs 136,000 sq. ft. facility. They can be located in the Sales
Engineers section of CWMs Website, or by calling Chicago White Metal.
Visit the CWM CNC Machining and CWM Contract Manufacturing Websites
For a detailed look at CWMs CNC Machining and CWM Contract Manufacturing
capabilities, visit the CNC Machining Technologies and CWM-CM Websites listed
below. To discuss a current or future die casting project, call or e-mail CWM.
Chicago
White Metal
Casting, Inc.
Website:
www.cwmdiecast.com
Website:
www.cnc-technology.com
Website:
www.cwm-contractmfrg.com
16
8313BRev