Design Issues

Circle.gif (3333 bytes)

The die casting design approach -- The casting engineers at Decardy Die Casting were given the challenge of producing the zinc housing, meeting stringent quality, cost, and delivery targets from the OEM producer, Unity Manufacturing.

The die casting engineers had three design imperatives -- performance, castability, and cost.

Critical Design Issues -- The requirements for performance, manufacturability/castability, and cost are closely interconnected. Five design issues played a major role in meeting the three design imperatives for the elbow housing.

Choose a metal alloy that best meets the performance and machinability requirements.
Optimize the die design to produce near-net shape to reduce machining costs.
Refine the gating and overflows to optimize metal flow and produce a pore-free casting.
Design the ejector pins and die cavity to give a high quality surface finish.
Tailor the thermal management process to ensure quality and produce extended die life.