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Die Casting Design Issues |
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| The casting engineers at
St. Clair Die Casting had stringent quality, cost, and
schedule targets for the heat sink block from the OEM manufacturer.
The heat sink block is a challenge
because it has a significantly heavier section thickness, which is
atypical for die cast aluminum parts. High production yield and
long die life require careful design and engineering.
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The die
casting engineers had three design imperatives
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Performance, Castability, and Cost.
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Critical Design
Issues -- The requirements for performance, manufacturability/castability, and
cost are closely interconnected. Four design issues played a major role in meeting the
three design imperatives for the heat sink block.
Choose
a metal alloy that best meets the performance and
cost requirements.
Optimize the block
design to reduce stress
concentrations in the die and to increase tool
life.
Refine the die
design to reduce production costs and optimize metal flow
in the casting.
Select
a tool steel alloy to give long tool life and keep tooling costs down.
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10 |
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