A die casting die is used to complete the die-casting process on a specialized die-casting machine and is a tool for casting metal pieces. Die casting is a manufacturing technique in which molten metal is poured into a mold and molded into a finished product. The cavity surface of the mold may be moved. The shrinkage cavity and porosity flaws of the blank are eliminated, and the internal structure of the blank reaches the broken grains in the forged state, considerably improving the overall mechanical qualities of the blank, through the cooling process of liquid metal. We’ll go over everything you’ll need to know about creating a die casting mold in this post.
Die-casting components are widely employed in the car sector, particularly in lightweight new energy structural components. Molds and alloys for die-casting can be found in a wide variety of shapes and sizes. With the horizontal cold chamber die-casting machine, we are focusing on the molds employed by metals such as aluminum, magnesium and zinc as the subject of our investigation today. Production of die castings requires the use of a die casting machine and material.
In the process of analyzing and verifying the progress of the project, including 3D confirmation and complete dimension inspection of the internal mold, as well as the blanking of the internal mold and the assembly of the 3D final assembly. There are few molds in the automobile industry that have been replicated, and the majority of molds are custom-made. Because of this, the creation and processing of molds is a lengthy and complicated process, and the capability of different manufacturers and their equipment varies widely. Mold design and production may be broken down into simple processes, allowing you to understand the true cost of a mold. Using positive accounting, for example, it is possible to determine the mold factory’s profit and loss.
It is possible to split the die into a die frame (die base), die core, and common accessories such as a guide post, guide sleeve and so on according to the overall structure of the die-casting die. The mold’s basic components are as follows. Other pieces may be required if the mold’s accuracy requirements are particularly high. Accounting for molds is challenging because of the wide variety of components and the varying costs associated with the various processing procedures; Many factors, such as if vacuum is required; whether there is a slider; or if it has to be utilized in huge die casting machines, need diverse designs for die-casting dies, which can vary greatly in size. As a result of these changes, mold design and processing will be different. A key factor in determining the die’s lifespan is the material used for the die core.
The expense of determining the mold’s composition:
Determine the cost components’ calculation formulas; Determine the source and quality of data;
Assume the preceding steps were followed.
For mold cost accounting, use a standard procedure.
We can easily identify and calculate the cost composition of mold processing if we slowly gather data and meticulously calculate; this is a reasonably simple task if we have the patience and perseverance to do so. Process fee is the most complex and water-heavy portion of mold manufacturing cost. The investment in labor and mold is difficult to identify if you don’t have the relevant experience, but you can learn from the experience of different suppliers, Summarize, to know the approximate cost composition of this type of parts.
Mold making and processing take a commensurate amount of time. We can calculate the typical market price and an estimate of how much water will be saved over time and in the production process. While some occupations require two shifts, others just require one. See if the supplier’s stated processing time is consistent with the time it takes to complete the task. Knowing the supply chain and the cost level of the supplier’s supplier is the only way to determine the supplier’s cost level. As a general rule, a typical mold factory has three profit points: material costs (which include raw materials), processing costs, and management costs.
Costs associated with design, materials, processing, management, and labor; inspection costs; mold trial costs; transportation costs; post-sale charges; and after-sale costs;
The expenses of materials and design are clearly obvious. All other costs, such as manufacturing, commissioning, shipping and verification costs, management fees as well as profits and other expenses, belong in the black box and should be tracked by a mold cost accounting system. Such information as design changes, projections has to be made available to the supply chain. Each of the above-mentioned components is included in the price of a set of two molds. Typically, the mold factory will include the auxiliary costs, around 5% of the mold cost, and the remainder is the mold’s profit.
Cost of design:
To get a more accurate idea of labor costs, it’s important to know what the going rate is in the supplier’s location. CAD structural design and 2D drawing, CAE mold flow analysis, and CAM programming are commonly used in mold design. Mold design costs are often only taken into account when using CAD and CAE.
The cost of the materials is as follows:
Die frame (frame) and die core are the two most expensive components of a die casting die (kernel). The mold base is separated into two categories: self-made and standard. Because the mold base processing equipment needs to travel a longer distance for higher mold tonnages, the majority of mold producers use outsourced mold bases and standard mold bases instead. Soft molds require only a few hundred molds to form. Mold core material can be used as a substitute for mold foundation.
Only the mold base and core cost a significant amount. Consider if the mold base can be reused if its service life is over before opening the duplicate mold; if it can be reused, the cost of copying molds is considerably reduced. Heating and quenching are two major costs for die-casting molds in addition to the costs associated with other heat treatment processes like vacuum quenching or nitrating. According to the size and scope of the provider, the exact pricing will vary. Machine tool, spark machine, wire cutting, and other equipment expenditures as well as labor expenses like mold matching and polishing are all part of the manufacturing process’ total cost of production. According to industry standards, mold processing costs should not exceed 20% of the overall mold cost.
Cost of the inspection:
Inspections are mostly focused on the mold’s critical dimensions, electrodes and core, which account for 1-2 percent of the overall cost of the finished product.
The trial mold’s transportation and packing costs
As a rule of thumb, the mold testing cost for molds smaller than 800 tons is 1-1.5 percent, whereas the cost of mold testing larger than 800 tons is 2 percent. Because magnesium alloy has more stringent standards for material safety performance, the die test costs for aluminum alloy die casting will be lower. However, because magnesium alloy has a higher material unit cost, the die test costs for magnesium alloy die casting will be higher. It’s important to keep in mind that the maximum number of mold experiments should not be greater than three. There must be an issue with their own mold, which necessitates many mold trials, thus the mold factory should bear the expense of these trials. Mold testing will go more smoothly if the equipment’s settings have been thoroughly debugged.
Depending on where clients are located, transportation costs typically range between 0.5 percent and 1.5 percent of distance. Considering that a single mold can only be transported in the trunk of a single car, the cost of shipping is going to be greater.