Lettering Symbols and Ornamentations Produced Through Die Casti

  • Because of this, the designer of many cast parts must add lettering, logos, trademarks, and other forms of identification to the casting. Other castings have date marks to identify the manufacturing date, which allows for easy differentiation between batches.

    Read more: what are the advantages of zinc die casting techniques


    The creation of these characteristics is accomplished in two different ways by the manufacturers. The use of raised letters is the first method, and it's the one that's both the most common and the most cost effective. Additionally, due to the fact that the lettering is embedded into the cavity using this method, they are more durable. The second method involves forming characters that stick out from the die in order to create a depression in the component for the letterings. This method results in an increase in the cost of manufacturing the die, as well as an increase in the susceptibility of the characters to wear and the amount of maintenance that is required.

    Die Casting Designs With Bosses Integrated Into Them
    Bosses are necessary for many different parts because they serve as mounting points and standoffs. When incorporating this feature, the designer needs to exercise extreme caution in order to keep the wall thickness constant. Because of this, the boss will need to have a hole drilled right in the middle of it. Additionally, there must be a draft between the inner and outer surfaces. Molten metal has a difficult time flowing up a tall, narrow boss feature in order to fill it to its maximum level. Because of this, designers of die castings typically include a substantial number of fillets and ribs (also known as gussets) in order to facilitate the flow of molten metal into specific areas and the process of ejecting the finished part from the die.

    Die Castings Can Have a Surface Finish That Is Cast.
    The finished surface of a die cast component will be determined by the finish that is applied to the tooling. Producing high-quality surface casting parts requires a die with a finish that is highly polished. Producing a finish with a matte appearance is made relatively simple by the surface roughness of most tooling. The application of an external surface finish is necessary for certain decorative cast components, in addition to other casting parts and products.

    The North American Die Casting Association (NADCA) categorizes surface finishes into five different classes and provides the following recommendations for each so that designers and manufacturers can plan for as-cast surface finishes from the very beginning of the die design process:

    Class 1 is known as Utility Grade, and it does not have any cosmetic requirements for as-cast finishes. Therefore, it is acceptable for this class to have cold shut, rubs, porosity, lubricant build-up, and other imperfections. The finish for the end-use product can be left "as cast," or the customer can opt for a protective coating like anodize (which is not decorative) or chromate (which is yellow and clear).

    Class 2 is referred to as the Functional Grade, and it permits surface imperfections that can either be removed with spot polishing or covered with heavy paint. The customer has the option of choosing a decorative coating for the final finish, which can range from lacquers and enamels to plating (Al), chemical finish, or polished finish.

    Class 3 is known as Commercial Grade, and it enables the removal of surface imperfections using techniques that have been prearranged with the client. The design may require the installation of structural components in high-stress areas in order to achieve the desired end result. Plating (Zn), electrostatic painting, and transparent paints are three additional available choices.

    Class 4 is the Consumer Grade, and it refers to products that have surface imperfections that are not objectionable. The customer and the die caster can come to an agreement on a plan of action to take in the event that the product is rejected due to surface waviness (flatness), which can be determined by observing how the light is reflected. The designer may choose to use decorative parts for the final product.

    Class 5 is the Superior Grade, and it denotes a finish with a maximum value that is expressed in micro-inches on the part's print. This finish only covers a portion of the part. O-Ring Seats or Gasket areas are the final application for this material.

    Surface categories that apply to as-cast castings do not apply to machined surfaces. On the design drawing, the designer needs to make a note of finished machined surfaces in a separate section. Both the customer and the die caster are required to reach a consensus on the final choice.

    CAD Feature Order
    The National Association of Die Casting Association (NADCA) suggests utilizing the following CAD Feature Order in order to make the development of a die casting design model easier and to reduce the likelihood of feature tree errors occurring:

    Features that make up the base geometry of the model should be placed at the very top of the feature tree. These features include bosses, extrusions, revolves, cuts, shells, lofts, and sweeps. Other features that make up the base geometry of the model include revolves and cuts.

    Cast cored holes are holes that you will cast during the manufacturing process, and zinc die casting is possible (but not guaranteed) that you will tap or machine these holes in the future.

    The placement of the parting lines next in the feature order, including any parting lines that appear in a component after applying the draft. Parting lines are also included in this placement.

    In the next draft, we will implement this feature.

    Fillets: With a few parting lines as an exception, add fillets to all of the geometries.

    Machining: Finally, add any and all machine features that have been suppressed or unsuppressed to the very end of the feature order.

    The creation of as-cast and machined model configurations is made much simpler when the machining features are left until last. This is an effective method for distinguishing between features that can be used as-cast and features that need to be machined. There are times when extremely large fillets, draft, or components that are highly tapered can be included as core geometry features. It is recommended that these design elements be placed at the very top of the feature order tree.