We consult our customers in the following two areas:

1. Transfer of casting molds which are currently in operation from Asian countries to Eastern European countries.

Consultants in the area of aluminum casting from SI Castings have experience in operating both new pressure die casting molds and those previously operated by other manufacturers. In the issue of transferring casting molds already available at the customer’s disposal, it is important to compare all the possible costs with the potential benefit from such changes.

Our work will result in a detailed report containing exhaustive information to make a decision on the expediency of transferring of already existing casting molds; for example, from the PRC to countries of Eastern Europe.

2. Control of the design and manufacture of the casting molds.

SI Castings cooperates with professional manufacturers of casting molds, which have wide experience in the production of any complexity and with excellent quality.

Normally, we act as experts for the Customer in the process of casting molds design in order that the tool design will ensure:

  • Maximum lifecycle
  • Minimum number of rejected products
  • Maximum productivity
  • Speed and ease of maintenance
  • Speed and optimum financial costs during repair of the molds

Reference

For different kinds of metal casting are used of different types of casting molds.

They are:

Non-expendable mold casting
– Permanent mold casting
– Die casting
– Semi-solid metal casting
– Centrifugal casting
– Continuous casting

Expendable mold casting

– Sand casting
– Plaster mold casting
– Shell molding
– Investment casting
– Waste molding of plaster
– Evaporative-pattern casting (Lost-foam casting and Full-mold casting)

In the die casting process using casting molds of following design.
Two dies are used in die casting; one is called the “cover die half” and the other the “ejector die half”. The place called the ‘Parting line’ is where they meet. The cover die contains the sprue (for hot-chamber machines) or shot hole (for cold-chamber machines). They allows the molten metal to flow into the dies. This feature matches up with the injector nozzle on the hot-chamber machines or the shot chamber in the cold-chamber machines. The ejector die has the ejector pins and usually the runner. It is the path from the sprue or shot hole to the mold cavity. The cover die is secured to the stationary, or front, platen of the casting machine, while the ejector die is attached to the movable platen. The mold cavity is cut into two cavity inserts, which are separate pieces that can be replaced relatively easily and bolt into the die halves.

The dies of casting molds are designed so that the finished casting product will slide off the cover half of the die and stay in the ejector half as the dies are opened. This assures that the casting will be ejected every cycle by ejector pins which contained in the ejector half to push the casting out of that die half. The ejector pins are driven by an ejector pin plate.

Other die components of casting molds include cores and slides. Cores are components that usually form holes or opening. There are three types of cores: fixed, movable, and loose. Fixed cores are ones that are oriented parallel to the pull direction of the dies (i.e. the direction the dies open), therefore they are fixed, or permanently attached to the die. Movable cores (they are also called ‘Inserts’) are ones that are oriented in any other way than parallel to the pull direction. These cores must be removed from the die cavity after the shot solidifies, but before the dies open, using a separate mechanism. Slides are similar to movable cores, except they are used to form undercut surfaces. Loose cores, also called pick-outs, are used to cast intricate features, such as threaded holes. These loose cores are inserted into the die by hand before each cycle and then ejected with the part at the end of the cycle. The core then must be removed by hand. Other features in the dies include water-cooling passages and vents along the parting lines. These vents are usually wide and thin (approximately 0.13 mm or 0.005 in) so that when the molten metal starts filling them the metal quickly solidifies and minimizes scrap.

Clear description of how to construct the mold is at this link.