Summaries of Chapters 7

            In this chapter, a systematic approach has been used towards the die casting features which are keen on increasing the costs for the production of parts and for the estimation of while part cost, material costs, processing costs, and even the relative tooling costs. The similarity of the system has been shown in the chapter concerning the injection molding. In order to help in the minimization of costs by producing efficient features, the features that increase the costs are highlighted.

        In chapter 7, the similarity between die casting and injection molding has been discussed. In both of the techniques under pressure, a melt is poured or injected into the mold of metal. Before solidifying, the mold is shrunken and cooled and then mold’s shape is taken. Moving on, the mold opens for the ejection of part. The three most important cost features or elements have been described of the part in die casting. They compromise of processing cost, tooling cost, and material cost. The influencing elements such as material of the part, size, geometry, and part quality requirements have also been discussed. Actually, the applications of coding systems which are previous along with cost models are elaborated for die casting in the chapter.

        Moving on in the chapter, tooling cost has been defined as a die material cost and construction cost’s function in injection molding. When it comes to the die construction cost, it is the function of tolerance, subsidiary complexity, and complexity. The basic complexity, however, depends on the size of part, parting surface location, type and number of present undercuts. It has also been illustrated that internal threads along with internal undercuts normally cannot be die casted. This is basically due to the mix of high velocities of injections, pressure, and temperatures which are needed for die casting. In die casting, all of the tooling is developed with usually the same finish of surface. On the surface of die, the molten metal’s effect is such that surface’s deterioration is so quick that surface finish’s various grades are unwarranted.

        In the chapter, the relative mold material cost along with the total relative has also been discussed. Moving on towards the die-cast part, the relative tooling has been discussed and the results have been elaborated. For the reduction in costs, the decrease in cavity detail is needed. In the chapter, the surface finish and the produced smoothness are discussed along with the categorization of as-cast requirements of the surface finish. Paint grade, mechanical grade, and high grade are the ones in the categories. For the reduction of relative cycle time, there are several ways discussed. However, the best one concerns the removal of cast-in inserts. Finally, a rise in the savings is examined which is due to the reduction of relative cycle time. Therefore, savings increase with the production volume.