System for computer-aided cavity layout design for die-casting dies

Die-casting is one of the methods used to produce a large number of components with a good surface finish by injecting cast alloys into a metal mould under high pressure. The design of a die-casting die requires human expertise and is normally performed by trial and error, which leads to monetary and time losses. Automation at the initial die design stage would result in higher productivity and would reduce the production lead time. Decisions regarding the number of cavities, the layout pattern and the placement of cavities in die-casting are critical for die design and manufacturing. This paper presents research work on a system for computer-aided cavity layout design for die-casting dies. The proposed system consists of three modules: (1) determination of number of cavities; (2) selection of layout pattern; and (3) placement of cavities in the die base. It enables die designers to generate a cavity layout design automatically from a computer-aided design (CAD) file of the part with little information provided manually. The optimal number of cavities is determined by considering economic, technical, geometrical and time limitations, followed by the selection of a layout pattern. Thereafter, cavities are placed in the die base. The developed system depends on a database of die-casting machines and materials along with a knowledge base of die design. This system has been tested on a number of die-casting parts and results have been found to be along the lines of those obtained by the industry. The proposed system is more comprehensive than those presently available and is a step in the right direction for design-manufacturing integration for die-casting.