The metal casting process requires precise and durable casting tooling. Metal casting refers to pouring molten metal into the mold, where it cools and turns into the desired shape. The metal casting method can make most shapes, from DIY tools to complex engine parts. Casting tooling is the key to creating such precise and durable products. In this case, Dawang Casting is a world-class manufacturer making all types of metal tools and equipment, engine parts, pumps, mechanical equipment, etc.
Dawang casting regulates three primary types of casting methods in the foundries. Sand casting and investment casting are the most common there. However, we have also worked with die casting and centrifugal castings. Dawang Casting is famous for making complex shapes. Therefore, casting tooling for these metal casting methods is also an important step for us.
Dawang Casting aims to make precise, efficient, and unique metal products. It means we can’t fail even in a harsh environment. In this case, we not only focus on our machinery but also on making the perfect tooling for casting. Considering the importance in mind, we have prepared this article so that our customers can realize how important it is to create ideal tooling from the sketch.
What is casting tooling?
Casting tooling is a casting mold-making process that can be temporary or permanent based on customer design specifications. It is crucial that metal casting is a dangerous process. Even then, Dawang casting believes they can optimize the danger by implementing engineered controlled technology and safety measures. Casting tooling is one of the most critical engineered, controlled technology in metal casting processes.
Sometimes people get confused about casting patterns and casting tooling. In short, casting patterns are temporary or permanent structures that help create molds where the molten metal cools and solidifies. On the other hand, the process of making such molds is known as casting tooling.
Based on the state of different casting molds, there are different types: permanent mold, sand mold, ceramic mold, multi-piece mold, etc. On the other hand, based on the number of parts, there are four different types of molds: one-part molds, two-part molds, multi-part molds, and multi-cavity molds.
Casting tooling for different casting processes
We have already mentioned that casting molds can be permanent or temporary. Usually, the centrifugal metal casting process uses permanent molds. In this case, the molten metal directly makes the shape from the incredibly durable and reusable molds. Dawang Casting is a popular metal casting company that keeps the most extensive permanent casting molds. As a result, our die-casting methods save both manufacturing time and costs. On the other hand, investment casting and sand casting processes use temporary molds due to complex customized designs from the customer. Usually, these casting toolings are used one or two times or at a specific time of application.
The foundry pattern directly creates the mold in the sand casting process, where the molten metal cools and solidifies. On the other hand, the foundry pattern for the investment casting process has a cavity inside. The process injects the wax inside the pit, which later melts and creates the mold. It removes the casting mold and separates the casting component when the investment casting process is complete.
How to select the Casting Tooling Method
When you have finalized the correct metal casting method, it is also crucial to define the type of mold for the development of the component. Most of the time, the casting tooling depends mainly on customer design specifications. However, a few things must be considered before selecting the best foundry tooling technique.
1. Part Design Considerations
Simplified design, along with the part design rules, creates the best outcome. In this case, the design rules according to the appropriate metal casting methods must be considered. However, simplified design requires manual mold-making processes. On the other hand, complex design requires multiple tooling steps to make a multi-part mold based on the complexity of the plans. Besides, intricate design may require modern manufacturing tools such as CNC machines or 3D printers.
2. Production Quantity
Large production volumes require efficient and durable foundry tooling. Due to continuous manufacturing, this casting tooling gradually wears off. Therefore, it is crucial to consider good quality casting tooling. In this case, fabricating time-consuming and costly tools is the appropriate choice for large production. On the other hand, lower production volume may not require such expensive tools; relatively cheaper molds would be suitable. These types of molds are also popular as sacrificial molds or soft molds.
3. Part Finishing and dimensional accuracy
The quality of the final part represents the functionality and performance properties. The best example of this factor would be the quality between investment casting and sand casting. Usually, sand casting creates a rougher surface than investment casting because of the tooling type. In contrast, investment casting ceramic slurry creates a more fine surface finishing than typical investment casting.
Casting tooling wears off due to gradual casting. As a result, used casting tooling changes the dimensional accuracy of the projected metal part. Therefore, dimensional accuracy is a crucial part of the metal casting process.
Dawang Casting ensures some processing control steps, including pre and post-processing inspections. The inspection depends on the metal casting method, casting tooling material, and the number of casting processes done in the tooling.
Foundry Tooling Design and Engineering
An efficient casting tool ensures the quality of the castings. Therefore, making such a casting tool is crucial before any casting method. An efficient casting tooling process starts from a design approach. Most of the time, custom designs come from the customer’s requirements. As a result, they must consider the manufacturing process for the individual plan.
After the design approach, the expert engineers from Dawang Casting focus on the CAD model of the part. Later after the manufacturing process, the CAD model turns into casting patterns. Casting patterns are also known as master models. Finally, these casting patterns help in making respective casting tooling.
CAD Model --> Casting Patterns--> Casting Tooling
While creating the casting tooling, it is essential to ensure the dimensional accuracy of the tooling. Therefore, the casting tooling can fine construction and allow proper function. If there are multiple parts, they should interact properly. Finally, before creating casting tooling, it is essential to save tooling time and manufacturing costs.
Benefits of Casting Patterns in Tooling
Casting patterns are the replica of the final castings. Casting tooling requires casting patterns to make the mold for respective metal casting processes. In this case, perfect casting tooling comes from casting patterns with precise dimensions. “10 Different types of Patterns in casting” describes the fundamentals of casting patterns and their types.
The foundry pattern must be a perfect replica of the customer’s specification. It should be cost-effective and should have less wastage as possible. It would be best to consider the simplest production method possible for your design to get quality and cost-effective patterns.
A simplified casting pattern with a perfect shape and quality finishing is crucial for perfect casting methods free from defects. Since every metal shrinks when it gets cooler, it is necessary to consider this while making the patterns for casting. Many foundry tooling design features, such as fillets and drafts techniques, achieve perfect patterns. Besides, there are other integral parts to consider to get the perfect castings.
Undoubtedly quality pattern-making requires deep knowledge and experience in manufacturing castings. Therefore, Dawang Casting ensures its engineering team got a wealth of knowledge in metal casting to promise the quality of the products.
How much does foundry tooling cost?
foundry tooling cost mostly depends on the customers’ specification requirements. In detail, foundry tooling also depends on the following factors. The simpler the design is, the cheaper the cost will be.
- Casting Method: The casting method is the first and most crucial factor in every casting step. Die casting, and centrifugal casting requires cheaper tooling than sand and investment casting. On the other hand, large production volumes require expensive fabricating tooling.
- Part geometry: Part geometry highly influences the complexity of the design. Simplified casting with no internal shape will cost lower. Detailed geometry with multiple inner shapes will cost relatively higher.
- Material Type: Low-density board or wood is the choice in the DIY casting method. But large production in the foundry where the primary material is steel or cast iron requires the most expensive options.
- Durability: The casting tooling required for how many times to do casting is necessary to consider in cost measurement. Casting impression determines the number of casting processes needed for a specific production volume. In this case, the casting tooling cost is lower for fewer impressions.
- The number of tooling parts: Simplified pattern requires a single or double part mold tooling. As long as the foundry tooling design gets complex, the number of casting tooling parts increases. As a result, the cost of casting tooling also increases.
Casting tooling comes from casting patterns. The patterns are made from the revised CAD model of the original design. However, foundry tooling is also famous as a metal mold chamber. These tooling can be single or multiple parts based on the design’s complexity. In this case, foundry tooling design is tricky due to metal shrinkage properties. Therefore, some factors should be considered while designing the casting tools.
Dawang Casting ensures the quality of the foundry tooling as the perfect casting tool creates the best castings. Therefore, our customers come up with any design, whether complex or simple, and we always promise the best outcome quality. We keep the latest technology for foundry tooling to save both production time and the cost of the castings.