System for Computer Aided Cavity Layout Design for Diecasting Dies

Diecasting is one of the forming methods which is used for producing large number of components with good surface finish by injecting cast alloys in a metal mould under high pressure. Design of a diecasting die requires human expertise and is normally performed by trial and error method, which leads to monetary and time loss. Automation at initial die design stage will result in higher productivity besides reducing production lead time. Decision about number of cavities, layout pattern and placement of cavities in diecasting is critical for die design and manufacturing. This paper presents research work related to system for computer aided cavity layout design for diecasting dies. Proposed system consists of three modules namely determination of number of cavities, selection of layout pattern and placement of cavities in the die-base. It enables die designers to generate cavity layout design automatically from CAD (Computer Aided Design) file of the part with little information provided manually. Optimal number of cavities is determined by considering economic, technical, geometrical and time limitations followed by selection of layout pattern. Thereafter, cavities are placed in the die-base. The developed system depends upon database of diecasting machines and materials along with a knowledgebase of die design. This system has been tried on a number of diecasting parts and results have been found to be on the lines of those obtained from industry. Proposed system is more comprehensive than those available presently and is a step forward in the direction of designmanufacturing integration for diecasting.