(1) Requirements for the design of castings:

The function of ribs is to enhance the strength and rigidity of the parts after reducing the wall thickness, prevent the casting from shrinking and deforming, and avoid deformation when the workpiece is ejected from the mold. Ribs also serve as auxiliary flow paths (for metal flow). The thickness of the ribs in die-cast parts should be less than the thickness of the wall they are in, generally taken as 2/3 to 3/4 of the wall thickness at that location.

(2) Requirements for the wall thickness in casting design:

The wall thickness of die-cast parts (commonly referred to as wall thickness) is a factor of special significance in the die-casting process. The wall thickness is closely related to the entire process specifications, such as the calculation of filling time, selection of inner gate speed, calculation of solidification time, analysis of mold temperature gradient, the effect of pressure (final pressure), duration of mold retention, ejection temperature of the casting, and operational efficiency.

a. If the wall thickness of the part is too thick, the mechanical properties of the die-cast part will significantly decrease. Thin-walled castings have good density, which relatively increases the strength and pressure resistance of the casting.

b. The wall thickness of the casting cannot be too thin; if it is too thin, it will lead to poor filling of the aluminum liquid, difficulties in forming, poor welding of the aluminum alloy, and the casting surface is prone to defects such as cold laps, which brings difficulties to the die-casting process. As the wall thickness of die-cast parts increases, defects such as internal pores and shrinkage cavities also increase. Therefore, while ensuring that the casting has sufficient strength and rigidity, the wall thickness should be minimized, and the thickness of the cross-section should be kept uniform. To avoid defects such as shrinkage, the thick-walled areas of the casting should be reduced (material reduction) and ribs added. For large-area thick-walled castings like flat plates, ribs should be set to reduce the wall thickness of the casting.

(3) Requirements for the shape and structure of die-cast parts:

a. Eliminate internal side concavities;

b. Avoid or reduce core pulling areas;

c. Avoid core intersections.