Pressure diecasting die design: Old approach

Following methods (one or more) were (still being followed) being adopted for
designing and manufacturing of diecasting dies depending upon the complexity of the
part and facilities available for tooling:
 Create a pattern for copy milling – mechanical stylus follows the surface
contours and translates into shape directly on the die steel or electrode.
 Rough milling – with the help of marking & templates keeping 5~10 mm
excess machining allowance using conventional machines.
 Final Milling – with the help of indexing table, rotary table and other traditional
accessories.
 Specific Machining – with profile cutters for machining of different shapes.
 E.D.M. – using conventional electrodes for individual feature, shape and sharp
corner.
 Grinding – conventional grinding to achieve final dimensions and shape.
 Polishing - manual operation to improve the surface finish of the die at final
stage.