Customer Requirements
What the customer needed
The customer is a Tier-1 EV supplier producing:EV battery tray systemsElectric drive motor housingsPower electronics housingsLightweight structural castingsAnnual production:
Case Study
Mold & Die Case Study 03 / 15Die Casting Mold Machining Case Study
Die casting is one of the most important manufacturing processes in modern automotive and electric vehicle production.
die casting mold machining case studymold die cnc machiningcnc machine for mold manufacturing
Project Overview
Standard case data fields.
Industry Mold & Die / Automotive / EV
Product Die Casting Mold
Material H13 / SKD61 / Dievar / 1.2344
Process CNC Milling + EDM + Heat Treatment + Grinding
Machine Model HYR VMC1060 / VMC1165
Tolerance +/-0.005 mm
Surface Finish Ra0.4-0.8
Application EV Battery Tray / Motor Housing / Structural Casting
Challenges
Machining difficulty
Die casting molds operate under extreme conditions:High Temperature+High Pressure+Molten Metal Impact+Thermal CyclingBecause it involves high thermal load, erosion, and complex cavity structures.
HYR CNC Solution
Machine configuration
Machine: HYR VMC or gantry CNC system selected according to mold size, steel hardness and accuracy target
Process: Rough machining, stress relief, semi-finishing, EDM support, polishing preparation and inspection
Accuracy Control: Thermal stability, fixture rigidity, finishing allowance control and CMM inspection
Cost Method: Published with existing website assets first to keep implementation cost low
Machining Process
Timeline from raw material to inspection.
01 Material preparation
02 Rough machining
03 Stress relief
04 Finish machining
05 Inspection
Full Case Article
Machining background, difficulty and solution logic.
Quick Facts
Item
Details
Industry Mold & Die / Automotive / EV Product Die Casting Mold Materials H13 / SKD61 / Dievar / 1.2344 Process CNC Milling + EDM + Heat Treatment + Grinding Machine HYR VMC1060 / VMC1165 Tolerance +/-0.005 mm Surface Finish Ra0.4-0.8 Application EV Battery Tray / Motor Housing / Structural Casting
Introduction
Die casting is one of the most important manufacturing processes in modern automotive and electric vehicle production.
It is widely used for producing: EV battery trays Motor housings Inverter housings E-axle structures Structural aluminum frames The die casting mold is the core tool that determines: Casting QualityDimensional AccuracySurface IntegrityProduction Efficiency In the EV industry: Die Casting Mold=Mass Production Foundation
What Is A Die Casting Mold?
A die casting mold is a precision steel tool used to inject molten aluminum or zinc alloy under high pressure into a cavity.
Basic structure: Mold BaseFixed Die (Cavity Side)Moving Die (Core Side)Cooling SystemEjection System Process: Molten AluminumHigh Pressure InjectionRapid CoolingSolidificationDie Cast Part
Customer Background
HYR CNC provided a full die casting mold machining solution.
The customer is a Tier-1 EV supplier producing: EV battery tray systems Electric drive motor housings Power electronics housings Lightweight structural castings Annual production: 50,000+ sets of die casting components Main challenges: High thermal load Extreme wear resistance requirements Large cavity machining Cooling efficiency optimization Tight dimensional control
Why Die Casting Mold Machining Is Extremely Difficult
Die casting molds operate under extreme conditions: High Temperature+High Pressure+Molten Metal Impact+Thermal Cycling
Challenge 1
Extreme Thermal Load During production: 700 degreesC AluminumMold Surface HeatingThermal Fatigue Result: Cracking risk Surface degradation Dimensional drift
Challenge 2
Erosion And Wear High-speed molten metal causes: Surface ErosionCavity WearReduced Mold Life
Challenge 3
This increases machining difficulty significantly.
Large Structural Cavities EV components require: Large battery tray cavities Deep ribs Thin-wall structures
Challenge 4
Cooling Channel Complexity Cooling system must control: Thermal BalanceCycle TimeCasting Quality Cooling channels are: Deep 3D curved High density layout
Cavity (Fixed Side)
Function: Outer Shape Formation Requirements: High wear resistance Mirror surface finish
Core (Moving Side)
Function: Internal Geometry Formation Requires: High precision Structural rigidity
Mold Insert
Function: Replaceable Wear Area Benefit: Maintenance cost reduction Flexible design
Ejection System
Function: Part Release Mechanism Requires: Precision alignment Smooth movement
H13 Steel (Most Common)
Advantages: High HardnessThermal Fatigue ResistanceWear Resistance Applications: EV die casting molds Automotive structural parts
SKD61
Advantages: Good ToughnessHeat Resistance Applications: Medium load die casting molds
Dievar Steel
Advantages: Premium Hot Work SteelLong Mold Life Applications: High-end EV structural casting molds
HYR VMC1060
Best for: Medium die casting molds EV housing molds Advantages: Stability Precision
HYR VMC1165
Best for: Large battery tray molds Structural casting molds Advantages: Large travel Heavy cutting capability
Step 1
Raw Material Preparation Forged tool steel blocks Pre-hardened steel
Step 2
Rough Machining Remove: 70-85% Material Create: Basic cavity Structural framework
Step 3
Stress Relief Treatment Reduce: Internal StressDeformation Risk
Step 4
Semi-Finishing Core shaping Cavity profiling Cooling channel preparation
Step 5
EDM Electrode Machining Used for: Deep ribs Sharp internal corners Complex geometries
Step 6
EDM Die Sinking Final cavity forming High precision detailing
Step 7
Finish Machining Requirement: +/-0.005 mmRa0.4
Step 8
Surface Treatment Nitriding Coating (PVD) Heat treatment
CMM Inspection
Checks: Cavity geometry Core alignment Cooling channel position
Surface Hardness Test
Ensures: Thermal resistance Wear resistance
Surface Finish Test
Requirement: Ra0.4-0.8
Mold Trial
Validates: Casting quality Shrinkage control Dimensional accuracy
Results
Item
After HYR CNC implementation: Before After Machining Time 100% -32% Accuracy +/-0.015 mm +/-0.005 mm Mold Life Baseline +40% Scrap Rate 2.5% 0.3% Cooling Efficiency Standard +25%
Impact On EV Industry
This die casting mold directly supports: EV Battery Tray production Lightweight chassis systems Motor housing manufacturing Inverter structural design
HYR VMC1060
Standard EV die casting molds
HYR VMC1165
Large battery tray molds & structural molds
Related Articles
Injection Mold Machining Case Study Automotive Mold Machining Case Study EV Battery Tray Machining Case Study Motor Housing Machining Case Study Inverter Housing Machining Case Study
What is a die casting mold?
A tool used to produce metal parts by injecting molten aluminum or zinc under high pressure.
Why is die casting mold machining difficult?
Because it involves high thermal load, erosion, and complex cavity structures.
What materials are used?
H13, SKD61, Dievar are most common.
Where is it used?
Mainly in EV and automotive structural components.
What tolerance is required?
Typically: +/-0.005 mm
Conclusion
Die casting molds are the backbone of modern EV and automotive structural manufacturing.
They operate under extreme thermal and mechanical conditions, requiring highly precise CNC machining and robust material selection.
With advanced machining capability and EV industry experience, HYR CNC delivers reliable die casting mold solutions for global automotive manufacturers.
Results
Before and after machining improvement.
| Item | Before | After |
|---|---|---|
| Result 1 | Before optimization | After HYR CNC implementation: |
| Result 2 | Before optimization | Machining Time |
| Result 3 | Before optimization | 100% |
FAQ
Common buyer questions for this case.
What is this mold case about?
This page covers die casting mold requirements, machining difficulty, process planning and machine selection.
Which machines are recommended?
HYR VMC850, VMC1060, VMC1165 and gantry CNC systems are selected according to mold size and machining difficulty.
Can HYR-CNC support similar mold projects?
Yes. Send drawings, mold steel, tolerance, surface finish and mold size for a suitable machining proposal.
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