Chapter 4

Core, Cavity and Side-Core Design for a Multi-Cavity

In the die-design process, design of core, cavity and side-core is a non-trivial

task, which requires much attention and time of the die designer. This is because of the

reason that design of core, cavity and side-core should take care of the existing practices

and rules being followed by the industry. Generating CAD models of the core, cavity

and side-core is also a major requirement not only for their computer-aided assembly

with other components of the die but for their manufacturing too. Both the activities of

design and CAD model generation of core, cavity and side-core become even more

complex in case of a multi-cavity die, use of which is very common in the die-casting

industry. In this chapter a system for core, cavity and side-core design for a multi-cavity

die-casting die is presented that takes care of design and CAD model generation of

core, cavity and side-core with minimal user interaction at some of the steps.

The design of core, cavity and side-core is instantiated with the information,

such as cavity design, number of cavities, cavity layout and die-base size, which

information is derived from the system for cavity layout design for a multi-cavity die-

casting die that has been already presented in Chapter 3.

To generate CAD models of the core, cavity and side-core, two approaches,

namely Euler-based approach (EBA) and Boolean-based approach (BBA) are most

commonly used [45]. In EBA, Euler operation is used which is inherently efficient to

generate surfaces of the core, cavity and side-core. However, this method can generate

89
ambiguous results, when two or more than two undercuts overlap [55]. In BBA, the

core, cavity and side-core are generated using Boolean regularized difference operation

(BRDO) between the part model and bounding box. Subsequently, the bounding box is

separated along the parting surface to get CAD models of core and cavity. The system

for core, cavity and side-core design for a multi-cavity die-casting die presented in this

chapter uses BRDO method to generate CAD models of core, cavity and side-core. The

steps of BRDO method are briefly explained in the following paragraphs.

Parting Surface
Bounding Box Part Model

(a) Part model with bounding box (b) Generate parting surface

Core

Cavity

(c) Resultant solid after Boolean operation (d) Generated core and cavity

Fig. 4.1: Instances of the steps to generate core and cavity

90
 Step 1: Bounding box of the part model is generated. The bounding box is a

solid box with usual clearances to accommodate other mechanisms of the die, such as

side-core, and cooling system. A snapshot of the bounding box of a part is shown in

Figure 4.1 (a).

Step 2: The parting surfaces is generated at a suitable location, an instance of

which is shown in Figure 4.1(b).

Step 3: The part model is subtracted from the bounding box using BRDO

method. An instance of subtraction of the part model from the bounding box is shown

in Figure 4.1(c).

Step 4: The bounding box is split into two halves along the parting surface to

generate core and cavity. An instance of splitting of the bounding box is shown in

Figure 4.1(d).

The proposed system for core, cavity and side-core design for a multi-cavity die-

casting die consists of five modules, which are mentioned below. Subsequent sections

of this chapter explain each of the five steps.

i. Parting line selection,

ii. Shut-off surface creation,

iii. Core and cavity generation for a single-cavity,

iv. Side-core design, and

v. Multi-cavity core and cavity generation.

The organization of this chapter is discussed. Section 4.1 presents the parting

line selection module, which helps the user to select parting line interactively using a

part CAD model. Section 4.2 discusses the shut-off surface creation module; a shut-off

91
surface separates an undercut surface from the core or cavity surface in case of a

through feature. Section 4.3 discusses the core and cavity generation for a single-cavity

module. Section 4.4 discusses the side-core design module, which helps to generate

side-core for a single-cavity. Section 4.5 discusses the multi-cavity core and cavity

generation module, which helps to generate CAD models of core, cavity and side-core

for multi-cavity die. Section 4.6 discusses the system implementation and results.

Lastly, section 4.7 discusses conclusions drawn from the research work presented in

this chapter.

4.1 Parting Line Selection

Parting line selection module is used for selection of a parting line for a given

part interactively by using SolidWorks software. The designer needs to select edges of

the parting line one by one on the part model. If selected edges form a closed loop, the

system shows the message parting line created successfully else the message of

wrong loop selection is displayed. A snapshot of the GUI for parting line selection

module is shown in Figure 4.2. The algorithm for selection of parting line is shown in

part 1 of Figure 4.3.

Parting
Line

Fig. 4.2: A snapshot of the GUI for parting line selection module

92
 User interface User

Load solid part model CAD File

Part feature
data

Default parting direction Y/-Y axis

1 Re-select

Select edges to create parting line

Wrong loop selection

Do selected
No
edges form a
closed loop?

Yes

Display created parting line

2
Is through No
undercut > 0?

Re-select Yes

Select inside edges of through undercut

Wrong loop selection

No Do selected
edges form a
closed loop?

Yes

Display created patch surfaces

Create inside and outside shut-off surfaces

93
 X

3
Create a plane at highest point of the parting line

Create rectangular sketch on this plane

Generate parting surface by extruding the parting line

Generate core and cavity by taking parting surfaces as split faces

Is through No
undercut > 0?

Yes

Select a through undercut

Create or select an existing sketch for side-core generation

Extrude the sketch and split bodies

Generate side-core

No If all
undercuts
done?

Yes

5
Orient core-cavity of single-cavity as per selected layout pattern

Create bounding box for complete layout

Split bounding box along the parting surface

Boolean operation to create final core and cavity

Final core-cavity and side-core for a multi-cavity die

Fig. 4.3: Information flow diagram of the system for core, cavity and side-core design
for a multi-cavity die-casting die
94
4.2 Shut-Off Surface Creation

Undercut(s) may be present in some of the die-cast parts. Those regions of the

part, which form the undercut(s) cannot be realized by either core or cavity and need

special tooling, which is known as the side-core. Sometimes, the undercut feature may

be a through hole. This creates a through passage from the undercut region to either the

core or the cavity region. The undercut(s) therefore need to be separated from the

regions to be covered by core and cavity. This is done by creating a surface or a patch at

the interface of the undercut region with core or cavity. This surface creation is done by

using fill surface command, wherein the user is prompted to select inner edges of

undercut feature. The purpose of creating this patch is to facilitate formation of shut-off

surfaces. A shut-off surface is nothing but a surface formed by stitching all the core side

surfaces (core shut-off surface) and cavity side surfaces (cavity shut-off surface) of the

part.

Core shut-off
surface

Part model

Undercut
side
Undercut
side
Cavity shut-
off surface

Fig. 4.4: A snapshot of the GUI of shut-off surface creation module

95
 The Mould Tool which is an application of SolidWorks software is used for the

purpose of creating shut-off surfaces. The algorithm for shut-off surface creation is

shown in part 2 of Figure 4.3. A snapshot of core and cavity shut-off surfaces of a part

model having undercuts on two sides is shown in Figure 4.4.

4.3 Core and Cavity Generation for a Single-Cavity

Core and cavity generation for a single-cavity module is used for generation of

core and cavity for a single-cavity die. The single core and cavity so generated are

utilized in later modules to generate multi-cavity core and cavity. The sequence of steps

followed in this module is as follows:

Create a plane at highest point of the parting line.

Draw a rectangular sketch on this plane, whose size equals maximum

projected dimensions of the die-cast part.

This rectangular sketch is offset by applicable clearances.

Parting surface is created by extruding the parting line beyond this

rectangular sketch.

This rectangular sketch is extruded in bi-direction to create solid box called

bounding box around part model.

The bounding box is divided into core and cavity halves by taking parting

surface as the dividing surface using Tooling Split function of SolidWorks

API. The Tooling Split function subtracts the part model from the bounding

box and also keeps a copy of part model.

Core and cavity shut-off surfaces are used to separate core and cavity halves

to get core, cavity for a single-cavity.

96
 All the steps described above are automated in the developed system and the

user only needs to click a button named core and cavity for single-cavity to generate the

core and cavity blocks. The algorithm pertaining to this module is shown in part 3 of

the Figure 4.3. The output from this module is used as an input to the next module of

the system, namely the side-core design module.

4.4 Side-Core Design

This module of the developed system for core, cavity and side-core design is

used for generating side-core(s) for a single-cavity. The direction of side-core removal

is the same as that selected by the user interactively in the part model. The steps used in

this module are mentioned below.

A plane parallel to the parting direction is created on that side of the die-cast

part where an undercut is present.

The user needs to select the outer edges of the undercut feature and the

undercut withdrawal direction. These selected edges form a closed loop to

form a sketch, which is selected for the next step.

The selected sketch is extruded up to the plane, which was created in the first

step of this module.

To generate side-cores, split feature of SolidWorks is used to create multiple

bodies from a single body.

Figure 4.5 shows a part model having two undercuts. The first undercut is

cylindrical in shape having Plus X withdrawal direction, and the second undercut is

hexagonal shaped having Plus Z withdrawal direction. For the cylindrical shaped

undercut, the generated side-core is shown in Figure 4.5. The procedure followed to

generate side-core for the second undercut is described. The user only needs to select

97
the side-core direction (shown as Plus Z in Figure 4.5) and sketch2 shown on the

part model itself (shown in construction history as well) to generate the side-core.

Generated
Side Core

Z
X

Construction Selected sketch

Fig. 4.5: A snapshot of the GUI of side-core design

4.5 Multi-Cavity Core and Cavity Generation

The multi-cavity core and cavity generation module of the developed system for

core, cavity and side-core design for a multi-cavity die-casting die, which is used to

generate core, cavity and side-core for a multi-cavity die, is discussed in following

paragraphs.

4.5.1 Relationship between single-cavity and multi-cavity

As already discussed in Chapter 1, in a single-cavity die only one part is

produced in a die-casting processing cycle. A multi-cavity die is used to produce a

number of parts in a single die-casting processing cycle. A multi-cavity die has a

98
number of identical impressions, which are generally arranged in a particular layout

pattern. The layout pattern in which the cavities are arranged has already been discussed

in Chapter 3. The identical impressions, also known as cavities are connected with a

gating system, which is used to feed all the cavities. For generating a multi-cavity die,

details of a single-cavity are first figured out, which are then utilized for design of the

multi-cavity in a definite relationship. The relationship between a single-cavity and

multi-cavity is outlined in the following points.

Parting surface, which is the surface that divides the cavity into core and

cavity halves remains the same in a single-cavity as well as in a multi-cavity

die.

The undercut features, which are recognized for a single-cavity, are also

applicable for the multi-cavity.

The individual cavities in a multi-cavity die are placed in the die-base in

such a way that there is sufficient clearance distance between any two

adjacent cavities.

In both single-cavity and multi-cavity dies, the clearance distance between a

cavity and edges of the die-base remain the same.

Same shrinkage rate and draft allowance rules are applicable in both the

single-cavity and multi-cavity dies.

4.5.2 Generation of multi-cavity die

This module of the developed system for core, cavity and side-core design for a

multi-cavity die-casting die provides final output in the form of CAD model of the core

and cavity for a multi-cavity die. The core and cavity CAD models can be directly used

for process planning and manufacturing of the die. The steps followed in this module to

generate multi-cavity core and cavity are mentioned below.

99
 The output of the previous module, core and cavity generation for a single-

cavity is taken as input.

Single core-half and cavity-half are patterned as per previously determined

number of cavities in the selected layout pattern (see Chapter 3).

The complete arrangement of above mentioned core-halves and cavity-halves

is enclosed inside a bounding box with applicable clearances on all six sides

(+/-X, +/-Y, +/-Z direction).

The bounding box is then split along parting surface into two halves.

Boolean operation is performed to subtract all patterned core-halves from

upper half of the bounding box to form a super-core.

Similarly, all cavity-halves are subtracted from lower half of the bounding

box to get a resulting solid.

Subsequently, all the side-cores are also subtracted from the resulting solid to

form a super-cavity. Super-core and super-cavity are the final core and cavity

halves for the multi-cavity die.

One example of multi-cavity core, cavity and side-core is shown in an exploded

view in Figure 4.8.

4.6 System Implementation and Results

An automated system for core, cavity and side-core design for a multi-cavity

die-casting die for die-casting is developed using API of SolidWorks [13] with

Windows XP operating system. An application programming interface (API) is a

particular set of rules and specifications that any CAD system can follow to

communicate with the design of a component. It serves as an interface between

different software programs and facilitates their interaction, similar to the way the user

100
interface facilitates interaction between humans and computers [81]. The system uses

object orientated programming approach used with Microsoft Visual Basic.NET

(VB.NET) language [93].

The geometrical information of the part such as projected area, wall thickness,

longest part depth, number of undercuts and their location is the only information to be

provided by the user. Furthermore, the user has to provide data related to delivery date,

lot size and total production time along-with the part material. Developed system is

tested on a number of parts. To demonstrate the capabilities of the developed system,

results obtained from the system for four die-cast parts are being presented in the

following case studies.

Case study: Part 1

The die-cast part taken in this case study is an example part, which is shown in

Figure 4.6. This part is having the characteristics of: Zinc alloy material, two undercut

features in the selected parting direction and envelope size of 180 mm x 90 mm x 40

mm (Length x Breadth x Height).

Undercut

Undercut

Fig. 4.6: Case study part 1

101
 Die-base

Fig. 4.7: The cavity layout design for case study part 1

Super
Core

Cavities
(4) Side-cores
(8)

Super
Cavity

Fig. 4.8: Multi-cavity core and cavity along-with side-cores for case study part 1

102
 Results generated by the system for core, cavity and side-core design for a

multi-cavity die-casting die for this case study part are presented in Figure 4.7. The

system generated a cavity layout arrangement in which the undercuts were on outer

sides. The number of cavities determined by the system in this case study is four and

the layout pattern is symmetric with central feeding system. Four is the maximum

possible number of cavities when a die-casting part is having undercuts on two sides.

The envelope size for a single cavity in this case is 218 mm x 128 mm x 120 mm,

whereas size of the die base is 519 mm x 519 mm x 120 mm. The die layout generated

in this case study is also satisfying the condition of minimum die-base size

requirements. The standard die-base size selected by the system is 546 mm x 546 mm x

140 mm. CAD models of super-core, super-cavity and side-cores generated by the

system in this case are presented in Figure 4.8 in an exploded view.

Case study: Part 2

The die-cast part taken in this case study is an example part, which is shown in

Figure 4.9. This part is having the characteristics of: ZA alloy material, one undercut

features in the selected parting direction and envelope size of 138.97 mm x 119.26 mm

x 72 mm (Length x Breadth x Height).

Undercut
Side

Fig. 4.9: Case study part 2

103
 Die-base

Fig. 4.10: The cavity layout design for case study part 2

Super
Core

Cavities
(6)

Side-
cores
(12)

Super
Cavity

Fig. 4.11: Multi-cavity core and cavity along-with side-cores for case study part 2

104
 Results generated by the system for core, cavity and side-core design for a

multi-cavity die-casting die for this case study are presented in Figure 4.10. The system

generates a cavity layout arrangement in which the undercuts are lying on outer and

opposite sides. The number of cavities determined by the system in this case study is six

and the selected layout pattern is series with central feeding system. Envelope size for

single cavity in this case is 176.97 mm x 157.26 mm x 152 mm, while size of the die

base is 716.91 mm x 471.52 mm x 152 mm. The die layout generated in this case study

is also satisfying the condition of minimum die-base size requirements. The standard

die-base size selected by the system is 796 mm x 496 mm x 170 mm. The CAD models

of super-core, super-cavity and side-cores generated by the system in this case study are

presented in Figure 4.11 in an exploded view.

Case study: Part 3 (Cylinder Head Cover)

The die-cast part taken in this case study is of an automotive part named

cylinder head cover, which is shown in Figure 4.12. This part is having the

characteristics of: aluminium alloy material, no undercut features in the selected parting

direction and envelope size of 82.8 mm x 65.3 mm x 15 mm (Length x Breadth x

Height).

Fig. 4.12: Cylinder head cover

105
 Fig. 4.13: The cavity layout design for cylinder head cover

Super
Core

Cavities
(4)

Super
Cavity

Fig. 4.14: Multi-cavity core and cavity for cylinder head cover

106
 Results generated by the system for core, cavity and side-core design for a

multi-cavity die-casting die for this case study part are presented in Figure 4.13. The

number of cavities determined by the system in this case study is four and the selected

layout pattern is series with bottom feeding system. The envelope size for a single

cavity in this case is 120.8 mm x 103.3 mm x 95 mm, whereas size of the die base is

490.6 mm x 355.6 mm x 95 mm. The die layout generated in this case study is also

satisfying the condition of minimum die-base size requirements. The standard die-base

size selected by the system is 496 mm x 396 mm x 115 mm. The CAD models of super-

core, and super-cavity generated by the system in this case are presented in Figure 4.14

in an exploded view.

Case study: Part 4 (Clutch Centre)

The die-cast part taken in this case study is of an automotive part named clutch

centre, which is shown in Figure 4.15. This part is having the characteristics of:

aluminium alloy material, no undercut features in the selected parting direction and

envelope size of 67.8 mm x 67.8 mm x 50 mm (Length x Breadth x Height).

Fig. 4.15: Clutch centre

107
 Fig. 4.16: The cavity layout design for clutch centre

Super
Core

Cavities
(5)

Super
Cavity

Fig. 4.17: Multi-cavity core and cavity for clutch centre

multi-cavity die-casting die for this case study part are presented in Figure 4.16. The

number of cavities determined by the system in this case study is five and the selected

layout pattern is half-circular with bottom feeding system. The envelope size for a

single cavity in this case is 105.8 mm x 105.8 mm x 130 mm, whereas size of the die

base is 585.6 mm x 576.7 mm x 130 mm. The die layout generated in this case study is

also satisfying the condition of minimum die-base size requirements. The standard die-

base size selected by the system was 596 mm x 596 mm x 150 mm. CAD models of

super-core and super-cavity generated by the system in this case are presented in Figure

4.17 in an exploded view.

Discussion: The present system depends upon a knowledge-base, which is

developed with the help of available literature and guidelines provided by the industry

experts. Opinions of the industrial experts were taken to verify results. Furthermore,

enough flexibility has been provided in the system that enables the user to alter

suggested decisions interactively, which makes the system quite useful under practical

situations.

4.7 Conclusions

A system for core, cavity and side-core design for a multi-cavity die-casting die

has been presented which can be used for design of a multi-cavity die-casting die. It

uses CAD model of the part (as a SolidWorks part file) along-with user interaction to

generate CAD files of core, cavity and side-cores for a multi-cavity die-casting die in a

semi-automated fashion. The API toolkit of SolidWorks along-with VB.NET

programming is used to develop this system. The proposed system is an effort to

integrate die-casting die-design application into an existing CAD software.

109
 The developed system is able to perform several die-design steps in very less

time with some interaction from the user. The system for core, cavity and side-core

design for a multi-cavity die-casting die generates CAD models of core, cavity and side-

core for a multi-cavity die. Use of databases of alloys, machines, clearances and

standard die-bases, along-with die-casting die-design rules makes this system least

dependent on the die-design expert; the system alongside reduces lead time for

producing a die-cast part. CAD files of different die components, such as core, cavity

and side-core, which are generated by the system, can subsequently be used for their

computer-aided manufacturing. The computer-aided manufacturing of the die

components is however not in the scope of this thesis. The proposed system can

therefore be used as an add-on application of SolidWorks which can be further extended

to other CAD packages like CATIA, Pro/E and NX.

Since SolidWorks is proprietary software, some of the data extraction from CAD

file of the part is not feasible, which was therefore taken as an input from the user. The

identification of undercut features and their location and determination of parting

direction [18-21, 24-27] in an automated manner would increase the level of automation

and make the system more useful.

Following paragraphs summarize some of the major advantages of the

developed system. An overview of the comparison between the developed system and

the existing mould tool applications is provided in Table 4.1.

The developed system works as an add-on application for design of core, cavity

and side-core for multi-cavity die-casting die for an existing CAD software,

which in this case is SolidWorks. Such an application is much desirable by the

110
 die-casting industry since available mould design applications of CAD software

do not provide such functionalities especially suitable for die-casting.

The generation of core, cavity blocks for single-cavity die require a number of

activities to be carried out with manual interaction. The time spent in this

activity usually varies from 15 to 30 minutes, which depends upon the

complexities of the die-cast part. In the developed system, the core and cavity

generation for a single-cavity die is semi-automated and can be completed in 2-3

minutes.

The time taken for generation of side-core usually varies from 15 to 30 minutes

depending upon the number of side-cores requires. This function is also semi-

automated in the developed system, and the time taken to generate a side-core

using the proposed system is around 5 minute, which is a significant saving of

time.

Multi-cavity dies are quite common in the industry, but most of the existing

systems do not provides direct facility to generate their core, cavity and side-

core. A number of activities need to be performed by the designer using his/her

experience to generate CAD model of core, cavity and side-core. The developed

system is capable to generate CAD model of core, cavity and side-cores for

multi-cavity dies in very less time in a semi-automated manner.

111
 Table 4.1: Comparison of developed system for core, cavity and side-core design core, cavity and side-core with an existing mould tool design
application

Developed system for core, cavity and side- How developed system
Modules Existing mould tool design application
core design is better?
Parting line a) Input parting direction a) Parting direction is by default +Y/-Y
No difference
selection b) Select edges to create parting line b) Select edges to create parting line
Shut-off surface a) Select edges to create shut-off a) Select edges to create shut-off
No difference
creation surfaces surfaces
a) Parting surface creation
b) Core and cavity generation using
Core, cavity Reduce human
Tooling Split command of mould Fully automatic
generation for a expertise
tool application, which requires (completed in 2-3 minute)
single-cavity Time saving of 80%
number of inputs from the user
c) Time Taken: 15 ~ 30 Minutes
a) The side-core design requires a
number of activities to be carried a) Side-core creation requires only two
out, such as selection of the side activities to be carried out by the Reduce human
on which the side-core is needed, designer, i.e., selection of the sketch expertise
Side-core design
shape of the side-core, side-core to define side-core shape, and side- Time saving of 60%
withdrawal direction, and length of core withdrawal direction.
side-core b) Time Taken: 5 Minutes
b) Time Taken: 15 ~ 30 Minutes
a) Creation of core and cavity for a
multi-cavity die involves a number Reduce human
Multi-cavity core
of activities to be carried out that Fully automatic expertise
and cavity
requires knowledge and (completed in 2-3 minute) Time saving of 80%
generation
experience of a die-designer.
b) Time Taken: 30 ~ 60 Minutes

112