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- Installation and debugging of die... | cameldie.com
Installation and debugging of die casting mold 4.7.1 Mold installation 1.Preparation before installation (1) Familiar with process documents 1) According to the product drawing and mold assembly drawing, understand the mold structure and working characteristics, understand the mold ejection method, core pulling method and fixing method. 2) Understand the relevant process documents and the main technical parameters of related die-casting. (2) Check the mold and installation conditions 1) Understand the structural characteristics of the mold to be installed. 2) Check the mold: ① Check the sign to understand the basic information. Check the overall dimensions of the mold, whether the length and width can be installed on the selected die-casting machine, whether it is within the distance of the tie rod, if there is a hydraulic cylinder, check whether it can be directly installed, if not, you need to determine whether it can be connected to the mold after installation On the mold; ②Check the total height of the mold, the total height should be greater than the minimum opening of the machine, and the total height of the mold + the mold opening stroke should be less than the maximum opening of the machine; ③Check the mold opening stroke, whether there is enough distance after the mold is opened Eject and remove the casting. Minimum stroke: the maximum height of the protruding part of the movable mold + the maximum height of the casting + the reserved margin 3~5m; ④Check whether the size and position of the mold fixing holes, lifting holes and slots are appropriate; ⑤Check whether the installation position of the mold cooling water pipe interferes; ⑥Check whether the top (pull) rod position corresponds to the machine, and whether the pull position has tooth patterns; ⑦Check whether the sprue sleeve and the machine nozzle size and matching method are appropriate; horizontal machine The inner diameter and height of the sprue sleeve are the same as the basic size of the nozzle; the vertical and hot chamber machinesThe mold inlet hole is generally 0.5~1.0mm larger than the machine nozzle; ⑧ check whether the movable parts of the mold are flexible; ⑨If necessary, open the mold to check the mold cavity, clean the mold installation joint surface must be wiped clean, there must be no oil and debris; the edge of the spray liquid should be removed, ready for installation. (3) Turn on and check the die casting machine 1) Whether the work is normal, each mechanism is in good condition, the movement is stable, and the ejector rod is reset. 2) Adjust the movable and fixed template to the proper position, clean the installation surface, and remove oil and debris. (4) Check the lifting equipmentCheck whether the hoisting equipment is normal, safe and reliable.Prepare the relevant tools for installing the mold, such as wrenches, pressure plates, bolts, hooks (rings), afterburners, cooling water pipes (5) Preparation toolsPrepare the relevant tools for installing the mold, such as wrenches, pressure plates, bolts, hooks (rings), afterburners, cooling water pipe joints, tie rods, etc. 2. Install the mold According to the size and weight of the mold, it can be divided into small molds, medium molds, (super) large molds, and mold installation steps are roughly the same, but there are some differences. Small molds can generally be moved and installed directly, which is very easy. Medium and large molds must be installed by special hoisting equipment. The difference is that large molds generally use splitHoisting, that is, moving and fixed molds are installed separately. The following are the basic steps of mold installation: (1) For hoisting, use a crane or other special lifting tools to hoist the mold between the movable and fixed template of the machine tool. First, the plane of the fixed mold and the fixed template of the machine tool should be close. (2) Properly adjust the position of the hoisting equipment so that the press chamber or nozzle of the machine tool is inserted into the hole of the mold sprue, and the positioning is done. (3) Start the machine, make the movable mold of the machine tool approach slowly, and stop when the mold is 3~5mm closed. (4) Confirm that the mold is positioned accurately, click to close the mold, close it slowly, check it carefully, and close it slowly. (5) Turn off the machine, install the pressure plate (note that the pressure plate should be flattened), lock the movable and fixed molds on the movable and fixed template of the machine respectively, and tighten the bolts. (6) Fasten the movable and fixed molds with afterburners, and they shall not be loosened. (7) Install auxiliary systems, such as cooling water pipes, hydraulic oil pipes, tie rods, etc. (8) Complete the installation, clean up and put away the tools. 3 matters needing attention (1) The fixed mold should be installed before the large mold is installed, but the fixing device cannot be tightened when the fixed mold does not fall off. You must wait for the fixed mold to be installed and closed before tightening together. (2) When installing the mold, pay attention to safety, and the operator cannot be directly under the lifting mold. (3) When the mold is installed, there are 2 people andWork together to ensure safety, and then act in unison. 4.7.2 Mold debugging After the mold is installed, relevant inspections need to be done before the mold can be opened and debugged. Be careful during the debugging process. The machine action should not be too large at a time, otherwise the mold will be easily damaged when there is an abnormality, especially if there is a core pulling device and a reset mechanism. Mold. (1) Adjust the clamping force according to the process regulations and the machine manual. (2) Select a reasonable machine action program according to the process requirements (3) If you need to pull the core first and then open the mold, check the hydraulic core pulling system, whether the oil circuit is unobstructed, whether the core pulling action is smooth, and whether the core pulling position sensor works normally (for the later core pulling, you can check after opening the mold). (4) Check the overall installation and tightening status of the mold. (5) Open the mold slowly, and stop immediately if there is any abnormality (to avoid mold damage, you can click to open the mold). (6) Adjust the ejection device of the machine tool after the movable template is in place and stop to ensure that the ejection distance is reasonable. (7) If there is no abnormality, open and close the mold slowly several times. During the process, pay attention to observe whether the movement of the machine tool and the mold is stable and there is no abnormality. (8) After determining the reliability, add lubricating oil to the movable part, and then open and close the mold to check to ensure that it is working properly.
- Die Casting Mold For Magnesium Alloy | cameldie.com
HPDC - Magnesium Alloy Die Casting Molds Magnesium Alloy is the lightest commonly used structural metal. Its use in die cast parts has grown dramatically, often replacing plastic parts with greater strength and rigidity at no weight penalty. Mg alloy AZ91D is the most widely-used magnesium die casting alloy, offering high purity with excellent corrosion resistance, excellent strength, and excellent castability. Corrosion resistance in AZ91D is achieved by enforcing strict limits on metallic impurities. Magnesium’s high cost limits it to weight-sensitive applications in the aerospace and automotive industries. Commonly used magnesium die casting alloys metals grades: AZ91D, AZ31B, AZ40, AZ41, AM60B, AM50A, etc. The Main Physical Of Magnesium Alloys As Below: ●AZ91D belongs to the category of cast magnesium alloy, which has a low affinity with iron, less mold sticking, and has a longer mold life than aluminum alloy. Magnesium alloy is the lightest metal among practical metals, with high strength and high rigidity. It is mostly used in lightweight parts such as automobile instrument panel frame, wiper bracket, bicycle wheel hub, steering wheel frame, etc. Magnesium alloy die castings are mainly processed by die casting assisted by subsequent processing, and the appearance can be changed by surface methods such as electrophoresis. ●AZ31B magnesium alloy is a wrought magnesium alloy with good mechanical properties and is mainly used for automobile parts, machine parts, and communication equipment. ●AZ40 magnesium alloy product use: engine gear casing, oil pump and oil pipe, instrument panel, gearbox body, crankcase, engine front cover, cylinder head, air conditioner casing, etc. ●AZ41 magnesium alloy has high strength and hardness, electrical and thermal conductivity, good wear resistance, and wear resistance. After aging treatment, the hardness, strength, electrical conductivity, and thermal conductivity are significantly improved, and it is easy to weld. ● AM60B has high elongation and impact resistance. Steering wheels and seats on cars, etc. ●AM50A has high elongation and impact resistance. Steering wheels and seats on cars, etc. Magnesium alloy die casting die life depends upon the part/tool design, as well as the Tool steels used. Commonly mold steels are used: H-13, H-13, ESR, Assab 8407, Bohler W302, and Assab 8418. etc. CAMEL is a professional high-pressure die-casting molds (HPDC) manufacturer in China, The main products include aluminum alloy die-casting molds, zinc alloy die-casting molds, and magnesium alloy die-casting molds. From tools design & build to die casting parts pre & mass production. The main industries we support are Automotive Industry, Motorcycle Industry, Aerospace Industry, Office furniture Industry, Lock Industry, Electrical Industry, Lighting Industry, Casino Industry, Home Appliances Industry, Machinery Industry, Communications Industry, and Others. Capabilities: Currently, We occupy 54,000 square feet with a workshop plant located at Huizhou City, And another plant 49,000 square feet workshop plant located at Dongguan City, China. Quantities of Major Machines: 15 sets of CNC Machining Centers 5 sets of EDM Machining 2 sets of Wire cutting 2 sets of CMM 2 sets of Projector 2 sets of Spot Machine Take care of all projects according to the mold projects management system. DFM ( 2 days) Moldflow Analysis (24 Hours) Mold Design (2-3 days) Weekly Tooling Schedule Mold Trial Mold Shipment Die Casting Molds We Build: Trimming Die High-Pressure Zinc alloy die casting mold High-Pressure Aluminum alloy die casting mold High-Pressure Magnesium alloy die casting mold Free Quote & Part Analysis → contact
- What is Die Casting Mold | Mold Design and Production | cameldie.com
What is Die Casting Mold? Die Casting Mold Definition Die casting mold is composed of two parts, which are separated according to the draft angle of the product. The molten metal is injected from the stationary end, and the die casting part is solidified by cooling. The die casting part will stay on the moving side, and the moving side will pass through the thimble Eject the die casting, spray lubricant on the mold after the die casting is taken out. If you want to learn about the glossary of die casting mold, please see here. In the early stage of the mold, it is necessary to confirm the mold flow analysis and product analysis report, and start simple mold design until the product drawing is approved by the customer; analyze the die-casting material, shape, structure, and size of the product parts from the perspective of die casting processing performance accuracy. High-pressure Die Casting(HPDC) HPDC is poured metal material in the molten state into the pressure chamber of the die casting machine, filled in the cavity of the die casting mold at a very high speed under the moving of high pressure, and the molten alloy material is cooled and solidified under high pressure to cast the high-efficiency precision casting method. Also die casting mold is a tool for casting metal parts, a tool for completing the die casting process on a dedicated die-casting machine. Need to use a cold chamber die casting machine or a hot chamber die casting machine. The usual pressure for die casting is from several MPa to several tens of MPa, and the initial filling speed is in the range of (0.5~70) m/s. Therefore, high pressure and high speed are important features of die casting. The Process Analysis Of General Parts Drawing Should Pay Attention To The Following Points: The material meets the customer's performance requirements Dimensional accuracy Easy to fill Wall thickness, wall connections, ribs, and fillets Parting, die direction and draft angle Slide block and mold core cross, undercut, etc Ejection direction, push rod position Patterns, text, and symbols Other special quality requirements Design Manual Of Die Casting Mold: Biscuit must ensure sufficient fluidity Consider the existing processing range of machinery and equipment CNC, mold saving, EDM processing convenience Emission of gas in the mold Try to consider the post-processing technology Pay attention to the strength of the mold base and insert mold, Design necessary mold temperature device to facilitate performance adjustment during production The balance of the mold when lifting, easy to transport Die Casting Mold Is The Key Process Tool For Casting Production Whether production can proceed smoothly and the quality of castings can be guaranteed depending on the reasonable mold structure. And the design of the die casting mold is essentially a comprehensive reflection of various factors that may appear in the production process. So it is necessary to analyze the casting structure in the design process, be familiar with the operation process, understand the possibility of the implementation of the process parameters, master the filling conditions in different situations, and consider the impact on the economic effect. Reasonable, practical, and able to meet the production requirements of die casting tools. The Important Factor Of Die Casting Mold In The Production Process Determine the accurate shape and casting part size Determine gate system and the filling condition of the molten metal Determine overflow system affects the filling conditions of molten metal The strength of the mold limited the maximum injection pressure Control and adjust the heat balance of the die-casting process The quality of castings when they are taken out The mold casting surface not only affects the quality of the casting and affects the coating spraying Die Casting Mold Manufacturing Process CNC, heat treatment, internal stress removal, deep hole drilling, EDM, slow wire walking, grinding machine processing, drilling machine processing, electrode processing, mold matching, lathe, mold saving, nitriding, coating. Die Casting Mold Base Runner and overflow Die Casting Dies Structure, More Details : 1. Molding System The casting shape is molding after the die casting cavity and the moving core are closed. The molding system includes core, cavity, sliders, inserts, and inserts pins. 2. Mold Base System The mold base included various steel plates, frames, and other structural parts. The function is to combine and fix the various parts of the mold and enable the mold to be installed on the die casting machine. 3. Ejection System Ejector function to eject the casting parts from the mold, including ejection and returned parts, and the guiding parts. Used same material as forming parts to make the ejector pins and easily damaged parts. 4. Runner System It is connected with the molding part and the pressure chamber to guide the metal material into cavities in a certain direction. It directly affects the speed and pressure of the molten metal molding part. It is composed of a sprue, a runner, an inner gate, etc. 5. Overflow System The overflow system is a channel to remove the air from the pressure chamber. and generally includes venting slots and overflow slots. Sometimes, In order to improve the venting conditions, installed vent plugs in deep cavities. 6. Other There are other components such as bolts and pins for fastening and positioning parts for positioning in the mold. Free Quote & Part Analysis → General Steel Materials For Die Casting Molds: The selection of die casting molds mainly depends on the temperature and type of the cast metal. How to choose suitable mold steel to increase the mold life of die casting molds, especially high melting point metals. 1. Aluminum alloy die casting mold The temperature of the aluminum alloy melt is usually around 1202~1292℉. The mold life of aluminum alloy die casting molds should be focused on whether mold sticking and early dry cracking of the mold cavity occur. At present, General used aluminum alloy die casting mold steels included: 4Cr5MoSiV1 (H13), 4Cr5MoSiV (H11), 3Cr2W8V, and new steel grades Y10 and HM3. 2. Zinc alloy die casting mold The melting point of zinc alloy is 752~806℉, and the surface temperature of the zinc alloy die-casting mold cavity will not exceed 400°C. The materials generally used to manufacture zinc alloy die-casting molds are alloy structural steels 40Cr, 30CrMnSi, 40CrMo, etc., alloy mold steels 5CrNiMo, 5CrMnMo, 4Cr5MoSiV, 4Cr5MoSiV1, 3Cr2W8V, CrWMn, etc. 3. Magnesium alloy die casting mold The melting point of magnesium alloy is 1202℉. Die-casting has a good molding feature. The tensile strength of magnesium alloy castings is equivalent to that of aluminum alloy castings, generally up to 250Mpa, up to more than 600Mpa. The most commonly used is H13 steel or materials with similar properties. After machining, the cavity part is quenched and annealed to make the hardness within the range of 46-48HRC. Only the cavity part and special parts of the mold need to use H13 steel, and these parts generally account for 20-30% of the weight of the entire mold. The other parts of the mold are made of low-carbon steel and medium-carbon steel. For smaller die cast parts with relatively simple geometric switches, molds of standardized modules are often used. Compared with aluminum alloy, magnesium alloy has lower hot melt, and its iron content is also very low. Therefore, the mold has a longer life. How To Maintain A Die Casting Mold During The Non-working Period After the tool is running for a period of time and before storage, check the important dimensions and the mold components may damage that need to be repaired or replaced. After confirming all tool components are no damaged, they must be cleaned up completely. Check whether there is residual material in the cavity, whether the material runner is clean, and whether the parting surface of the mold, top block, and sliding block working surface are strained. The surface of the cavity should be carefully inspected. If there is rust or water rust, it should be polished again. After the cavity is cleaned, to prevent rust, apply anti-rust oil. Before the mold is placed in the storage place, remove the residual cooling water in the mold and the residual oil in the oil pipe, and then use the locking plate to fix the moving plate and the fixed mold to prevent it open. Mold storage is required to be in a flat, dry, clean place that is convenient for lifting and handling. The storage should be classified, and similar molds should be placed together. contact us
- Our Advantage | cameldie.com
IN THE DIE CASTING PROCESS, IT IS THE DIE THAT IS KEY FOR PRODUCTIVITY AND PART QUALITY We focus on die casting dies design and build, and we have accrued more than 11 years of experience exporting die casting die (100% exporting ), customers can enjoy the high quality of service, responsiveness, and flexibility from CAMEL . We aim to create a long-term partnership that will be based on competence, reliability, and engagement with customers. At the customer’s request, We can assist in any segment of the development process: from castability optimization of the desired castings, through die design and building, to prototyping and sampling. Our valuable experience and commitment to quality ensure our customers will create a quality product at a competitive price. 1. The optimized runner design and heat energy control prove to be essential factors for achieving the highest productivity and part quality. The die has the biggest impact on the casting driven successful or not. Precision and dimensional accuracy are not the only ones needed to efficiently produce high-quality castings. The optimized runner design and heat energy control prove to be essential factors for achieving the highest productivity and part quality. Our job is to develop and build dies that support best-in-class cycle-time, part quality, and die-life. Fixed Side Movable Side 2. To get the optimized runner system, we always do the flow simulation base on the calculation of energy inputs and outputs as a basis for an optimal cooling design and optimize the runner layout to get the best one for each dies. Benefit: Most die casting dies could be sampled successfully in one time to export the dies in a short time. The customer can do die-casting with optimal cycle time from the beginning. The casting quality and die life can be guaranteed with no compromise. Free Quote & Part Analysis → 3. In casting production, the problems with the die are often the leading cause of production stoppages. Improving factory utilization usually offers the most potential benefit. In casting production, the problems with the die are often the leading cause of production stoppages. We have considered these potential issues and solves them by mold design in advance to minimize downtime. Quick to change insert on the die-casting machine directly. (<10 min from shot to shot are possible). Do tempering before the mold trial to guarantee the die-life. Do PVD coating for the deep feature areas and easy flush areas. PVD Coating Treatment Optimized Design 4. We have standardized the trial processes to guarantee mold life. The Irregular mold trial process could put the operators in a high-risk situation also shortens the mold life heavily. 1) Use spotting blue to confirm the parting line whether is in good sealing property, avoid no materials fly out to hurt the operator. 2) Use infrared thermography to confirm if the mold temperature is good enough to start the trial, avoid the risk of mold crack from sampling in Unsuitable temperatures. Spotting Blue 5. Even once reasonably well-functioning production has been established, improvements in quality can be used to minimize waste and rework rates. We analyze the potential and actual casting defects and develop a solution suggestion for customers, we perform very precise and detailed simulations for this purpose. Exact design and placement of squeeze pins where required, jet cooling, additive manufactured contour parts and partial insert, vacuum support. 6. We are a professional technical team and IT team to continuously improve the capability study of our processes. We have passed ISO TS 16949 and ISO 9001. All of our working processes are integrated into an autonomous ERP system, all of our die castings dies can be guaranteed to complete on time, we are a professional technical team and IT team to continuously improve the capability study of our processes. Jet Cooling Design ISO 9001:2015 CAMEL Autonomous ERP System Our success is based on highly qualified and trained employees. Systematic development of skills helped us in building a strong, experienced, and innovative team. Continuous improvement of our knowledge ensures sustainable success. Preliminary Version Optimizing Version Fixed Side Movable Side
- 9 Steps Of Die Casting Die(HPDC Mold) Design II | cameldie.com
Steps Of Die Casting Die(HPDC Mold) Design II Die casting mold design, We often said as design of die casting dies or die casting die design. Also, Which be called die casting mould design in some countries. The basic die casting die design steps are summarized as follows: 1. Understand and determine the task 2. Design preparation 3. Select the parting surface and die casting system 4. Choose the die casting equipment 5. Determine the appropriate mold structure and draw the mold assembly sketch * 6. Calculation and verification of relevant parameters * 7. Draw the die casting mold pattern * 8. Proofreading and review * 9. Organize and archive design materials Next, Introduces steps 4-5 of die casting mold design on this page. STEPS OF DIE CASTING DIE(HPDC MOLD) DESIGN II 4. Choose the die casting equipment 4 Dies design is carried out according to the type of die casting equipment, so it is necessary to be familiar with the performance, specifications, and characteristics of various die-casting equipment. For die casting machines, the following should be understood in terms of specifications: clamping force, pressure chamber capacity, injection pressure, mold opening stroke, mold opening force and ejection force, mold installation dimensions, ejection device and its size, die casting machine Gate displacement distance, gate sleeve positioning ring size, mold maximum, and minimum thickness, installation matching size, etc. According to the quality of the die casting and the total projected area of the die casting on the parting surface, the required clamping force is calculated, and the overall dimensions of the die are preliminarily estimated. Combined with the actual die casting machine situation of the die casting production unit, the die casting machine is initially selected. 5. Determine the appropriate mold structure and draw the mold assembly sketch * 5 The main content of this part includes (1) The form of the gating system and the overflow system, including the sprue, the runner, and the position, shape, and size of the inner gate, as well as the exhaust overflow method, etc. (2) The structure of the formed part (3) The demolding method of die castings, the method and sequence of mold opening, the selection and design of the ejection mechanism, etc. (4) The structure of the main parts and the ruler and the required installation cooperation relationship (5) Selection of mold base, combination design of supporting and connecting parts (6) Cooling and heating method and mold temperature adjustment system When determining the structure of the die-casting mold, the following conditions should be considered (1) Each structural element in the mold should have sufficient rigidity to withstand the clamping force and the back pressure during liquid metal filling without deformation. All parts in contact with molten metal should be heat-resistant die steel. (2) Try to prevent the molten metal from impacting or scouring the core from the front to avoid erosion at the inflow of the inner gate. When the above situation is unavoidable, the eroded part should be made into a block type so that it can be replaced frequently. It is also possible to use a larger internal gate section and maintain the thermal balance of the mold to improve the life of the mold. (3) Reasonably choose the combination of mold inserts to avoid sharp corners and sharp splits to meet the requirements of heat treatment. The push rod and core hole should keep a certain distance from the edge of the insert to avoid weakening the strength of the insert. The fragile parts of the mold should also consider the inlay structure for easy replacement. (4) After splicing at the forming part, it is easy to leave splicing marks on the die casting. The location of splicing marks should consider the aesthetics and performance of the die casting. (5) The size of the mold should correspond to the selected die-casting machine. Drawing a sketch of the mold structure can check the coordination relationship between the considered structures. For inexperienced designers, this sketch is used to solicit the opinions of mold manufacturing and mold operators so as to introduce their rich practical experience into the design. 6. Calculation and verification of relevant parameters * 6 (1) Calculate the working size of the formed part; (2) Calculate and verify the thickness of the side wall and bottom plate of the formed part cavity to determine the size of the template; (3) Calculate core-pulling force, core-pulling distance, mold-opening stroke required for core-pulling, and size of related core-pulling parts such as diagonal pins; (4) Check of push rod compression instability; (5) Calculate the temperature adjustment system parameters; (6) Checking the relevant parameters of the die casting machine Link to: STEPS OF DIE CASTING DIE(HPDC MOLD) DESIGN I Link to: STEPS OF DIE CASTING DIE(HPDC MOLD) DESIGN III contact
- Mold Making | Die Casting Mold Manufacturing Process | cameldie.com
Mold Making & Die Casting Mold Manufacturing Process Mold Making Mold Making refers to the processing of forming and blanking tools, in addition to shearing and die-cutting dies. Normally, the mold consists of two parts: the cavity die and the core die. A steel plate is placed between the upper and lower dies, and the material is molded under the action of a press. When the press is opened, the workpiece defined by the shape of the die is obtained, or the corresponding scrap is removed. Workpieces were as small as an electronic connector or as large as an automotive dashboard can be formed with a die. A progressive die is a set of dies that automatically moves the machined workpiece from one station to another and gets the molded part at the last station. Die processing process includes: cutting die , blanking die, compound die, extrusion die, four-slide die, progressive die, stamping die, die cutting die, etc. Die Casting Mold Manufacturing Process Die-casting materials, die-casting machines , and molds are the three significant elements of die-casting production, and none of them are indispensable. The so-called die-casting process is the organic and comprehensive application of these three elements to enable stable, rhythmic, and efficient production of qualified castings with good appearance, internal quality, and dimensions that meet the requirements of the drawing or agreement, or even high-quality castings. The Latest Technology Die Casting Mold Die casting mold is a tool for die casting metal parts, a tool for completing the die casting process on a dedicated die casting die forging machine. The basic process of CAMEL die-casting is first low-speed or high-speed casting of molten metal into the mold's cavity. Next, the mold has a movable cavity surface, which is pressurized forged with the cooling process of the molten metal, which eliminates the shrinkage of the blank. Shrinkage defects also make the internal structure of the blank reach broken grains in the forged state. As a result, the comprehensive mechanical properties of the blank have been significantly improved. A variety of new die-casting mold surface treatment technologies continue to emerge, but generally can be divided into the following three categories: (1) Improved technology of traditional heat treatment process; (2) Surface modification technology, including surface thermal expansion treatment, surface phase change strengthening, electric spark strengthening technology, etc.; (3) Coating technology, including electroless plating, etc. Die-casting molds are a large category of molds. It is still difficult to meet the ever-increasing performance requirements by relying only on the application of new mold materials . Various surface treatment technologies must be applied to the surface treatment of die-casting molds in order to achieve Requirements for high efficiency, high precision, and long life. Among various molds, the working conditions of die-casting molds are relatively harsh. Die casting is to fill the mold cavity with molten metal under high pressure and high speed and die-casting. It repeatedly contacts the hot metal during the working process. Therefore, the die-casting mold is required to have high thermal fatigue, thermal conductivity, wear resistance, and corrosion resistance. , Impact toughness, red hardness, good mold release, etc. Therefore, the surface treatment technology requirements for die-casting molds are relatively high. 2. Surface modification technology Surface thermal diffusion technology This type includes carburizing, nitriding, boronizing, carbonitriding, sulfur carbonitriding, and so on. Carburizing and carbonitriding The carburizing process is used in cold, hot work and surface strengthening of plastic molds, which can improve the life of the mold . For example, the die-casting mold made of 3Cr2W8V steel is first carburized, quenched at 1140~1150℃, and tempered twice at 550℃. As a result, the surface hardness can reach HRC56~61, which increases the die life of die-casting non-ferrous metals and their alloys by 1.8~3.0 times. When carburizing, the main process methods include solid powder carburizing, gas carburizing, vacuum carburizing, ion carburizing, and carbonitriding formed by adding nitrogen to the carburizing atmosphere. Among them, vacuum carburizing and ion carburizing are technologies that have been developed in the past 20 years. This technology has the characteristics of fast carburizing, uniform carburizing, smooth carbon concentration gradient, and small deformation of the workpiece. It will be used on the surface of the mold, especially the precision mold. Play an increasingly important role in surface treatment. 1. Improved technology of traditional heat treatment process The traditional heat treatment process of die-casting molds is quenching-tempering, and later surface treatment technology has been developed. Due to the variety of materials that can be used as die-casting molds, the same surface treatment technology and process applied to different materials will produce different effects. CAMEL proposes substrate pretreatment technology for mold substrate and surface treatment technology. On the basis of traditional technology, it proposes suitable processing technology for different mold materials to improve mold performance and increase mold life. Another development direction for the improvement of heat treatment technology is to combine traditional heat treatment technology with advanced surface treatment technology to increase the service life of die-casting molds. For example, the chemical heat treatment method carbonitriding, NQN combined with the conventional quenching and tempering process (namely carbonitriding-quenching-carbonitriding composite strengthening, not only obtains higher surface hardness, but also effective hardening layer The depth increases, the hardness gradient distribution of the infiltrated layer is reasonable, the tempering stability and the corrosion resistance are improved, so that while the die-casting mold obtains good core performance, the surface quality and performance are greatly improved. 3. Nitriding and related low-temperature thermal expansion technology Including nitriding, ion nitriding, carbonitriding, oxygen nitriding, sulfur nitriding, and ternary sulfur carbon nitriding, oxygen, nitrogen, and sulfur. These methods have simple processing technology, strong adaptability, low diffusion temperature, generally 480-600°C, and small workpiece deformation. They are especially suitable for surface strengthening of precision molds. The nitride layer has high hardness, good wear resistance, and good impact resistance. The nitriding process is a commonly used process for surface treatment of die-casting molds, but when a thin and brittle white layer appears in the nitriding layer, it cannot resist the effect of alternating thermal stress and is prone to micro-cracks. Crack and reduce thermal fatigue resistance. Therefore, in the nitriding process, the process must be strictly controlled to avoid the formation of brittle layers. Die casting and mold are both different and connected. The birth of the die-casting mold industry is a perfect combination of the two. In other words, die-casting, molds, and die-casting molds are three different industries, and their relationship mainly exists in several aspects. : Die-casting and mold integration, all molds are manufactured by ourselves, and rarely do molds for other companies; professional die-casting mold manufacturing, no die-casting; only die-casting, no mold manufacturing capabilities. CAMEL is a professional die casting mold manufacturer based in China. Our design team with more than 10 years of experience. Please contact us if you have technical difficulties.
- What is Die Casting | Die Casting Process and Types | cameldie.com
What is Die Casting Die Casting Definition Die casting meaning a metal processing process in which molten metal is injected into the machine, allowing it to cool and harden then formed into a specific model. Die casting molds are cycled under standard conditions to produce a dimensionally or functionally alloy product. Die castings are used in a wide range of applications, lighting, automotive, aviation, large equipment, furniture, engines, motorbikes, special properties, and mass production have led to die casting is used in life. Cast metal The most used metal materials are zinc, aluminum, magnesium, copper, lead, tin. Specific die casting metal includes: Aluminium : ADC12, A380, Alsi9Cu3, Alsi12Cu1, AC4CHT6, YL102, YL112, YL113. Magnesium : AZ91D, AZ80, AZ31B, AZ40M, AZ31, ZK60, ZK61, AM60M, ME20M, ZK60A, ZK50B, ZK51A. Zinc : Zamak2, Zamak3, Zamak5, Zamak7, Zamak8. Copper : Brass, Bronze. Market Distribution Of Die Castings China is the largest producer of die casting molds, North America is the largest use region, India is the first producer, and Italy is the first echelon in the European region. So when you are a part of die casting, the below image will help you understand how the global die casting market is distributed. We provide a constantly updated list of global die casting manufacturers here for you. Advantages Of Die Casting Higher impact strength than plastic, especially large machinery and equipment such as trucks and cars More stability in dimension is a very important element. For example, POM or other plastic products with special shapes are transported from Asia to Europe, the size will change under the influence of temperature, but die castings will never have such a big change. Product has a longer life,special parts like robot arms, engine covers, LED, etc., after the long-term operation and high and low temperatures, there will still be no changes in material and strength More resistant to corrosion,some ship components, chemical vessels, weapon components, etc. need to be immersed in liquid or exposed to the gas for a long time without oxidation and decomposition Wall thickness also does not affect, some parts like large furnaces, clocks, aerospace components, and trucks are often so thick and strong only casting can achieve the required strength. Disadvantages Of Die Casting More dangerous when casting in workshop,more requirements in terms of safety in production,more insurance and protection All other types of casting except die casting are not suitable for thin walls Heavier than plastic products, more shipping costs, and packaging costs More demanding on the environment,dirtier and messier workshops, exhaust and effluent discharge not easily dealt with No complex die structures can be used, for the same product, plastic molds can complete more structures, die-casting molds need secondary processing, CNC, WEDM More cost than plastic, like materials, tools, transport, environment, and secondary processing Types of Casting Die casting , a high precision casting process is usually used for die castings with dimensional requirements, such as aerospace, automotive, custom equipment, etc., precision components, all processes are completed in the machine, including injection, pressure-holding, and cooling. Sand casting , a low-cost casting method, half manual, and half machine operation, multiple layouts in one cavity, molds and cores no need high cost, no high requirements for mold appearance and steel hardness, subsequent appearance treatment after forming, almost no requirements for product density and accuracy.Can be used for a wide range of casting materials. Investment casting , a complex process of casting for die castings with complex shapes and structures. The first step is to make a wax mold with a similar structure as the plastic mold, fill it with wax and shape it (the shape of the wax is the shape of the final die casting); the second step is to take the product out and coating it evenly with two special materials, the first coating is fine to make the surface of the die casting smooth and ensure that the wax product will not crack easily at a certain temperature after air-drying the second coating is applied, the second coating will form the mold of the part shell, the melting point of the coating is a little higher than the melting point of the die casting; the third step into the furnace, the surface material after high temperature to form the shell, the wax has been melted, Investment Casting is formed, pour the melted die-casting material and cover for insulation, crack the shell to remove the part. Low-pressure casting , a simple casting method that differs from high pressure die casting in three ways: 1. the molten metal is injected into the die using air, 2. the furnace is placed at the bottom of the die to facilitate air pressure, and 3. the shape of the product must appear to be a mirror image to facilitate pressure balancing within the die. low-pressure casting is not suitable for most die castings. The reason sees here. Gravity die casting , the simplest form of casting, with only a cavity and a core, not even a machine to clamp it, the molten metal is poured in through the top of the die and knocked out when it cools, suitable for small batches of die castings. Vacuum die casting , a method of improving the quality of casting, usually for magnesium alloys, where the air is pumped out of the cavity before the molten metal is fed in (some special dies are injected with oxygen after the air has been pumped out) and then the metal is injected, resulting in a die casting with fewer pores and high density, which is more complex in batch production conditions and prone to explosions caused by leaks. What's The Difference Between Die Casting, Sand Casting, Gravity Die Casting, Vacuum Die Casting, Investment Casting? Vacuum die casting is the best in quality Die casting is the highest in efficiency and good in the casting of thin rib Gravity die casting is the best in cost Sand casting is best in small batches Investment casting is best on complex structures Free Quote & Part Analysis → What Are The Factors Affecting Casting Quality? Stable machine , stable material supply, no pores, and residue. The core and cavity are at the specified temperature during the heat treatment process to ensure that the material is in the best performance. It is important to choose the right die casting steel for the cavity and core because the production is always in a high-temperature environment . The metal material has no impurities and the temperature is suitable, then the surface of the die casting will be smoother The gate, slag strap, and ejector design in the mold are reasonable, and the casting process is smooth, without excessive pressure and material waste Points Of Die Casting Mold Design In the design process, the following points in the 3d part drawing should be avoided: Sharp corners. Little or no draft. Heavy walls. The following points of mold design should be noted(Make Moldflow analysis report will be better): Gate. Runner. Exhaust seat. Cooling. The following points need to be designed before testing: Support pillar as much as possible Pre-heating temperature according to material requirements Control cycle time Control mold temperature and metal temperature Machine size Difference Between Die Casting And Plastic In The Environment According to scientists, fish, birds, and animals were killed by plastic floating in the ocean due to accidental eating. Die-casting parts are rarely discarded in the ocean. Even if they are discarded in the ocean, they will sink to the bottom of the sea. Will be recycled again, the discarding of die castings will have very little environmental harm in the future, but the discarding of plastic will have a very bad impact on the environment. Why Does The Color Of Die Castings Change? When the die casting material is melted, some iron filings will be mixed and introduced into the furnace. After the casting is completed, the iron will be oxidized with oxygen in the air. the surface color of the die casting will become different. If your requirements are stricter, vacuum die casting will be better. Processes After Die Casting Production Rough and precision punching. Deburring, clean the hole. CNC, EDM, WEDM. Surface corrosion protection. Sandblasting, oil blasting, electroplating, and even positive oxidation. contact
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EQUIPMENT Equipment list of CAMEL, include CNC Machine, EDM Machine,Coordinate Measuring Machine, Profile Projector, Wire cut Machine, Grinding Machine, Milling Machine, Tapping Machine, Fitting Machine, Chamfering Machine, Die Casting Machine(280Ton, 350Ton, 500Ton, 800Ton, 1250Ton, 1650Ton, 3000Ton),etc.
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DIE CASTING MOLD MANUFACTURE We mainly manufacture molds for aluminum alloy die casting dies, zinc alloy die casting dies, and magnesium alloy die casting dies. ALUMINUM DIE CASTING MOLD FOR VOLKSWAGEN Product Material: AL380 Product Size (LxWxH): 173.68x175.17x54.32mm Product Size (LxWxH): 173.67x175.74x55.62mm Product Industry: Auto industry ( used for Top cover of auto air conditioning compressor) Qty Of Cavity: 2+2 Qty Of Slider: 0 Mold Type: 2-Plate mold Machine Tons: 550Ton Mold Size (mm): 880x720x470 Lead Time: 32 days We used die casting machines for mold trial ranging from 280 tons to 3000 tons.( 280T, 350T, 500T, 800T, 1250T,1650T, 3000T), Our capability from tooling design to build dies about 12-15 sets of big die casting dies per month. BLOG Die casting companies What is die casting What is die casting mold HPDC VS LPDC die casting What is Aluminum die casting mold High-pressure Zinc alloy die casting molds What is high-pressure Magnesium die casting mold Steps of die casting mold(HPDC mold)design Failure mode and analysis of die-casting dies How to extend the life of die casting tool contact us
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搜尋結果 All (96) Blog Posts (39) Other Pages (57) 96 items found for "" Blog Posts (39) Aluminum Die Casting Defects Case Study Automotive engine oil pan 1, defects that appear The product is an essential part of the car engine, the working environment is harsh, and it is required not to leak oil. We mainly encounter the sensor hole air holes in the production of this product that can not meet the requirements, large plane local air holes into pepper powder, it is difficult to lift. 2, the reasons for the generation 1) Oil sump is a deep cavity part, aluminum liquid from the water mouth to the water tail, the process is long, easy to produce cold material. And the sensing air hole is an isolated part, which is not conducive to the discharge of cold material. 2) The principle of product die-casting release agent is manual spraying, the amount of spraying changes every time, and there are more unstable factors, causing the product to be easily deformed. 3) Bad exhaust. 3, Solution 1) Open a slag collection bag in the sensor part to facilitate the discharge of cold material in this part. 2) Use ABB robots to ensure stable and fast spraying. 3) Open an exhaust block on the mold to get the best exhaust effect. Thermostat housing 1, Defects that occur The product needs not to show water under high temperatures and pressure, so the sealing groove of the product is required to be very strict. Product sealing slot requirements do not allow air holes, such as in production, the end of the product often appear pepper-like air holes, will cause the product scrap; and the proportion of air leakage caused by more. 2, the reasons for the generation 1) complex structure of the product, more tabs in the middle, the aluminum liquid is not smooth in the flow, at the end of the product is easy to produce rolled gas. 2) The wall thickness of the product varies too much, the smallest place is only 4 mm, but the thickest place can reach 30 mm, and it is easy to produce shrinkage and shrinkage holes in the wall thickness. 3) There is an 85 mm long sliding block on the product, which is easy to pull on and crack the product, causing air leakage. 3, Improvement measures 1) Add a vacuum exhaust device to the mold to reduce the amount of gas in the mold cavity. 2) Open a partial extrusion pin at the product wall thickness to reduce the product shrinkage and shrinkage hole. 3) Make program changes to the machine, set core extraction spraying, and spray lubrication to the oblique extraction core to reduce the phenomenon of strain and cracking. Aluminum alloy base 1, defects The problem of casting inlet buckling, buckling crack, and deformation after cooling occurs during the trial production of the product. 2, Causes of occurrence 1) Casting heat sink with the thin and narrow wall, in order to cast water tail heat sink forming good and take high speed and high-pressure molding, resulting in a large impact on the inlet port buckling die buckling crack. 2) The casting is too long, uneven wall thickness, different crystallization strength of each part, and the shrinkage in cooling have different differences causing distortion and deformation. 3, improvement measures 1) Do surface cloaking treatment at the inlet of the mold to improve the buckling mold. 2) Take vacuum die-casting, not to reduce the inner gate speed and improve the internal quality when reducing the injection speed and pressure, so as to reduce the impact on the inlet port during the injection and improve the buckling mold. 3) Adopt cooling without water spout to reduce the deformation by pulling the casting during cooling. 4) Pre-align the product in the condition of semi-cooling of the casting, when the internal stress of the product is not completely released. Gear chamber 1, Defective problem Air leakage was found during product air inspection. 2, Cause Analysis The casting structure is complex, and in order to achieve a good appearance and required strength, the filling speed is up to about 60m/s and the specific pressure is more than 820kg/cm2. Therefore, a great impact on the part shown, so that the product surface burns, sticky aluminum; at the same time, due to the large difference in wall thickness of the part, the cooling rate is not the same and will lead to shrinkage, shrinkage crack, and these defects will lead to air leakage in the product in the gas inspection. 3, solution 1) Adopt point cooling method for die cooling in the corresponding part, which increases the local cooling effect; adopt local extrusion pin process to solve the problem of shrinkage. 2) Do surface cloaking treatment at the inlet of the mold to improve the buckling die and solve the burn. The gas station connection body 1, defect problem Casting both sides of the core extraction cavity buckling injury and lamination, the fixed mold forming surface of the two fixed columns has water lines or cold separation. 2, cause analysis 1) Due to the thin and long cores on both sides, the casting is wrapped by aluminum liquid, the temperature rises quickly, causing the cores to adhere to the inner cavity of the casting, and strains when taking off the mold. 2) After closing the mold, the core and the mold with a gap, resulting in feeding, forming a flying edge, after opening the mold, the core extraction, the flying edge can not be normal off, was caught in the mold, after closing the mold, the flying edge with the core inserted, the next filling, aluminum liquid in the flying edge on both sides of the molding, forming a sandwich. 3) The two fixed pillars on the molding surface of the fixed mold extend into the mold 35 mm, and are slender, with cooling water inside the mold, the top of the pillar is closer to the cooling water channel, after opening the mold, the pillar position cools down faster, and when spraying, the mold release agent is easy to remain because of the small space in the cavity of the pillar. 3, Solution 1) Install additional cooling points inside the extractor core on both sides of the mold to take away the heat from the end properly. 2) Polish the surface of the extractor core to stick to aluminum and cloak it to prevent the flying edge from sticking. Enable deceleration, deceleration position 525 mm to prevent flying edge. 3) Open 1/3 of the cooling water at the two pillars after normal, reduce the mold temperature appropriately, and blow out the residual mold release agent in the inner cavity after spraying in the fixed mold. Factors Affecting the Size of Die Castings Factors affecting the size of die castings are broadly the following. 1, molding compression is caused by the size of the error. Molding shrinkage is the main factor affecting the size of die castings. Because molding compression is a complex process, so the shrinkage rate has a wide range of choices. According to the external shape of the die casting and structural characteristics, respectively, select the size of each part of the appropriate molding shrinkage and determine the size of the molding, is to ensure that the die casting size accuracy of the key issues. 2, the manufacturing error of molding parts. 2.1, the molding parts of the insert, mold processing datum, and the impact of processing technology. 2.2, machining errors of molded parts. 2.3, assembly errors of molded parts. 2.4, the error caused by the slope of the molded parts of the mold. 3, the influence of fluctuations in molding shrinkage during die-casting. 3.1, the influence of die-casting molding process parameters, such as press injection ratio pressure and internal gate speed. 3.2, the effect of mold temperature. 3.3, the effect of the temperature of the die casting when the mold is removed. Die castings in the shrinkage process, broadly divided into the following three stages. a, liquid shrinkage, after die casting, still in the liquid metal liquid temperature reduction caused by shrinkage; b, solidification shrinkage, in the cooling and solidification process, the metal liquid from the liquid to solid crystallization stage shrinkage; c, solid shrinkage, metal completely solidified when the crystallization is completed stage and out of the mold body shrinkage. In die casting, because the superheat temperature of the metal liquid is not high, so the volume shrinkage in the liquid shrinkage stage is not large; shrinkage in the solidification stage, although larger, but is completed in the mold forming parts, and therefore by the molding parts, especially the core of the resistance limit. When the die-casting die temperature decreases and can reach the temperature of the mold, die castings from the mold body, only after the free shrinkage state, that is, the solid-state shrinkage stage. This shrinkage process has continued until the die casting reaches room temperature before the basic end. Therefore, it can be said that the temperature of the mold of the final shrinkage of the die casting plays an important role in determining the amount. 4, the error caused by the phase time movement of the structural parts. 4.1, mold closing errors. 4.2, the movement error of the side-drawing core and the movable core. 4.3, the error caused by the precision of the die-casting machine and the instability of the process performance. 5, punching error. 5.1, molding parts by the impact of pressure injection deformation caused by the error. 5.2, forming parts surface by the metal liquid or impurity erosion generated by the error. 5.3, subject to pressure injection stamping, template, or forming parts to produce elastic deformation or plastic deformation and the formation of forming part of the size error. Design for Die Casting Mold of Middle Shell Side Gating 1, structural process analysis of die casting 1.1 The reasonable choice of materials used in die casting. Aluminum alloy because of its good die-casting performance, specific strength, and specific stiffness is high, high and low-temperature mechanical properties are also good, its surface has a dense oxide film, and certain corrosion resistance and in the production of die castings are used in large quantities, widely. 1.2 The minimum wall thickness of the die casting is 3mm, and the minimum wall thickness is also by the process requirements, and the 3mm*54mm rib on the two long sides, 8mm*4mm rectangular hole, R4mm flange, etc. are also by the requirements of the die casting process. 1.3 Because of the strong affinity between aluminum alloy and iron at high temperatures, it is easy to bond with the pressure chamber, and the die-casting mold design should use a cold chamber die-casting machine as far as possible. 2, the choice of parting surface According to the middle shell for the long frame hollow parts, both sides of the long side have different side convex, step, small rectangular hole structure characteristics. The die casting parting surface of this die casting, except for the horizontal parting between the moving die and the fixed die, is chosen in the upper face of the shell, and the forming of both long sides needs to adopt the lateral parting mold structure form (i.e. the form of lateral core extraction of the inclined pin slider). 3, the determination of the pouring system Due to the thin wall thickness of the four sides of the intermediate shell and the difference between the plant and width dimensions, to prevent cold separation and ensure the thermal balance of the mold, the pouring system uses side gates. The molten alloy is pressed in simultaneously from both ends of the long side of the casting, and a larger overflow slot is set at the part where the metal liquid meets or is likely to produce eddy currents. A larger overflow slot can be set both exhaust role and can set slag and conducive to the thermal balance of the mold. 4, the choice of die-casting machine The middle shell is no insert die-casting, can choose horizontal cold room die-casting machine, according to the actual production of enterprises to choose the appropriate die-casting machine, to meet the actual production requirements. 5, die-casting mold forming parts working size calculation and determination By die-casting alloy comprehensive shrinkage rate list data can be seen: aluminum alloy shrinkage rate in the free shrinkage rate of 0.50%-0.75%; hindered shrinkage rate of 0.40%-0.65%. After separate analysis and calculation, it is determined. 6, die-casting process protocol The process protocol is mainly to determine the process parameters of die-casting production. Die-casting production process parameters mainly include die-casting with new, old material reasonable ratio (old material is impossible to abandon, new, old material unreasonable ratio will affect the material performance and shrinkage rate), determine the die-casting production process protocol, equipment, the correct use of paint (because it has the role of improving the working conditions of the mold, improve molding conditions, improve the quality of castings and extend the life of the mold and essential), etc. 7, die-casting mold assembly design There are two structural options in the design of die assembly. Program one: die-casting forming castings, the shape of the inner cavity mold forming part are designed into the form of the overall structure; program two: forming castings, the shape of the mold work parts are designed into the set, set block set combination of structural form. After analysis and comparison, although program one uses less material, good strength, short processing cycle, but the mold manufacturing accuracy is difficult to ensure that the mold damage and wear are not easy to repair. While the second option increases the use of alloy steel, the processing cycle is extended, but the precision of the working parts of the mold is easy to ensure, and the size adjustment of the working parts of the mold and the wear and damage formed after a certain period of production is also convenient to repair and replace. In the assembly structure of the mold, the fixed mold insert and the fixed mold insert of the fixed mold part are set into the fixed mold plate in the form of grouping. For the moving side, the moving die insert and the moving die insert are inserted into the moving template in a group. The die plate is made of medium carbon steel. The working parts are made of hot work die steel for die casting, the strength, and processing accuracy of the die can be guaranteed, and the adjustment of each forming size is also convenient. Because the hollow shell of die casting has long sides of rectangular holes, flanges, convex tendons, and other structures respectively. So both sides need to use different slider structure forming, tilt pin core parting, wedge tight block locking lateral forming form. Considering the thin wall thickness around the middle shell, and the size of the overflow groove has been enlarged, so pushrods are set on the overflow groove and the cross sprue, and 8 rectangular sheet pushrods are set on both sides of the long side of the die casting to ensure the smooth and synchronous launch of the overflow groove, cross sprue and die casting. The mold is reset by the reset rod to push the pushrod fixed plate to reset. View All Other Pages (57) How does Cold-chamber Die Casting Machine Work | cameldie.com How does cold-chamber die casting machine work During operation, the pressure chamber is placed vertically, and the upper punch is above the pressure chamber, and the lower punch is located at the position where the nozzle orifice is blocked, to prevent molten metal from pouring into the pressure chamber and flowing into the nozzle hole by itself. The opening and closing movements of the mold move horizontally. After the mold is opened, the die casting remains in the movable mold. The working steps of the cold chamber die casting machine are as follows: Close the mold. Pour molten metal into the press chamber manually or by other means. The upper punch moves down at a lower injection speed and enters the pressure chamber until it just touches the molten metal surface. When the upper punch is turned to a higher injection speed and pressed down, the lower punch and the upper punch will move down synchronously while maintaining the relative distance between the upper punch and the molten metal. When the lower punch moves down to let out the nozzle orifice, it just descends to the nozzle part and is supported, therefore, the upper and lower punches squeeze the molten metal at high speed to the nozzle hole (part of the sprue) injection. The molten metal is filled into the mold cavity from the inner gate through the sprue composed of the nozzle, the sprue sleeve, the tapered hole of the fixed mold, and the diverter. After the filling is completed, the upper punch can still maintain a certain pressure until the molten metal in the cavity is completely solidified into the die casting 1, and the molten metal in the runner and the pressure chamber solidifies into the direct gate and the remaining material respectively cake. The upper punch lifts and resets; at the same time, the lower punch moves upwards to cut away the remaining cake that is still connected to the straight gate. The lower punch continues to rise, lift the remaining cake out of the top surface of the pressure chamber, and then take it away manually or by other means. Move the lower punch down and reset to block the nozzle orifice. Open the mold, the die-casting part and the straight gate remain on the movable mold together, and then eject and take out the die-casting part; once the remaining material cake is cut away, the mold opening action can be executed immediately, or it can be executed at an appropriate time, Has nothing to do with the movement of the lower punch to complete the lifting and resetting. 9 Failure Mode and Analysis of Aluminum Alloy Die-casting Dies| cameldie.com Failure Mode And Analysis Of Die-casting Dies For Aluminum Alloy The vigorous development of the automobile industry and the need for lightweight, so that Aluminum alloy Die-casting is to the large-scale and complex direction of rapid development. Die-casting dies as the main equipment of Die-casting production is to achieve the basic guarantee of high quality and efficient production of Die-casting, its life directly affects the quality of Die-castings, production, as well as the production cost of enterprises and market competitiveness. At present, in most countries, the low service life of the Aluminum alloy Die-casting dies problem becomes the main factor that restricts the further development of die-casting industry, the failure mode of Aluminum alloy die-casting dies is more problematic. 1. Working environment of Aluminum alloy Die-casting dies Aluminum alloy Die-casting dies as a carrier of high temperature, high pressure, high speed Aluminum liquid, its working environment is extremely harsh. When working, the cavity surface is repeatedly flushed by the Aluminum liquid, the specific pressure is more than 40MPa, the inner sprue speed is 30~65m/s, the mold cavity surface temperature can reach 1112°F or more instantly, and after opening the mold, the mold cavity surface temperature drops sharply due to spraying and other reasons. This kind of hot and cold alternating effect in the die-casting cycle repeatedly, making the mold cavity surface temperature changes dramatically. 2. Failure mode and analysis of Die-casting dies According to the field statistics, the common failure forms of Die-casting dies are cracked, cracking, erosion, adhesion, and deformation, etc. Among them, cracked, cracking, erosion, and adhesion mainly occur in the mold cavity surface. (1) Cracked: In each Die-casting cycle, due to the existence of intense heat exchange, the mold temperature changes dramatically, the resulting thermal stress leads to thermal fatigue on the surface of the mold cavity, forming micro cracks. With the increase of Die-casting cycle, the micro-cracks further expand and form crack. This is the main mode of Die-casting dies failure field. (2) Cracking: In the Die-casting production, in addition to thermal stress, due to the high-pressure impact of Aluminum, in the mold internal also produced other stresses. When these stresses exceed the fatigue limit of the mold material will produce cracking, especially easy to produce stress concentration of the sharp corner parts, the possibility of cracking is greater. In addition, if the stress generated during the processing of the mold is not completely eliminated, the mold is more likely to crack. (3) Erosion: Aluminum high speed filling cavity friction heat, so that the surface temperature of the area on the surface of the mold cavity towards the inner sprue, coupled with the violent impact of Aluminum, so the surface protection layer of this part is easy to be destroyed. The Aluminum solution further reacts with the exposed metal substrate to produce harder compounds. In the process of removing these compounds, it is easy to take away the substrate material and expose the fresh surface, and so on, intensifying the damage of the cavity surface, forming a serious erosion. (4) Adhesion: Pressure injection, the instantaneous temperature of the cavity surface at 1112°F. above, at this time, the affinity between the mold material and Aluminum liquid, strong adhesion, easy to form cavity adhesion. (5) Deformation: In the Die-casting process, Die-casting dies to withstand the clamping force, injection backpressure, and other stresses, if the template stiffness is not enough, the mold in these stresses under the long-term role of bending deformation. (6) Movement Obstacle: In Die-casting production, the temperature difference between inside and outside the mold, resulting in different thermal deformation of each part of the mold. Different heat deformation amount leads to different changes in the size of each part of the mold, thus changing the fit relationship between the mold parts. This change of fit relationship may cause significant movement obstruction of the mold parts with relative movement. LINKS: 1. How to Extend The Service Life Of Die-casting Tools 2. How to Choose Steel For Die Casting Mold 3. Steps Of Design Of Die-casting Dies (HPDC Mold) 4. Specification Of Die-casting Dies 5. Die Casting Mold From CAMEL DIE LIMITED 6. Introduction Of Aluminum Alloy Die Casting Mold contact Aluminum Die Casting Mold For Volkswagen | cameldie.com ALUMINUM DIE CASTING MOLD FOR VOLKSWAGEN In recent years, the types of die casting products in China have been diversified, including parts for automobiles, motorcycles, communications, home appliances, hardware products, power tools, IT, lighting, escalator steps, toy lights, etc. Automobiles and motorcycles accounted for 542,700 tons of die castings in China, accounting for 62.8% for hardware toys, 138,200 tons accounting for 16% the electronics industry, 101,900 tons accounting for 11.8%; and 81,400 tons accounting for 9.4% of other fields. During the "Eleventh Five-Year Plan" period, through measures such as increasing investment in scientific research, eliminating outdated production capacity, and advancing mergers and reorganizations, the effect of optimization and upgrading of the foundry industry structure was obvious, and the industrial concentration increased, and a batch of the top 100 companies with advanced technology, management and quality emerged. In 2014, the national output of die-casting parts was 3.0642 million tons. In 2015, the total output of die-casting parts nationwide was about 3.7 million tons, which is still maintaining a steady growth compared with 2014. Among the existing die-casting enterprises in China, the annual growth rate of die-casting production has remained above 20%, and aluminum alloy die-castings account for more than 3/4 of all die-casting production. Due to the internal optimization and upgrading of the automotive industry in recent years, aluminum alloy castings are gradually replacing gray iron castings, which continuously stimulates the growth of demand for aluminum alloy die castings. Driven by the trend of lightweight automobiles, the global aluminum alloy die casting market has seen huge demand. In the 21st century, China’s magnesium industry has developed rapidly and has become the world's largest magnesium producer and exporter. Whether it is mobile phones, computer shells, car steering wheels, gearbox housings, central control brackets, seats, and aerospace materials, magnesium and magnesium alloy products have quickly entered people’s lives and become the most valuable applications for development and one of the prospective emerging applications of non-ferrous metals. Product Parameters Product Material: AL380 Product Size ( L*W*H ): 173.68*175.17*54.32mm Product Size ( L*W*H ): 173.68*175.74*55.62mm Product Industry: Auto industry ( used for top cover of auto air conditioning compressor ) In the research and development of die casting technology, the deepening of aluminum alloy die casting will still be a main direction of die casting technology development. The first part is to promote the application of new high-strength, high-wear resistance die-casting alloys, to study colorable die-casting alloys and new die-casting alloys used in castings with special safety requirements; the second is to develop die-casting with stable performance and easy-to-control composition Aluminum alloy; The third is to simplify the alloy composition and reduce the alloy grades to provide a basis for realizing green production; the fourth is to develop and apply more die-cast aluminum alloy auto parts. The following is a project we made for Volkswagen in 2013, Which is called “Front Project.” From that time until now, we have been providing services to world-renowned auto companies and have been recognized by various customers as a top supplier. MORE CASES→ View All
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CAMEL DIE MOLD FACTORY Our first factory is located in Dongguan city with 5,400 square meters, and the second factory is located in Huizhou city with 6,100 square meters to build tools & dies around 240 sets of large molds per year. WORKSHOP Regular workshops, standardized operating procedures, safety production first. OFFICE AREA Clean office environment, humanized management, teamwork to assist cooperation. EQUIPMENT High-performance machinery and equipment, complete processing chain, one-stop internal processing and equipment. EQUIPMENT LIST OF CAMEL Equipment list of CAMEL, include CNC Machine, EDM Machine, Coordinate Measuring Machine, Profile Projector, Wire cut Machine, Grinding Machine, Milling Machine, Tapping Machine, Fitting Machine, Chamfering Machine, Die Casting Machine(280Ton, 350Ton, 500Ton, 800Ton, 1250Ton, 1650Ton, 3000Ton), etc. We offer you fast, affordable, reliable service while also providing your company with first-rate quality products, we understand that our customers need both quality and service to manufacture their top-quality products. With this understood, we will exceed our customers' expectations at a fantastic price. Die casting companies What is die casting What is die casting mold HPDC VS LPDC die casting What is Aluminum die casting mold High-pressure Zinc alloy die casting molds What is high-pressure Magnesium die casting mold Steps of die casting mold(HPDC mold)design Failure mode and analysis of die-casting dies How to extend the life of die casting tool BLOG workshop office area equipment contact us