After the design of the large frame of the die-casting mold was completed, the design of the pouring system began. Previously, this part was done based on practical experience by looking at two-dimensional or three-dimensional drawings. Adjust the position and direction of the internal sprue of the die-casting mold during the production process based on the internal quality of the product.

With the continuous development of numerical simulation technology for casting filling and solidification process and the market demand of the casting industry, commercial software for casting process simulation is constantly emerging. Many main manufacturers also require to see the die casting simulation process before designing the mold. Therefore, many die casting mold manufacturers use two simulation software, MAGMASoft or ANYCASTING, to import the designed 3D into this program at the beginning of design, After setting the process parameters of the die-casting mold, the simulation software obtains a simulation animation that is close to the actual production effect through certain calculations.

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The simulation results required for the die-casting process of die-casting molds are as follows:

(1) The alloy liquid should reach the inner runner at the same time.

(2) During the filling process, the alloy liquid should be filled smoothly.

(3) During the filling process, there should be no entrainment or turbulence.

(4) Before the filling is completed, the alloy liquid cannot seal the passage of the slag collection bag tightly.

(5) The cold metal generated during the filling process should not be present in the casting and should be completely driven into the slag collection bag.

According to the filling simulation and particle tracking simulation of the die-casting mold casting process, as well as the requirements of the die-casting process, the position and size of the runner and slag collection ladle of the die-casting mold should be optimized accordingly; Based on solidification simulation and the wall thickness of the casting, the positions of cooling water and heating oil pipes in the die-casting mold, as well as point cooling, can be determined; Based on the erosion simulation of die-casting molds, it is possible to determine which areas of the mold require key spraying.

Through simulation analysis, the manual optimization process of the gate and slag collection bag was solved during the design process, which saved the mold modification process caused by deviation based on experience during die casting mold manufacturing.

In order to further improve the quality of castings, some companies use vacuum technology to reduce the scrap rate and create higher value. Japan's vacuum pumping technology is very mature, and China has also borrowed some of their experience. The vacuum pumping technology requires a ratio of 1:100 between the area of the exhaust duct of the die-casting mold and the area of the punch. Start the vacuum pump 0.4 seconds before the start of rapid injection, and when designing the die-casting mold, the number of vacuum exhaust wave plates or vacuum valves can be determined based on the complexity of the product and the size of the mold.

In the case of good application of vacuum technology, the scrap rate of castings should be reduced to at least 20% of the original scrap rate. However, due to the high price of vacuum equipment, some die-casting factories only use it on die-casting molds with high scrap rates.

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Fenda | Die Casting Mold Solution