1、 Principle of Die Casting Mold Technology

The die-casting mold process refers to the process of rapidly filling the cavity of the die-casting mold with molten metal under high pressure, and cooling and solidification of the molten metal to form a casting. There are two basic methods for die-casting mold technology: cold chamber die-casting and hot chamber die-casting. In modern industrial production, die-casting mold technology is commonly used to produce various metal parts. The use of die-casting mold technology requires little or no metal cutting during the production process, resulting in high production efficiency and significant economic benefits.

2、 Aluminum alloy die-casting production process flow

The production process of aluminum alloy die-casting includes steps such as die-casting machine debugging, die-casting mold installation, mold preheating, coating, die-casting mold closing, pouring and injection, pressure maintaining, mold opening, rough grinding, and precision grinding (see figure).

3、 Characteristics of Die Casting Mold Process

The die-casting mold process integrates process factors such as temperature, pressure, time, and speed, resulting in fast die-casting speed and high efficiency. It has obvious advantages in the parts production industry:

① The die-casting mold process can produce complex metal parts; Molten metal can maintain high fluidity under high pressure, so die-casting technology is more commonly used in the production of metal parts with complex shapes, clear contours, and thin-walled deep cavities compared to other process methods.

② The precision and quality of die-casting parts are high; The dimensional accuracy of general die-casting parts is in the IT9-IT13 level, and the surface roughness of die-casting parts is between Ra0.8 and 3.2um. The structure of the parts is dense, with high strength and hardness, and excellent interchangeability.

③ High material utilization rate in die casting mold process; Due to the high accuracy of die castings, only a small amount of mechanical processing is required during the production process for assembly and use. Therefore, the material utilization rate is usually 60% to 80%, and the blank utilization rate can even reach over 90%.

④ High production efficiency of die-casting mold process; The metal liquid filling speed is fast, the time is short, and the solidification is fast. The hot pressing chamber die-casting machine die-casts 400 to 1000 times per hour, and the cold pressing chamber die-casting machine die-casts 80 to 100 times per hour. Compared with other production processes, the die-casting process has high production efficiency and is more suitable for mass production.

⑤ Easy to meet local special performance requirements of parts; Setting up a positioning mechanism on the die-casting mold can embed embedded parts, which can better meet the special needs of local parts.

4、 Difficulties in process control of die-casting molds

No process method can achieve perfection, and die-casting mold technology is no exception, so comprehensive evaluation and resolution are necessary.

① Pores and shrinkage porosity; The metal liquid quickly fills the mold cavity and cools it quickly. This process takes a very short time. If the gas in the mold cavity cannot be quickly discharged, there will be pores or oxide inclusions in the die casting, which affects the quality of the die casting.

② High cost, not suitable for small-scale production; The production of die-casting involves three essential factors: die-casting machines, die-casting molds, and molten metal. Among them, die-casting machines and die-casting molds are expensive and not suitable for small-scale production.

③ The types of die-casting alloys are limited, and the size of die-casting parts is limited; Due to the temperature limitations of die-casting molds, the main alloys available for die-casting operations are aluminum alloy, zinc alloy, copper alloy, and magnesium alloy. In addition, the size limitations of the pressure casting machine and die casting mold make it impossible to carry out die casting of large parts.

④ The service life of the mold is relatively short; Due to technical limitations, cracks, brittle fractures, and corrosion often occur during the use of die-casting molds, greatly shortening the service life of die-casting molds.

Selected from industry journals to provide learning and exchange.

For more information on die-casting molds, please follow Fenda Mold.