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On this page, you will understand the meaning of die casting mold, the manufacturing process of the die casting mold, the difference between HPDC and LPDC, what elements will affect the stability, the description of each part, and the common types of alloys. 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

SHENZHEN CAMEL DIE LIMITED'S core businesses are Die casting mold development & manufacturing, Product structure optimization, and Small-batch mass production of die-casting parts. The Chamber of Commerce and Municipal Government Office in Shenzhen Jointly Visited Member Units Authors, Wang Yanjun 23/03/2021 The Executive Chairman, Wang Yanjun and Secretary-General of Shenzhen Xingtai Chamber of Commerce, Wang Rui, Vice-Chairman, and Wang Xianliang, Deputy Director of the Investment Promotion Office of Xingtai Municipal People’s Government in Shenzhen, jointly visited Vice-Chairman Tian Shimin'S company-Shenzhen CAMEL DIE LTD on the afternoon of March 22. SHENZHEN CAMEL DIE LTD is headquartered near Tian'an Digital City in Longgang District, Shenzhen City. It was established in June 2009. The company initially focused on precision mold engineering services and overseas sales for automobiles and white goods and expanded to the current R&D and manufacturing of plastic molds. Four core businesses are Plastic mold development & manufacturing, Die casting mold development & manufacturing, Product structure optimization, and Small-batch mass production of plastic parts & die-casting parts. After 11 years of experience accumulation and improvement, it has now developed into three domestic branches, two South China factories, two overseas after-sales service points, and multiple overseas technical service cooperation points, integrating R&D, production, and holding industry quality systems of mold manufacturing and product production enterprise integrating certification and after-sales technical support. The main service industries include aviation, automobiles, white goods, agricultural irrigation, lighting, and security. The main service customers are the first-class parts suppliers of world-renowned brands, such as General Motors, Chrysler, General Electric, British Lotus, London Taxi, Bentley, Tier 1 supplier of Boeing aircraft seats, and Whirlpool. CAMELer takes "respect, efficiency, and self-examination" as its core value, and continues to standardize the triangular win-win relationship with customers, employees, and partners. In innovative design concepts, cutting-edge manufacturing technology research and development, scientific management system, and other aspects, make unremitting efforts to form a global industry standard and go all out for the Chinese manufacturing industry to go global. -End- [Reprinted from Toutiao Read the original text] CAMEL IS A PROFESSIONAL DIE CASTING MOLDS MANUFACTURER BASED IN CHINA, OUR DESIGN TEAM WITHIN MORE THAN 12 YEARS OF DESIGNING AND MAKING STABLE ALUMINUM ALLOY HIGH-PRESSURE DIE CASTING TOOL AND DIE EXPERIENCE. PLEASE CONTACT US IF YOU HAVE ANY ALUMINUM DIE CASTING DIES PROBLEMS IN ALL INDUSTRIES!

In order to smoothly process the dies manufacturing, trial mold, and normal use, the technical requirements for manufacturing, assembling, use, and other processes must be indicated on the assembly drawing and part drawing of the Die-casting dies. Technical specifications of die casting dies After the design of the Die-casting dies structure is completed, there are more important and more complex manufacturing, assembly, mold trial, and production application processes. To smoothly process the dies manufacturing, trial mold, and normal use, the technical requirements for manufacturing, assembling, use, and other processes must be indicated on the assembly drawing and part drawing of the Die-casting dies. 1. Technical requirements that should be indicated in the Die-casting dies assembly drawing 2. Technical requirements for the shape and installation position of the Die-casting dies 3. Technical requirements for overall assembly accuracy of Die-casting dies 4. Dimensional tolerance and fit of structural parts of Die-casting dies 5. Geometric tolerances and surface roughness requirements of Die-casting dies structural parts 1. Technical requirements that should be indicated in the Die-casting dies assembly drawing 1 The assembly drawing should indicate the following technical requirements (1) The maximum external dimensions of the dies(length×width×height). To facilitate the review of whether there is interference between the sliding components and the machine components when the dies are working, the size, position, and stroke of the hydraulic core-pulling cylinder, the size and position of the slider core-pulling mechanism, and the position of the slider to the endpoint sketches should be drawn. (2) Choose the Die-casting machine model. To facilitate the review of whether there is interference between the sliding components and the machine components when the dies is working, the size, position, and stroke of the hydraulic core-pulling cylinder, the size and position of the slider core-pulling mechanism and the position of the slider to the end point sketches should be drawn. (3) Choose the inner diameter, specific pressure, or nozzle diameter of the pressure chamber. (4) The minimum mold opening stroke (if the maximum mold opening stroke is limited, it should also be noted). (5) Push out the itinerary. (6) Indicate the cooling system, hydraulic system inlet, and outlet. (7) Pouring system and main dimensions. (8) Action stroke of special motion mechanism. 2. Technical requirements for the shape and installation position of the Die-casting dies 2 The shape and installation position of the Die-casting dies should meet the following technical requirements: (1) The edges of each template should be chamfered 2×45°, and the mounting surface should be smooth and flat, and there should be no protruding screw heads, pins, burrs, and scratches. (2) Mark obvious marks on the non-working surface of the dies, including the following: product code, dies number, manufacturing date, and dies manufacturer's name or code. (3) The movable and fixed molds are respectively provided with screw holes for lifting, and the larger parts (>25kg) should also be provided with lifting screw holes. The effective thread depth of the screw hole is not less than 1.5 times the diameter of the screw hole. (4) The relevant dimensions of the dies installation part should be by the relevant corresponding dimensions of the selected die-casting machine, and the installation and disassembly are convenient. The installation hole diameter and depth of the pressure chamber must be strictly inspected. (5) Except for the guide sleeve hole and the oblique pinhole on the parting surface, all process holes and screw holes in the dies manufacturing process should be blocked and flush with the parting surface. 3. Technical requirements for overall assembly accuracy of Die-casting dies 3 The overall assembly accuracy of the die-casting dies should be guaranteed to meet the following technical requirements (1) The parallelism between the dies parting surface and the installation plane of the movable and fixed dies seat plates is selected according to the provisions of the table below： The specified unit of parallelism between the dies parting surface and the installation plane of the movable and fixed dies base (unit: mm) The maximum linear length of the measured surface ≤160 160~250 250~400 400~630 630~1000 1000~1600 Tolerance value 0.06 0.08 0.1 0.12 0.16 0.2 (2) The verticality of the installation plane of the guidepost, guide sleeve, and fixed mold seat plate should be selected according to the provisions of the table below： The vertical regulation of guide post and guide sleeve to the installation plane of fixed and movable dies seat plate (unit: mm) Effective sliding length of guide post and guide sleeve ≤40 40~63 63~100 100~160 160~250 Tolerance value 0.015 0.02 0.025 0.030 0.040 (3) On the parting surface, the plane of the fixed dies and the movable dies insert should be flush with the fixed mold set plate and the movable dies set plate or slightly higher, but the height should be within the range of 0.05~0.10mm. (4) The push rod and the reset rod should be flush with the parting surface respectively. The pushrod is allowed to protrude from the profile surface, but not more than 0.1mm, and the reset rod is allowed to be lower than the profile surface, but not more than 0.05mm. The pushrod should be able to rotate flexibly in the pushrod fixed rod, but the axial clearance should not be greater than 0.10mm. (5) All movable parts of the dies should be accurate in position, reliable in movement, and free of skew and sluggishness; no movement between relatively fixed parts is allowed. (6) The sliding block is positioned accurately and reliably after the dies are opened. At the end of the core pulling action, the distance between the drawn core end face and the end face of the corresponding shape or hole on the casting shall not be less than 2mm. The sliding mechanism should be flexible in guiding and sliding, stable in movement, and proper clearance. After closing the dies, the sliding block and the wedge block should be compressed, the contact area is not less than 1/2, and has a certain prestress. (7) The surface roughness Ra of the runner should not be greater than 0.4m, the connecting part should be smoothly connected, the inserting part should be close, and the molding inclination should not be less than 5°. (8) When clamping the dies, the molding surface should fit closely. If there is a gap in some parts, the gap size should not be greater than 0.05mm (except for the exhaust groove). (9) The cooling water channel and temperature control oil channel should be unblocked, there should be no leakage, and the inlet and outlet should be clearly marked. (10) The surface roughness Ra of all forming surfaces is not greater than 0.4m, and all surfaces are not allowed to be damaged or rubbed. Injuries or micro cracks. 4. Dimensional tolerance and fit of structural parts of Die-casting dies 4 Die-casting dies work at high temperatures. Therefore, when selecting the matching tolerances of die-casting dies parts, not only a certain assembly accuracy is required at room temperature, but also the structural dimensions of each part are required to be stable and reliable in operation at working temperature. Especially the parts that are in direct contact with the molten metal are subjected to high pressure, high speed, and thermal alternating stress during the filling process, and the clearance with other parts is prone to change, which affects the normal progress of die casting. The change of the fit-gap is not only related to the temperature but also related to the material, shape, volume, heating degree of the working part of the parts of the dies, and the actual fit properties after processing and assembly. Therefore, the working conditions of die-casting dies parts are very complicated. Generally, the fit clearance should meet the following two requirements: ① For the fixed parts after assembly, there will be no position deviation under the impact of the molten metal. After being heated and expanded, the deformation cannot make the fit too tight, so that the dies inserts and the sleeve plate are locally overloaded seriously, causing the dies to crack. ② For parts that are active during work, after being heated, the nature of the clearance fit should be maintained to ensure normal movement, and during the filling process, the molten metal will not cause the fit clearance. Combined with the actual situation of die-casting dies manufacturing and use, the tolerance and matching accuracy of the main parts of the die-casting dies are now recommended as follows: (1) Tolerance of forming dimensions: The general tolerance level is specified as IT9, H for holes, h for shafts, and GB/T180F for length. Individual special sizes can be selected IT6~T8 level when necessary. (2) Tolerance and fit of matching parts for forming parts: ① The fixed parts of the larger parts that are in contact with the molten metal and are heated, mainly include the sleeve plate and the insert block, the insert block and the core, the sleeve plate and the sprue sleeve, the insert block and the shunt cone, etc. The integral type and accuracy are H7/h6 or H8/h7. The inlaid hole is H8, the largest one in the shaft is h7, and the rest of the spare parts in the shaft is js7, and the cumulative tolerance of the assembly is h7. ②The matching type and accuracy of the movable parts (including push rods, push tubes, formed push plates, sliders, slider grooves, etc.), the hole is H7, the axis is e7 Or d8. ③The height tolerance of inserts, inserts, and fixed cores is F8. ④The tolerance of the base size is taken as js8. (3) Tolerance and coordination of template size: the tolerance of the base size is taken as js8; the core is cylindrical or symmetrical, and the centerline size tolerance of the hole from the base to the fixed core on the template is taken as js8; the core is non-cylindrical Or when it is asymmetrical, the edge dimension tolerance from the base surface to the fixed core on the template is taken as js8; the thickness dimension tolerance of the combined sleeve plate is taken as h10; the depth dimension tolerance of the insert hole of the integral sleeve plate is taken as h10. (4) Dimension tolerance of sliding groove: ①The dimensional tolerance of the sliding block groove to the base surface is taken as f7. ②For the combined sleeve, the dimensional tolerance from the slider groove to the bottom surface of the sleeve is taken as js8. ③For the integral sleeve plate, the dimensional tolerance from the slider groove to the bottom surface of the insert hole is taken as js8. (5) Tolerance and fit of guide post and guide sleeve: For the fixed position of the guide post and guide sleeve, the hole is H7, and the axis is m6, r6, or k6; for the clearance fit of the guide post and guide sleeve, the hole is H7, and the axis is k6 or printed. ; If the hole is H8, the axis is e7. (6) The size between the guide post and guide sleeve and the base surface: the dimensional tolerance from the base surface to the center line of the guide post and guide sleeve is js7; the dimensional tolerance of the distance between the center line of the guide post and guide sleeve is js7, or cooperated processing. (7) The tolerance and fit between the push plate guide post and the push rod fixed plate and the push plate: the hole is H8, and the shaft is f8 or f9. (8) Tolerance of core table, push rod table, and corresponding dimensions: the depth of the hole table is +0.05~+0.10mm, and the height of the pillow block is -0.03~0.05mm. (9) The tolerance level of the unmarked tolerance dimensions of various parts is IT14 level, H for holes, h for shafts, and length (height) and distance dimensions are selected according to js14 accuracy. 5.Geometric tolerances and surface roughness requirements of Die-casting dies structural parts 5 Geometric tolerance is the deviation of the surface shape and position of the part. The deviation range of the geometric tolerance of the forming part of the formed part and the reference part of all other structural parts is generally required to be within the tolerance range of the size, and no additional mark is added on the drawing. The geometric tolerances of other surfaces of the parts of the Die-casting dies are selected according to the table below and marked on the drawing. The table below Selection accuracy grades of geometric tolerances of die casting dies parts: Geometric tolerances of relevant elements Selection accuracy Coaxial between the axis of the fixed part of the guide post and the axis of the guide sliding part Level 5~6 The coaxial of each forming step surface of the circular insert to the mounting surface Level 6 Concentricity between the inner diameter of the guide sleeve and the outer diameter axis Level 6~7 The axis of the fixed hole of the insert in the sleeve is coaxial with the common axis of the holes Level 7~8 on the other sleeves The perpendicularity between the axis of the guide post or the guide sleeve Level 5~6 mounting hole and the parting surface of the sleeve plate The two adjacent sides of the set of plates are the perpendicularity of the process reference plane Level 5~6 The perpendicularity of the two adjacent sides of the insert and the other side of the parting face Level 6~7 The perpendicularity between the surface of the insert hole in the sleeve and the parting surface Level 7~8 The perpendicularity of the axis of the core fixing hole on the insert to the parting surface Level 7~8 Parallelism of the two planes of the plate Level 5 The parallelism of the opposite sides of the insert and the bottom of the parting face Level 5 The axis of the insert hole in the sleeve and the end face of the parting surface are circularly run out Level 6~7 The radial runout of the axis of the circular insert to its end face Level 6~7 Parallelism of the parting surface of the insert, the sealing surface of the slider, the combined surface ≤0.05mm of the combined block, etc. The surface roughness of die-casting dies parts not only affects the surface quality of the die-casting part, but also affects the use, wear, and life of the dies. It should be selected according to the work needs of the part. The appropriate surface roughness is shown in the table below. Surface roughness of Die-casting dies: Surface position Surface roughness Ra/pm The forming surface of inserts, cores and other forming parts and the surface of the gating system 0.1~0.2 The mating surface of inserts, cores, sprue sleeves, shunt cones, and other parts ≤0.4 The mating surfaces of guide posts, guide sleeves, push rods, diagonal pins and other parts ≤0.8 Mold parting surface, joint surface between each template ≤0.8 Support surface of core, push rod, sprue bushing, shunt cone and other parts ≤1.6 Other non-working surfaces ≤6.3 contact