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  • 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.

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  • SHENZHEN CAMEL DIE LIMITED | DIE CASTING MOLD MANUFACTURER AND SUPPLIER IN CHINA | Die Casting Mold | No.310-315, Chengtou Business Building, Qinglin West Road, Longgang District, Shenzhen, CHINA

    OVER 10 YEARS OF DIE CASTING MOLDS BUILDING DIE CASTING MOLDS FACTORY OUR PHILOSOPHY REDUCE COST We focus on building quality die casting dies and trim tools to help the customer save costs for many years. OPTIMAL CYCLE-TIME It's Our job that develop and build dies that support best-in-class cycle-time, part quality, and the longer die life. EFFECTIVE COMMUNICATION Our engineers fully understand the mold industry and how to communicate effectively with your clients. EASY MAINTENANCE We deeply believe that good mold maintenance ensures a longer mold life and smooth production. HIGH-QUALITY PRODUCTION More than 10 years of experience work in the mold industry, Build over 240 sets of molds per year. SHORT LEAD-TIME 100% Export business from China to Europe and American, Professional shipping personnel to solve various cross-border transportation services. TEAM CO-DESIGN We communicate with the client about each specific matter and then meet to discuss the design plan until the best plan is reached. AVOID RISK We strictly control each phase of the processes and conduct staff safety training to ensure safe work and reduce processing risks. PROJECT MANAGEMENT We operate every step in strict accordance with or even beyond industry regulations and ERP system process specifications. 24/7 Hours Online Pre-sales Service 1. Request For Quote 2. Design For Manufacturing 3. Flow Simulation & FEM 4. Mold Design 5. Engineering Work 6. Quality Control 7. Sampling 8. Inspection Report 9. Maintenance 10. Shipment Global After-sales Service ABOUT US SHENZHEN CAMEL DIE LIMITED is a professional die casting mold manufacturer and supplier founded in 2009, China, provides high-quality die casting mold design , stable mold development , and mold production export from China to North America & Europe. One of the worldwide leading mold manufacturers specializing in high pressure die casting (HPDC) mold build in-house. Currently, our factory has 15 sets of CNC machines and the primary material covers aluminum alloy , zinc alloy , and magnesium alloy . In addition, one-stop manufacturing service for all industrial applications, such as automotive, telecom equipment, electrical appliances, mechanical, motorcycle accessories, lighting, home appliances, medical instruments, aerospace, and machinery industries, etc. Our first factory located in Dongguan city with 5,400 square meters for mold building , supplies a capacity of around 285 sets per year. And the second factory, estimated in 2019 located in Huizhou city with 6,100 square meters to make tools and dies about 240 sets of large molds per year. Essential equipment for die casting mold manufacture including CNC, EDM, WEDM, Fixtures, CMM, OMM, die spotting machine, oil temperature machine, and mold trial machine. ​ We are also ISO 9001:2015 and IATF 16949:2016 certificate plant. ABOUT US OUR PERFORMANCE 97.14% On-Time Delivery 240 Sets Average Annual Capacity 24- Hours Hotline Service 9 Locations Global After Service Contact

  • About Us | SHENZHEN CAMEL DIE LIMITED

    ABOUT US SHENZHEN CAMEL DIE LIMITED was founded in 2009, With over 12 years of molds manufacturing and cooperation with many famous companies, like GE, Boeing, Whirlpool, Harman/Kardon, Parker Hannifin, Bentley, Lotus Cars(UK), Range Rover, Jaguar, Mercedes-Benz, BMW, BRP, Audi, Nissan, Honda from automotive, appliance, aerospace and casino & gaming industries. A complete and highly active project control system with effective communication in English had been developed, ensure good quality and the best lead time . ​ Our first factory is located in Dongguan city with 5,400 square meters of molds making a capacity of around 285 sets per year. And the second factory estimated in 2019 located in Huizhou city with 6,100 square meters to build tools & dies around 240 sets of large molds per year. Key equipment for die casting mold build including CNC, EDM, WEDM, fixtures, CMM, OMM, die spotting machine, oil temperature machine, die-casting machine (mold testing), etc. PHILOSOPHY Respecting suppliers: Discuss the matter according to the facts. Conduct business fairly and communicate efficiently to solve any problems. Share our development goals together for a clear understanding. if the supplier does not match our standards, they will be replaced. 01 RESPECT Respecting colleagues: Listening carefully Equal communication Avoiding shirking responsibilities Solving problems together 02 Respecting work: Keeping our promise Valuing work time Observing professional ethics 03 How do we retain efficiency? 1. By focusing on doing things right the first time. 2. By planning accurately to reduce unnecessary work. 04 Presentation Of CAMEL DIE 2021 (.pdf)

  • 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

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