We will introduce each step in detail. It was divided into three web pages to share and now introduces steps 1-3 of die casting mold design on this page. Steps Of Die Casting Die(HPDC Mold) Design Die casting mold design, We often said as the design of die casting dies or die casting die design. Also, Which be called die casting mould design in some countries. The basic 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 We will introduce each step in detail. It was divided into three web pages to share and now introduces steps 1-3 of die casting mold design on this page. STEPS OF DIE CASTING DIE(HPDC MOLD)DESIGN I 1. Understand and determine the task 1 The task book of die-casting parts is usually given by the part designer, providing a formal part drawing after review and signing, and explaining the grades and performance requirements of the die-casting alloy materials, the use requirements or technical requirements of the die-casting parts, the production quantity and the delivery of the die-casting parts Delivery period, etc. The mold design task book is generally proposed by the die-casting parts technician according to the task book of the die-casting part, and the mold designer uses the die-casting part-task book and the mold design task book as the basis to design the mold. 2. Design preparation 2 1) Collect relevant information Collect and sort relevant parts design, die-casting process, die-casting equipment, mechanical processing, and special processing materials for use in mold design. Understand the melting of die-casting raw materials and die-casting process parameters. Digest the process data, analyze whether the die casting method, equipment model, material specification, mold structure type, and other requirements proposed in the process task book are appropriate, whether the die casting equipment of the die casting production unit, the processing capacity and equipment conditions of the die processing unit can be implemented. Die-casting materials should meet the strength requirements of die-casting parts and have good fluidity, uniformity, isotropy, and shrinkage. According to the purpose of die-casting parts, die-casting materials should meet the requirements of electroplating metal conditions, decorative properties, necessary mechanical properties, or weldability. 2) Structural analysis of die castings Digest the drawings of die-casting parts, understand the purpose of the parts, and analyze the technical requirements of die-casting parts such as manufacturability and dimensional accuracy. For example, what are the requirements for die-casting parts in terms of appearance and performance, whether the geometric structure of die-casting parts, slope inserts, etc. are reasonable, the allowable degree of die-casting defects such as flow marks, shrinkage holes, and porosity, whether there is a coating, Electroplating, machining, etc? Select the dimension with the highest dimensional accuracy of die-casting parts for analysis, and see if the estimated die-casting tolerance is lower than that of die-casting parts, and whether die-casting parts can be die-casted. Specifically including (1) Under the condition of satisfying the structural strength of die castings, a thin-walled structure should be adopted. This not only reduces the weight of die casting but also reduces the thermal load of the mold. The wall thickness of die castings should be uniform, avoid hot spots, reduce local heat concentration, and reduce thermal fatigue of mold materials. (2) All corners of die-casting parts should have appropriate casting fillets to avoid the formation of edges and corners in the corresponding parts of the mold, resulting in cracks and corners. (3) Narrow and deep cavities should be avoided as far as possible on die castings, so as not to cause sharp splits in the corresponding parts of the mold, which will deteriorate the heat sink and cause fractures. When the die castings have smaller size round holes, they can only be on the surface of the casting. Press the punching hole position of the sample, and then post-process the die-casting part. 3. Select the parting surface and die casting system 3 According to the basic principles of selecting the parting surface, the position of the parting surface is reasonably selected, and the number and distribution of the cavity are determined according to the structural characteristics of the die-casting part, and the form of the gating system is selected reasonably so that the die-casting part has the best die-casting forming conditions and the longest The mold life and the best mold machining performance. Link to: STEPS OF DIE CASTING DIE(HPDC MOLD)DESIGN II Link to: STEPS OF DIE CASTING DIE(HPDC MOLD)DESIGN III contact

Aluminum die casting mold manufacture of (HPDC) high pressure die casting molds, Commonly used alloys metals: ADC12, A380/ADC10, A360, etc. What is HPDC - Aluminum Alloy Die Casting Molds Aluminum alloy die castings can be used in a wide range of industries. Like: Motors, water pumps, electrical appliances, lamps, automobile and motorcycle accessories, electronics, home appliances, and some communication industries, machinery industries, etc. Some high-performance, high-precision, high-quality aluminum alloy products with high toughness are also used in large aircraft, ships, etc. In relatively demanding industries. They mainly used still in the parts of some equipment. Aluminum die parts have thermal conductivity, electrical conductivity, good cutting performance, small linear shrinkage, so it has good filling performance, low density, high strength, and its tensile strength to density ratio is 9-15. It works at high or low temperatures. At the same time, it also maintains good mechanical properties and has good corrosion resistance and oxidation resistance. Commonly used aluminum die casting alloys metals grades: ADC12，A380/ADC10，A360 etc. The Main Physical of Aluminum Alloys As Below: ● ADC12 has good fluidity, is easy to casting, and has relatively balanced properties; it is the most versatile die-cast aluminum alloy and is often used for parts with low-performance requirements such as auto parts, communication cavities, power tools accessories, and medical equipment. ● A380/ADC10 has good fluidity, is easy to casting, has a higher silicon content, and is better than ADC12 in mechanical properties and high-temperature resistance; it is mostly used in engine brackets, gearbox housings, valve bodies, etc. ● A360 has good forming performance, corrosion resistance, fatigue strength, and medium static strength; it is mostly used in instrument housings, street lamp brackets, etc. The aluminum die casting parts can reach a tolerance : Standard: +/- 0.010 inch per 1 inch — then +/- 0.001 inch for each additional inch Precision: +/- 0.002 inch per 1 inch — then +/- 0.001 inch for each additional inch Aluminum alloy die casting mold life: around 100,000- 300,000 shots for a die casting die life depend upon the part/tool design and the Tool steels used. Commonly Mold Steels Used: H-13, H-13, ESR, Assab 8407, Bohler W302, and Assab 8418. etc. CAMEL used Die casting machines for mold trials 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. As of 2020 business data, There are over 60% of die tool projects for aluminum alloy die casting molds in CAMEL. CAMEL is a company specializing in high-pressure die-casting molds (HPDC), and currently has 12 years of experience in the mold industry. 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, meanwhile including surface treatments service based on customers’ requirement, such as Plating chrome, Plating Tarnish, UV Coating, Powder coating, Painting, Anodizing, Blacking, Impregnating, etc. We are ISO 9001:2015 and IATF 16949:2016 certificated company. 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

On this page, you will learn about the types of common die-casting mold steels and their corresponding functions How To Choose Steel For Die Casting Molds What feature of die casting mold steel? Die casting mold steel has the characteristics of high production efficiency, short production process, high casting finish and strength, less machining allowance, and metal material saving. It can produce a good surface and internal quality stably and efficiently. The mold material is required to have high strength, hardness, and thermal stability, especially high thermal strength, thermal fatigue, toughness and wear resistance. Die casting mold generally use hot mold steel H13, SKD61, 8407, 8418. We recommend the steels from these two companies： https://www.swiss-steel.com/ https://www.lkm.com.cn/tool_steel_advantage.php The following requirements when selecting die casting mold steel: Working conditions of the die casting mold The working conditions of die-casting molds are very harsh compared with other molds. Because of different die-casting metals, they have to withstand a high pressure of 150-500MPa. It is often in contact with molten metal at 300℃～1000℃ when working, and the pouring temperature of different die-casting alloys is also different. And the heating and cooling are repeated continuously, and the temperature gradient along the cross-section is very large. When the mold cavity with molten metal injected at a high speed of 150m/s～70m/s, severe wear will occur. Under the action of liquid metal erosion, the metal is easy to adhere to the surface of the mold cavity, and even penetrate into the mold surface to corrode the mold. Other requirements of die casting mold steel Pressure casting can cast parts with complex shapes, high precision, small surface roughness, and good mechanical properties. Therefore, the die-casting mold steel should have the following requirements as below: Greater high-temperature strength and toughness Excellent high temperature wear resistance, oxidation resistance, and tempering resistance stability Good thermal fatigue performance High resistance to melt damage Good hardenability, small heat treatment distortion Good machinability and grinding properties The internal structure of the material is uniform without defects Principles for the selection of die casting mold materials It can meet the requirements of the working conditions of the die-cast material. The mold size is determined according to the size of the die-cast part. Large and medium-sized precision die-casting molds should be made of steel with good processing performance, reliable performance, and long mold life. Free Quote & Part Analysis → H13 die casting mold steel H13 is hot die steel, which is formed by adding alloying elements on the basis of carbon steel. H13 die steel is used to manufacture forging dies with high impact load, hot extrusion dies, precision forging dies; die-casting dies for aluminum, copper, and their alloys. 8407 die casting mold steel 8407 is mainly used for various metal die-casting molds, high-quality plastic injection molds. Such as engine molds, automobile lamp molds, etc. In die-casting molds, 8407 steel can be used for mold inserts, cores, cavities, gates, plungers, sleeves, etc. ASSAB 8407 The advantages of 8407: excellent thermal shock resistance and crack resistance, high-temperature strength, regardless of size, toughness, and ductility, high isotropy, excellent workability, and polishability, excellent hardenability, good heat treatment size Stability, and improvement of mold life. SKD61 die casting mold steel SKD61 has good toughness and high-temperature fatigue resistance, can withstand temperature fusion, is suitable for long-term work at high temperatures, and has good cutting performance and polishing performance. It is suitable for making aluminum, zinc, copper alloy die-casting molds, etc.; it is an ideal material for making ejector pins and barrels. 8418 die casting mold steel 8418 has excellent resistance to thermal fatigue cracking, thermal shock cracking, thermal wear, and plastic deformation. These unique properties make it the best choice for die-casting die steel. Used for zinc, magnesium, aluminum, titanium alloys die casting mold, etc. ASSAB 8418 has the following characteristics: 1. Excellent toughness, ductility, and homogeneity 2. Excellent anti-tempering softening performance 3. Excellent high-temperature strength 4. Excellent hardenability 5. Excellent heat treatment dimensional stability and plating performance How to improve mold life of die casting mold steel: 1.After heat treatment, the die-casting mold steel can ensure its required strength, hardness, stability, thermal fatigue resistance, and material cutting performance. 2.Strengthening the surface of die-casting die steel is currently the most effective way to extend the mold life of die-casting die steel. There are three main types of surface strengthening: It is not changing the surface chemical composition, laser phase change hardening, etc. It is changing the surface chemical composition, nitriding, etc. It is forming a covering layer on the surface, processing by vapor deposition technology, etc. By adjusting the general heat treatment process, the strength and toughness of steel can be effectively improved, and the mold surface can be given high hardness, wear, and corrosion resistance, seizure resistance, low friction coefficient, and many other excellent properties, so that the service life of die casting mold steel can be increased several times or even dozens of times. contact

CAMEL offers specialized die casting mold development and manufacturing for aluminum, Zamak, magnesium, and trim die in all industries. View Our Gallery of Excellence All Designed to Enhance Your Production Efficiency and Quality. Explore Our Gallery: Discover Precision Die-Casting Molds, Trial Production Cases, and Triming die and CNC Fixtures. Die-Casting Molds we bring proven expertise to meet your die-casting mold needs，With over 60% of our molds serving the automotive and machinery industries, and extensive experience in outdoor lighting, telecom, and Office Furniture. Trial Production Cases Our trial production services ensure your molds are production-ready , optimizing processes and performance so you can transition to mass production seamlessly and efficiently. Triming die and CNC Fixtures Beyond molds, we provide essential production tools like trimming dies, CNC fixtures, and inspection jigs, ensuring comprehensive support for your die-casting operations Your One-Stop Solution for Seamless Die-Casting Operations – From Precision Die-Casting Molds to Trial Production Cases and Essential Production Tools, we’re ready to serve you with proven expertise. Contact us today for all your die-casting needs! 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

Mold Components of a die casting mold, CAMEL is a professional die casting mold manufacturer based in China, has a design team with more than 10 years of mold industrial experience. Mold Components of a die casting mold In order to give you a better understanding of the various die words, we have made the following two pictures to give you a better understanding of the relationship between the various die components: Socket head cap screw(HSHCS) Shot sleeve Retaining insert Guide bushing Clamping slot A plate Cavity Guide pin Runner plate Core Heel block Runner Die casting part Ejector retainer plate Ejector plate Ejector pin Overflow Venting passage Vent insert Return pin Safety lock B plate Ejector pin Rails / ejector housing Water connector Support pillar

Trim dies are indispensable tools for high quantity production. Unprofessional mold makers need to adjust the multi-cavity trim die many times by welding. TRIM DIE Using trim tools to labor cost. We focus on building quality die casting dies and trim tools to help the customer save costs for many years. To lower the labor cost and speed up processing in the example below, CAMEL preferred to build five sliders to remove the burr for these 2.0mm small holes (total 10pcs). BLOG contact 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

On this page, you will learn about the differences between HPDC and LPDC, and their functions HPDC vs LPDC Die Casting High-pressure die casting(HPDC) High-pressure casting is a process in which molten metal is poured into a pressure chamber so that the molten metal fills the mold cavity at high speed and then solidifies under high pressure to form a casting. The flow speed during filling can reach 30-80mm/s, and the time for filling the cavity is extremely short. Advantages and disadvantage of HPDC It has the advantages of good surface finish, stable dimensions, and direct molding of thin-walled structures. It is mainly used for the manufacture of shells and other castings, Its work efficiency is high, and it will also provide a smoother surface for finishing. The surface finish depends on the finish of the mold. This high-quality surface can be directly applied to other paints. However, the disadvantage is that it generates high operating and investment costs. In high-pressure production, thicker parts may be difficult to cast. Porosity may also occur in high-pressure die-casting parts, which generally cannot be heat-treated and have high operating costs. Feature and application of HPDC High-speed, high-pressure, and metal casting are the main characteristics of pressure casting production. Thin-walled castings with complex shapes can be cast, and fine grains, holes, teeth, grooves, etc. can be directly cast. The dimensional accuracy and surface quality of the castings are relatively high. High, realizing less cutting or no cutting. Due to the high production efficiency of this die-casting machine and the high metal utilization rate, the application in the die-casting production of zinc, aluminum, and magnesium alloys has a growing trend. The strength and surface bending hardness of the casting are higher, and the tensile strength is 25%~30% higher than that of sand casting. However, due to the fast filling speed of liquid metal, the gas in the cavity is difficult to discharge, and it is often filled with gas under the surface Therefore, under normal circumstances, die castings cannot be heat treated or mechanically processed to avoid porosity on the surface of the casting. HPDC mainly used for the mass production of non-ferrous metals such as aluminum, magnesium, zinc, copper, etc., and it is widely used in industries such as automobiles, meters, electronics, aerospace, lighting, furniture, mechanical, hardware, and communication, etc. In recent years, new technologies such as vacuum die casting, new processes, as well as new equipment such as double-punch die-casting machines, horizontal parting full-vertical die casting machines, etc., have continued to emerge. Although the quality of castings has been greatly improved to effectively control casting defects, there are still have pores, shrinkage holes, and shrinkage porosity. At the same time, due to the continuous emergence of new die-casting materials, the scope of application of die casting will continue to expand. Free Quote & Part Analysis → Low-pressure die casting(LPDC) LPDC is to make the liquid alloy fill the cavity from bottom to top under lower pressure, and crystallize under pressure to cast the casting part. Therefore, compared with high-pressure casting, the pressure is different and the direction of liquid metal flow is different, and it can be heat treated. Advantages and disadvantage of LPDC Due to the stable filling of LPDC and the same direction of liquid flow and airflow, the castings produced by casting have fewer defects such as porosity and slag inclusion; the structure is dense and the mechanical properties of the castings are high; the filling ability is strong, which is conducive to the formation of clear and clear contours. Castings with smooth surface, so important aluminum alloy castings will be low-pressure casting. Although LPDC has a dense structure and better mechanical properties, its productivity is low. After HPDC, the surface quality is better, but there are inevitably some pores inside, and its productivity is high, so it is more suitable for thin-walled castings, but the castings are shrinkage and loose, not dense, and are not used for castings with high airtightness requirements. Feature and application of LPDC LPDC is used when selecting castings with high air-tightness requirements. The production batch is large, and small and medium-sized non-ferrous metal castings without tightness requirements are HPDC. The difference is that LPDC parts can be strengthened by heat treatment, and the toughness can be greatly improved. Therefore, the design depends on the product wall thickness and the weight of the entire product. If the wall thickness is thicker and the product weight is heavier, the LPDC process should be selected. Otherwise, if the wall thickness is lighter, the HPDC process should be selected. The feature of LPDC as below: LPDC can use sand, metal, graphite, etc., and has the following advantages: Filling with pure molten metal improves the purity of castings. The molten metal fills smoothly, thereby reducing the formation of oxide slag. The casting has good moldability. The molten metal is filled under pressure, which can improve the fluidity of the molten metal, which is beneficial to the formation of castings with clear contours and smooth surfaces, and is more beneficial for the molding of large thin-walled castings. The casting is solidified under pressure, and the structure of the casting is dense. Convenient production and operation, good working conditions, high production efficiency, and easy realization of mechanization and automation. contact

Failure Mode and Analysis of Aluminum Alloy Die-casting Dies. Aluminum alloy die-casting dies as bearing high temperature, high pressure, and high-speed aluminum liquid carrier, its working environment is extremely harsh. 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

​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 ALUMINUM DIE CASTING MOLD PROCESS PRODUCT PARAMETERS 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

Die-casting die life and material, design, manufacturing, and maintenance have a close relationship. In the actual application, we found that the influence of die-casting die life of each Factors accounted for the proportion of roughly as follows: mold design and manufacture How to extend the life of die casting dies The service life of die-casting dies is closely related to the material, design, manufacture, and maintenance. In the actual application, we found, affect the die-casting dies life of the proportion of each element is rough as follows: mold design and manufacturing about 80%; including mold materials about 10% ~ 15%; mold use and maintenance and maintenance of about 5% ~ 10%. Take the following measures is to avoid die-casting mold failure, improve its life effective method. 1. Mold material 2. Mold design 3. Mold manufacturing 4. Heat treatment of the mold 5. Use and maintenance of the mold 1. Mold material 1 Die cavity material should be selected with the excellent overall performance of the hot work mold steel. Try to use finer grain, isotropic good, good heat treatment performance of the material as the mold cavity material. At present, the domestic common use SK61, DACS5, 8407, and other imported materials as mold cavity materials. Before the mold material is put into processing, the appearance inspection, metallographic inspection, and ultrasonic flaw inspection should be used to check the material to avoid using defective material, which will cause early scrap of the mold. 2. Mold design 2 (1) Pouring system design The pouring system design is the core part of die casting mold design, especially the position and size of the inner sprue. When choosing the location of the inner sprue, try to avoid the frontal impact of the aluminum liquid on the core, in order to reduce the generation of erosion. In the case of ensuring that the casting is well-formed, increase the cross-sectional area of the inner sprue, so that the aluminum liquid enters the cavity in the form of laminar flow, thus reducing the speed of the inner sprue and reducing the impact of the aluminum liquid on the cavity. (2)Forming parts design As far as possible to avoid sharp corners, in order to prevent the corresponding parts of the mold due to stress concentration and cracking. The unavoidable vulnerable parts, such as the slender core, should be used in a reasonable patchwork structure, so as to facilitate timely replacement when damaged. (3)Formwork design Determine the appropriate thickness of the template, so that it has sufficient rigidity and strength to effectively resist bending deformation. In the template, especially the structure design of the moving mold template, the integral template instead of the traditional support plate and through the template, is conducive to improving the overall bearing capacity of the die casting mold. (4)Design of guiding parts First of all, each guide part should choose the correct tolerance fit and surface roughness level. Second, improve the structure of the guiding parts, such as with the slider with the side and bottom surface into easy to replace the guide slip, while the guide slip chooses to wear resistance and thermal expansion of better alloy materials. (5) Easy to replace the design of maintenance For the easily damaged core and sliding fit parts, design the structure to facilitate rapid replacement and maintenance. Such as the core from the step-type fixed structure to the screw-type connection structure. (6) Maintain the thermal balance of the mold Reasonable design of cooling system to ensure the overall thermal balance of the mold. If conditions permit, you can choose to configure the mold temperature balancing system. (7)Apply CAD/ CAE technology CAE simulation analysis is carried out to determine the distribution of temperature field, flow field, and stress field of the mold after the preliminary design has been completed. And on this basis, the mold design optimization, in order to improve the overall quality of mold design, so as to improve the die casting mold life to provide a strong guarantee. 3. Mold manufacturing 3 (1)Develop reasonable processing technology The machining process of the mold is the link that directly affects the life of the mold and needs to pay attention to the details of the process. For example: choose the appropriate processing benchmark, it is best to unify the parts of the processing benchmark, in order to reduce the cumulative error; two-sided butt method of processing longer cooling water hole, in order to ensure the smooth surface of the water hole at the same time, should also pay attention to ensure its coaxial, to avoid stress concentration and cracking; comprehensive use of CAD / CAM technology, improve the accuracy of processing, etc. (2)Electric discharge machining EDM is widely used in mold manufacturing. After EDM, a hardened layer appears on the surface of the cavity. The thickness of the hardened layer is determined by the current intensity and frequency of machining, which is deeper for rough machining and shallower for finishing.2 No matter how deep or shallow the hardened layer is, it will produce large stress on the surface of the mold. Therefore, the hardened layer should be eliminated or stress relieved by high-frequency EDM and other technological measures. (3) Grinding The large amount of frictional heat generated by grinding may soften the surface of the mold and reduce its ability to resist thermal fatigue, thus causing early failure of the mold. Therefore, when grinding, the amount of coolant should be moderate, and avoid excessive grinding volume and feed to avoid fine cracks in grinding. (4)Weld repair Welding is a common means of repairing mold processing errors. When welding, the surface is thoroughly cleaned and dried, the mold is preheated to 440~460℃ together with the welding rod, and after the surface of the mold is at the same temperature as the heart, the welding is carried out under protective gas. After the repair is completed, temper once at a temperature 50~80 below the original tempering temperature to eliminate stress. (5)Polishing Focus on polishing the narrow seams and deep grooves in the cavity to ensure that the overall roughness of the cavity reaches 0.2um, so as to reduce the flow resistance of the cavity surface and improve its resistance to galling and fatigue. 4. Heat treatment of the mold 4 (1)Quenching and tempering Vacuum quenching can effectively prevent the cavity surface decarburization and carbonization, reduce the early cracking of the mold caused by inadequate dissolution of carbide during heat treatment. After vacuum quenching, 2~4 times tempering is required. In general, the larger the mold, the higher the quenching temperature, and the lower the tempering temperature. (2)Stress relief tempering The new mold in the mold after passing the test should be tempered to eliminate stress. (3)Nitriding Nitriding treatment of cavity surface can improve the ability of mold surface to resist wear, adhesion, and thermal fatigue. After the new mold is qualified, the first nitriding is carried out. In the process of use, the timing of nitriding is determined according to the specific maintenance procedures and the condition of the mold. When nitriding, the hardness of the nitriding substrate should be between 35~43HRC, and the thickness of the nitriding layer should not exceed 0.15mm, and attention should be paid to the cleanliness of the nitriding surface to ensure the uniformity of the nitriding layer. When the cracking of the mold is serious, nitriding is not suitable. 5. Use and maintenance of the mold 5 (1)Reasonable setting of die-casting process parameters Under the premise of ensuring the quality of the castings, try to reduce the pouring temperature of the aluminum liquid, injection speed and injection pressure, shorten the high temperature holding time, especially to eliminate the practice of relying solely on increasing the injection pressure to improve the quality of the castings. In addition, you can use the parameter tester to seek the best combination between the parameters. (2) Evenly preheat the mold Avoid using the gas heating method to preheat the mold to prevent different thermal expansion of each part due to uneven preheating. It is better to preheat the mold with the oil temperature of the mold temperature machine. In the case of no mold temperature machine, can use the method of several molds before test pressing, rely on aluminum liquid preheat mold cavity. (3)Spraying evenly Focus on spraying the deep cavity of the mold, and at the same time, pay attention to avoid long-time spraying. (4)Keep the heat balance of the mold Regularly check and clean the cooling system to prevent the cooling water channel from being blocked, so as to ensure a stable mold temperature. (5)Timely mold inspection Pay attention to check whether there are cracks, crazing, and erosion on the mold surface. If these conditions appear, it is necessary to use the method of welding repair in time. If the nitriding layer on the surface of the mold cavity is partially damaged, the nitriding treatment should be carried out again. (6) Periodic stress relief tempering This is an effective method to retard cracking. According to the size and complexity of the mold to determine the time interval of stress-relieving tempering. In general, the aluminum alloy die casting mold in the first batch production 5000 ~ 8000 times, after every 10000 ~ 15000 times for stress relief treatment. However, if the mold cracking is serious, it is not suitable to carry out stress relief tempering, so as not to intensify the expansion of cracks. (7)The mold maintenance when stopping During the production, when stopping temporarily, you can reduce the cooling water flow and let the mold cool slowly. If it is stopped for a long time, the mold must be thoroughly cleaned and maintained and put into storage after passing the inspection. (8) Operation training Pay full attention to the operator's work training, to eliminate the mold damage caused by improper operation. Conclusion: Improving the life of aluminum alloy die-casting mold is a comprehensive technical issue. In the actual application, comprehensive consideration of the role of the influencing factors, and take targeted measures, it is possible to improve the service life of aluminum alloy die-casting dies. contact

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Zinc alloy is the main material for zinc die casting mold. such as Zamak #3 ZINC DIE CASTING MOLDS 1/1