Parts processing inspection is the fundamental guarantee and basis of parts accuracy and mold product quality, mold parts inspection content and inspection means depending on different production conditions and production scale and different. Because the mold processing belongs to the single-piece production, processing processes, parts surface complex, its quality inspection, and conventional testing are slightly different. At the same time for the mold cavity hardness, corrosion resistance and ornamental processing requirements are difficult to achieve through the general testing methods, only through certain processing methods and process measures to ensure. Sometimes the test results of mold parts can not be evaluated by qualified or not, such as the cavity surface polishing usually indicates the quality of polishing. This is the difference between mold parts testing and ordinary parts testing. Mold parts inspection content Mold parts inspection content is mainly geometric inspection, including size tolerance, shape tolerance, position tolerance, surface roughness and threaded core, cavity tolerance, etc. Dimensional tolerance requirements are to ensure the accuracy of the size of the parts, with dimensional tolerance requirements, are to ensure the interchangeability of the parts, the accuracy of the fit of the motion vice, fit clearance, and deviation. There are two kinds of dimensional tolerances: linear dimensional tolerance and angular taper tolerance. Shape tolerance requirements are to ensure the accuracy and working performance of the mold. Shape tolerance is for a single element, including straightness, flatness, roundness, cylindricity, line contour, and surface contour, etc. Position tolerance is for the associated elements, including parallelism, perpendicularity, inclination, coaxial, position, and symmetry, etc. Surface roughness is an indicator that characterizes the microscopic morphological error of the workpiece surface. Thread inspection includes single-content inspection (such as pitch, tooth angle, mid-diameter, etc.) and comprehensive inspection. 1. Mold plate parts This type of parts mainly affects the closing accuracy and movement accuracy of the mold and is also an important reference surface in the process of processing and assembly, which needs to focus on the inspection of the surface roughness of the upper and lower plane, parallelism, flatness, perpendicularity with the side, cylindricity of the hole system, perpendicularity, hole size, and hole spacing size. 2. Cavity type parts These parts are directly related to the dimensional accuracy of the plastic parts, which is the core part of the mold processing but also needs to focus on the content of the inspection. The inspection of cavity parts includes almost all the contents of dimensional tolerance, shape tolerance, position tolerance, surface roughness and tolerance of threaded core and cavity, etc. At the same time, there are also requirements of release slope and surface quality inspection, such as the evaluation of polishing quality and the judgment of whether the plating is off. 3. Structural parts These parts have the function of guidance and movement, such as guide pillars, guide bushings, sliders, etc., the surface quality requirements are high. Guide pillar inspection indicators are the coaxial, cylindricity, radial dimensions of each step axis section. The guide sleeve is mainly to detect the coaxial, cylindricity, and radial dimensions of its internal and external cylindrical surface. The slider has high accuracy requirements for the parallelism, flatness, and angle of the locking bevel of the sliding fit surface. The tie rod mainly detects the consistency of the axial functional dimensions, and the pressure plate mainly detects the parallelism, perpendicularity, and consistency of the functional dimensions. For push rods, reset rods, and other outsourced parts mainly from the incoming channels to ensure quality, you can test the radial dimension, hardness. 4. Standard parts class parts The inspection of standard parts class parts needs special equipment, which is difficult to carry out in general enterprises, but the premature fatigue of screws and premature failure of reset springs may cause damage to the mold. So we should use some products from famous enterprises with good quality and high reputation to avoid similar problems.

In addition to the quality of die casting is affected by a variety of process factors, the structural design of its parts is also a very important factor, its structural rationality and process adaptability determine whether the subsequent work can be carried out smoothly. Die-casting production technology problems encountered, such as the selection of the parting surface, the design of the sprue, the layout of the launch mechanism, the mastery of the shrinkage law, the guarantee of precision, the type and degree of defects are related to the die-casting process of the die casting itself. 1, Die-casting Process Requirements For Die Casting Structure. Design die casting in addition to structure, shape, and other aspects have certain requirements, but also should make die casting adapt to the die-casting process. Die casting structure design directly affects the die casting mold structure design and manufacturing of the degree of difficulty, productivity and mold life, and many other aspects, so the design of die casting must emphasize the cooperation between the designer and die casting process personnel, so that die casting in the die casting process may appear many unfavorable factors to be considered in advance and to be excluded. If the designer is also familiar with the die-casting process, then the design of the structure of the die casting is usually more reasonable. The requirements of the die-casting process for die-casting structure design are as follows. Requirements To be able to easily remove the die casting from the mold; To try to eliminate the side concave, deep cavity; To minimize the core extraction part; To eliminate the crossed parts of the mold core; The wall thickness should be uniform; To eliminate sharp corners. Description All the obstacles that are not conducive to the die casting out of the mold should try to eliminate in advance when designing the die casting; Internal side concavities and deep cavities are the biggest obstacles to mold release. When it cannot be avoided, it should also facilitate the extraction of cores to ensure that the die casting can be removed from the die casting mold smoothly; Each additional core extraction makes the mold more complex and increases the risk of mold failure; When the core crosses, not only make the mold structure complex but also prone to failure; When the wall thickness is not uniform, the die casting will have shrinkage deformation due to the different solidification rates and will produce internal shrinkage and pores, and other defects in the thick part; Reduce casting stress. 1.1 die casting should simplify the mold structure, extend the life of the mold. 1) design die castings as far as possible to make the parting surface simple; 2) to avoid partial thinning of the mold, to ensure that the mold has sufficient strength and rigidity; 3) to prevent the die casting deformation. 2, The Structure Of The Die Casting Process Elements The basic structural process elements of die casting include wall thickness, ribs, casting holes, casting rounding, release slope, thread, gear, slot gap, rivet head, convex pattern, mesh, text, logo, pattern, embedded casting, etc. 2.1 Wall thickness and rib design Die casting reasonable wall thickness depends on the specific structure of the casting, alloy properties and die-casting process, and many other factors. The practice has proved that, as a rule, the mechanical properties of die casting with the increase in wall thickness and decrease. Thin-walled castings than thick-walled castings have higher tensile strength and denseness, thin-walled die casting wears resistance is also good. Die castings with the increase in wall thickness, its internal porosity, and loosening and other defects also increased, so in order to ensure that die castings have sufficient strength and stiffness of the premise, a reasonable wall thickness should be designed into a thin wall and uniform wall thickness, otherwise, it will lead to the uneven internal organization of die castings, but also to the implementation of the die-casting process increases the difficulties. In the usual process conditions, the wall thickness of the die casting should not exceed 4.5mm, the maximum wall thickness and minimum wall thickness ratio should not be greater than 3:1. The thick wall of the die casting, in order to avoid defects such as sparse, should be thinned wall thickness and additional reinforcement ribs.

With the progression of science and technology, the market competition is becoming more and more fierce, and the product renewal cycle is getting shorter and shorter, therefore, shortening the development cycle of new products and reducing the development cost are the urgent problems faced by every manufacturer, and the requirement of rapid mold manufacturing comes into being. Rapid mold making technology includes the traditional rapid mold making technology, such as low melting point alloy mold, electroforming mold, etc., and Rapid Prototyping (RP) for rapid tooling. Principles and characteristics of rapid prototyping technology There are many specific process methods of rapid prototyping technology, but the basic principle is the same, that is, the material addition method is the basic method to rapidly transform a 3D CAD model into a 3D solid prototype composed of specific substances. Firstly, a 3D CAD model is obtained in the CAD modeling system, or the shape and size of the entity are measured by measuring instruments and transformed into a CAD model, then the model data is processed and discretized in a plane layering along a certain direction, and then the embryo is processed by a special CAM system for layering forming and stacking into a prototype. Rapid prototyping technology opens up the way to rapidly manufacture various parts without any tool and provides a new manufacturing means for parts or models that cannot or are difficult to manufacture by conventional methods. It has shown good application prospects in the fields of aerospace, automotive design, light industrial product design, human organ manufacturing, architectural design, mold design, and manufacturing. In summary, rapid forming technology has the following application characteristics. 1, because rapid forming technology uses the mechanism of transforming three-dimensional shapes into two-dimensional planar layered manufacturing, it is insensitive to the complexity of the geometric structure of the workpiece, thus it can manufacture complex parts, fully reflect the design details, and directly manufacture composite parts. 2, rapid manufacture of molds ①Can manufacture metal molds from die castings with the help of electroforming, arc spraying, and other technologies. ②The rapid manufacturing prototype as a vanishing mold also can be used for batch manufacturing of vanishing molds for precision casting by prototype turning and manufacturing master molds. ③Fast manufacturing of high precision complex master molds for further casting of metal parts. ④Make graphite electrode by prototype, and then process the mold cavity from graphite electrode. ⑤ Direct machining of ceramic cavities for precision casting. 3, application in new product development, through the prototype physical model, the designer can quickly assess the feasibility of a design and fully express its conception. ①Shape design. Although CAD modeling systems can view the design model of a product from all directions, they are in no way as intuitive and visible as the prototypes obtained from RP, especially for complex shapes. Manufacturers can use conceptual prototypes as a promotional tool to sell their products, i.e., they can use RP prototypes to quickly allow users to compare and evaluate the new products they develop and determine the optimal appearance. ②Checking design quality. Taking mold manufacturing as an example, the traditional method is to open the mold on a CNC machine according to the geometric shape, which is too risky for expensive and complex molds, and any carelessness in the design may cause irreparable damage. Using RPM technology, the parts to be die-cast can be accurately manufactured before the mold is opened, and various subtle problems and errors in the design can be seen at a glance on the model, greatly reducing the risk of blind mold opening. the model made by RP can also be used as a CNC copy milling machine against the mold. ③ Functional inspection. Using prototypes to quickly perform functional tests of different designs to optimize product design. For example, the design of a fan, etc., can obtain the best fan blade surface and the lowest noise structure. 4, rapid forming process room is highly automated, long time continuous, simple operation can do day and night unattended, once the machine is turned on, can automatically complete the whole workpiece processing. 5, the manufacturing process of rapid forming technology does not require the input of tooling, and its cost is only related to the operating cost of the forming machine, material cost, and operator's salary, and has nothing to do with the batch of products, which is suitable for the manufacturing of the single piece, small-batch, and special and new trial products. 6, reverse engineering in rapid modeling has a wide range of applications. Laser 3D scanners, automatic tomography scanners, and many other measuring devices can quickly measure the internal and external contours of objects with high precision and convert them into CAD model data for RP processing. RP-based Rapid Tooling Technology In the field of rapid prototyping technology, the most rapidly developing and obvious growth of production value is Rapid Tooling, RT technology. By applying Rapid Prototyping technology to make Rapid Tooling RP+RT, we can greatly improve the success rate of product development, effectively shorten the development time and reduce the cost by conducting new product trials and small batch production before the final production mold. RP+RT technology provides a new concept and method of manufacturing molds directly from mold CAD models, which integrates the conceptual design and machining process of molds within one CAD/CAM system, creating good conditions for the application of parallel engineering. RT technology adopts RP multi-loop, rapid information feedback design, and manufacturing method, combined with various computer simulation and analysis means, forming a set of A new mold design and manufacturing system. The manufacturing of rapid tooling using rapid prototyping technology can be divided into two categories: direct rapid tooling manufacturing and indirect rapid tooling manufacturing. 1, Direct Rapid Tooling Manufacturing Direct rapid tooling manufacturing refers to the direct fabrication of a mold using different types of rapid prototyping techniques, followed by some necessary post-treatment and machining to obtain the required mechanical properties, dimensional accuracy, and surface roughness of the mold. Currently, the rapid prototyping processes that can directly manufacture metal molds include selective laser sintering SLS, shape deposition manufacturing SDM, and 3D Welding. Direct rapid mold manufacturing links are simple and can more fully exploit the advantages of rapid forming technology, especially in close combination with computer technology, to quickly complete mold manufacturing. For those injection molds that require complex shapes and internal runner cooling, the use of direct rapid mold manufacturing has advantages that cannot be replaced by other methods. Production injection molds can be produced in 5-10 days using the SLS direct rapid mold manufacturing process. 2, Indirect Rapid Tooling Manufacturing Using rapid prototyping master mold and pouring soft materials such as wax, silicone rubber, epoxy resin, or polyurethane, it can constitute a soft mold. The mold life of the injection mold made with this synthetic material can be up to 50-5000 pieces. A hard mold can be made by combining a rapid prototyping master mold or a soft mold with traditional processes such as investment casting, ceramic precision casting, electroforming, or cold spraying, which can produce plastic or metal parts in bulk. Hard molds usually have better machinability and can be partially machined for better accuracy and can be embedded with inserts, cooling parts, and sprue, etc.

Production of high-quality, economic die castings, in addition to a reasonable casting structure, perfect die casting die, and good die casting machine, but also must choose the appropriate die casting alloy. CAMEL dedicated designers in the selection of die casting alloy must consider the die casting stress state, working environment, production conditions, and economic 4 aspects, must also consider the alloy itself comprehensive properties. Die casting alloys selection generally follows the following principles. 1. Sufficient strength and plasticity at high temperatures, no or less thermal embrittlement. 2. Small crystallization temperature range. 3. Sufficient fluidity when the superheat is not high. 4. Small shrinkage. 5. Good physical and chemical properties - wear resistance, corrosion resistance, electrical conductivity, and thermal expansion, etc. 6. Good processability. Types of die casting alloys Die casting alloys are divided into non-ferrous alloys and ferrous alloys, currently widely used non-ferrous alloys, classified as follows Die casting non-ferrous alloys Low melting point alloy: lead alloy, tin alloy, zinc alloys. High melting point alloys: aluminum alloys, magnesium alloys, copper alloys. Properties comparison Comparison of the properties of various die casting alloys The property varies from "1" to "5". "1" means the most desirable, and "5" means the worst. Main alloy material of die casting Among them, the density of die casting aluminum alloy is about 2.7g/cm3, which can also be called light metal, and its property characteristics are very suitable for the die casting process. Aluminum alloys is the most used alloy for die casting. Die casting aluminum alloy has the characteristics of low density, high specific strength, good corrosion resistance, wear resistance, good thermal conductivity, good electrical conductivity, good cutting properties, etc. The die casting process is accompanied by a fast solidification rate, making the die casting alloy slightly better than gravity casting and casting alloys with the same chemical composition. yl112 alloy has better machinability. The 518 alloy with magnesium as the main alloying chemical element has the best machinability. The A390 alloy with high silicon content and incipient silicon phase have the worst machinability.

Die Casting Process (Fully automatic die casting cycle) Mold cleaning Mold preheating Paint spraying Placement of inserts Mold closing Pouring Press injection Solidification Open the mold Push out and take the parts Die casting can be divided into two categories: hot chamber die casting machine pressure casting and cold chamber die casting machine pressure casting, of which cold chamber die casting machine pressure casting is divided into vertical, horizontal and full vertical die casting machine die casting. Commonly Used Die Casting Machine Die Casting Process 1, Hot press chamber die casting machine die casting process The pressure chamber of hot die casting machine is in the insulated crucible molten alloy, the press injection parts are mounted on top of the crucible, and when the press injection punch rises, the molten alloy enters the chamber through the inlet. When the die is closed and the press punch is pressed down, the molten alloy fills the die through the nozzle along the channel and cools and solidifies. When the die punch returns, the die is opened and the part is taken, completing a die casting cycle. 2, Die casting process of vertical cold chamber die casting machine The center of the vertical cold chamber die casting machine is parallel to the parting surface of the mold, which is called vertical side chamber. After closing the mold, the molten alloy poured into the chamber is held by the counter punch which has sealed the nozzle hole; when the press injection punch goes down to the molten alloy, the counter punch starts to descend to open the nozzle and the molten alloy is pressed into the mold cavity; after solidification, the press injection punch returns and the counter punch rises to cut off and push out the residual material; after the residual material is taken away, the counter punch descends to the original position and the mold is opened to take the parts, completing a die casting cycle, this die casting machine is especially suitable for This kind of die casting machine is especially suitable for the production of die casting machine with center gate. 3, Horizontal cold chamber die casting machine die casting process The center line of the horizontal cold chamber die casting machine is perpendicular to the mold parting surface, called horizontal chamber. After the mold is closed, the molten alloy is poured into the chamber, and the injection punch is pushed forward to fill the cavity through the sprue; when the mold is opened, the injection punch pushes out the remaining material, the die pushing out mechanism pushes out the die casting, and the punch is reset to complete a die casting cycle. 4, The die casting process of all vertical cold chamber die casting machine The die casting machine with vertical arrangement of die closing mechanism and press injection mechanism is called all-vertical die casting machine, which can be divided into the following two types. 1) The die-casting process of the punch head press type all-vertical cold chamber die-casting machine. The molten alloy is first poured into the chamber and then the die is closed, the pressurized injection punch rises to press the molten alloy into the mold cavity, and after cooling and solidifying, the die is opened and the die casting is pushed out, and the punch is reset to complete a die casting cycle. 2) The die casting process of punch down type all vertical cold chamber die casting machine. After the mold is closed, the molten alloy is poured into the mold, and when the pressurized punch goes down to the molten alloy, the counterpunch goes down to open the channel, and the molten alloy is pressed into the mold cavity through the sprue; after solidification, the pressurized punch returns, and the counterpunch goes up to cut off and push out the remaining material. After the remaining material is taken away, the counter punch is reset to complete a die-casting cycle. In the above die-casting method, horizontal cold chamber die-casting machine is most widely used. Global Brand Of Horizontal Cold Press Chamber High Pressure Die Casting Machine: China: LK, YIZUMI, HAITIAN, SANJI, ZITAI, RUIDA, YANHING, MULER Japan: TOYO ,TOSHIBA , UBE U.S.: HPM (Acquired by YIZUMI in 2011) Switzerland: BUHLER German: FRECH Italy: IDRA , ITALPRESSE

What is mold temperature control? and how to balance the heat energy in the mold processing program? Then we introduce the related MTC, heat energy balance, and cooling system to propose solutions. The Influence Of Mold Temperature On Mold And Die Casting Mold temperature is one of the important factors affecting the quality of die castings, but it is often not strictly controlled during the production process. Especially in the production of complex die castings, only the temperature is controlled within a certain range to produce qualified die castings, and this temperature range is relatively narrow. At this time, the mold temperature must be strictly controlled. In each die-casting cycle, the temperature in the mold cavity changes. The heat source to raise the temperature of the mold is the heat brought in by the molten metal, and the heat energy is converted into the part of the mechanical energy consumed by the molten metal to fill the cavity. When the mold receives heat, it also radiates heat to the surroundings. If the heat absorbed by the mold and the heat dissipated in a unit of time is equal and reaches an equilibrium state, it is called the heat energy balance of the mold. What is MTC(Mold Temperature Controller) The mold temperature controller controls the temperature of the mold during thermal equilibrium within the optimal working temperature of the mold. The temperature control of the mold is achieved through the heating and cooling system of the mold. In the continuous die-casting process, the mold temperature goes through a cycle of rising and falling for each injection. In order to avoid the thermal shock of the molten metal on the low-temperature die-casting mold and shorten the life of the die, the molten metal will be chilled to lose fluidity, increase the line shrinkage, cause cracks or cracks to affect the quality of the die-casting, the mold must be fully preheated before die-casting. In continuous production, especially when die-casting high melting point alloys, the mold heats up very quickly, causing the molten metal to stick to the mold, the die-casting part is pushed out and deformed, the mold is partially stuck or even damaged, and the mold opening time is prolonged, reducing the productivity, and the die-casting part cools slowly. And make the crystal grain coarse. Therefore, when the temperature of the die-casting mold is too high, cooling measures should be taken to keep the mold in thermal equilibrium. How Does CAMEL Balancing Heat Energy CAMEL designs ample cooling lines on the fixed side and movable side to control the heat energy balance to get the best cycle-time and part quality. The balanced heat energy also lowers the risk of die cracking.

When you first get involved in casting, especially die casting, one of the very important steps in the design process is mold flow simulation. But why we do mold flow analysis and what is mold flow simulation? We will start with these two aspects and introduce the reasons and methods. High Pressure Die Casting Simulation The die casting process designer is a complex and empirical creative job. In die casting production, the three main elements are die casting machine, die casting alloy and die casting mold. The die casting process is the organic combination of these three elements and the reasonable choice of settings. Therefore, to die casting process parameters for the correct selection, control, and adjustment, so that a variety of process parameters to meet the needs of die casting production, in order to produce qualified die casting under other conditions of quality. CAE Technology Make use of the powerful computing and graphic functions of computers to assist mold design, improve the design accuracy and design reliability, design reasonable mold structure and reasonable pouring system. Numerical simulation of the die casting process by CAE technology, commonly known as computerized mold testing, visualizes the whole process of flow and solidification of metal liquid in the cavity during casting generation and analyzes the factors of defect formation. Mold Flow Simulation and Analysis With the continuous development of simulation technology, computer hardware, and software, The needs of the casting market, the numerical simulation of the casting process is to establish the correct mathematical models, and through the appropriate values, use the computer to analyze these models and use them to guide the casting practice in terms of flow, temperature, organization, etc. The simulation results are observed through post-processing, and the flow and solidification process of the metal fluid in the cavity is animated through multiple angles and profiles to track the view and locate the defective parts inside the casting. To support our customers in getting the best productivity and part quality, CAMEL always provides flow simulation by designing various kinds of runner layouts. By doing this our T1 success rate is over 96%. In this preliminary flow simulation, it appears that the outermost feeders are not supplying hot metal directly to problem areas while the center section is filling well. CAMEL adjusted the runner layout as shown below for a successful T1. Step 1: Eliminate (2) end feeders and make them overflow. Step 2: Change the feeder angle and gate towards the outer edge of the part. ABOUT CAMEL CORE BUSINESS: Aluminum Alloy Die Casting Mold Magnesium Alloy Die Casting Mold Zinc Alloy Die Casting Mold Trim Die(Mold) Milling & Turning Design & Prototyping CUSTOMERS MAIN INDUSTRIES: Automotive Telecom Equipment Mechanical Electrical Lighting Furniture Medical Instruments

The Concept Of Die Casting Mold Qualification Rate Die casting mold qualified rate is a system concept, from die casting machine edge, die casting initial inspection, cleaning, post-treatment, machining, transportation, and other aspects of the qualified rate belongs to the composition of die casting qualified rate, which is also called straight through rate. For example, the problem of equipment, the problem of mold, the problem of spraying, and so on, the problem of these points has a significant impact on the qualified rate of die casting machine edge, the failure of equipment and mold will increase the number of cold mold parts; the instability of equipment and mold will increase the number of defective products of automatic identification, the unreasonable heat balance of mold and spraying will increase the appearance defects of castings. Die casting machine edge waste is the biggest part of die casting qualified rate scrap proportion, and also one of the biggest hidden points of die casting cost. Today we will discuss the qualified rate refers to the qualified rate of machining, mold circles often said the qualified rate is generally referred to in this data. Machined casting material waste is still attributed to the defects of die casting, there are often defects: porosity, shrinkage, leakage, inclusions, deformation, black skin, bruising, etc. The most important defect is the problem of gas shrinkage and leakage, which is also the most difficult to solve and continues to repeat. Die casting pass rate of 95% is a value that can be reached, as long as the die casting company has the basic management process and standard, excellent mold tooling, plus an excellent die casting process and continuous improvement team, 95% of the die casting pass rate is not difficult to achieve, in the real production process there are many cases in the mold is good enough under the premise of 95% pass rate is easier to achieve. However 99% pass rate is another concept, this discussion is a symbolic value, it represents a higher, more sustainable, and stable pass rate standard, it may be 97%, may also be 99.7%, the ultimate requirement is how we can pursue to excellence, it is how to step by step reality. How Does A Die Casting Mold Company Need To Do To Achieve A 99% Compliance Rate? CAMEL mold manufacturing process includes the following ways Establish a project team A high-standard project team is led or vice-led by the top management. As a senior manager, you must personally lead the core team through a few typical projects and then work together to develop effective processes and standards. Goal setting It is important to set a high target pass rate according to the difficulty of the casting. Goal decomposition and division of responsibilities Goal decomposition and division of responsibilities are particularly important, most of the problems that arise later are caused by the lack of comprehensive and careful analysis in the early stage; most of the implementation is not in place because of unclear responsibilities. Therefore, for the division of responsibilities must be designated the relevant responsible person, we must have more than one person to discuss the basic knowledge of a responsible, each thing is ultimately responsible for only one person. To avoid the emergence of localism and empiricism, and to designate the corresponding project management personnel to supervise. Casting feasibility analysis - DFM (ideally simultaneous design) Casting feasibility analysis is the most basic work because now many casting design engineers do not understand die-casting, the design of the casting is difficult to fully meet the process of die casting. Die casting problems and effective communication with customers (to solve the difficulties or apply for relaxation of standards) The feasibility analysis report of the casting is done is actually just the beginning, how to communicate effectively with the customer is very important. Mold design (pouring system design, heat balance system design, mold flow analysis, structure design, DFMEA) If you want to design a pouring system with a high pass rate, you should use the idea of process compensation to design the pouring system, which may increase the cost of post-processing, but it is worthwhile. Design of thermal balance Thermal balancing systems require strong logistical support, mold repair resources, and management capabilities. Mold review (checklist check) All important nodes in the process need to do the review, the review of mold design is the top priority, the key problems of solution A and alternate measures program B. LINK TO: 1.What Is Die Casting Mold 2.Custom Die Casting In China 3.Die Casting vs Permanent Mold Casting 4.Steps Of Die Casting Die(HPDC Mold) DesignTechnical 5.Specifications Of Die Casting Dies 6.How Does Hot-chamber Die Casting Machine Work 7.How Much Does a Die Casting Tool Cost? 8.Mold Making & Die Casting Mold Manufacturing Process 9.How to Make Die Cast Molds

The standardized mold production process is one of the core competitiveness in mold manufacturing. From mold order to mold output, it takes about dozens of steps; The key steps of making die cast molds organized are as follows. Order Preliminary Review → Final Mold Structure Review → Design Review Of Die Casting Mold; Design Review Of Trim Mold → Manufacturing Review → Mold Components Inspection; Mold Steel Hardness Inspection → Mold Base Inspection Report → Cavity & Core Inspection After CNC → Mold Electrode Inspection → Cavity & Core Inspection After Wire Cut → Cavity & Core Inspection After EDM → Mold Pre-Assembly Inspection → Trial Review → Sample Inspection Report → Die Casting Die Checking List → Trim Die Checking List; Inspection Qualified Notice Read More Details Design Review Of Die Casting Mold In the molding process, it is the Die that is key for productivity and part quality. Both precision and dimensional accuracy are needed to efficiently produce high-quality castings. Particularly during the casting process, the runner design and heat energy control prove to be essential factors for achieving the highest productivity and part quality. It is the CAMEL’s job to develop, and build dies that support best-in-class cycle-time, part quality, and die life. Tempering must be done before the mold trial to guarantee the die life. Before mold production, The design of die casting dies is also a top priority. We always do flow simulation by designing many kinds of runner layouts to get the best productivity and part quality. This way most of our die casting dies can be sampled successfully the first time. The preliminary flow simulation below appears to show that the overflow speed is too fast and may cause a high risk of mold flush issues. We reduced the area of overflow to control the speed and ensure a better cast and mold quality. Balanced Heat Energy CAMEL designs ample cooling lines to control the heat energy balance to get the best cycle-time and part quality. The balanced heat energy also lowers the risk of die cracking. Die Casting Parts Overflow is the essential factor for achieving the best part quality. We design all venting separately to ensure that venting can run smoothly and efficiently. This way parts will have a much lower risk of cold lap issues. Multi-cavity Trim Dies Trim dies are indispensable tools for high quantity production. Unprofessional mold makers need to adjust the multi-cavity trim die many times by welding. CAMEL designs all support blocks, cutters, guide pins, and guide bushes separately for each cavity. We also design separate locating components to control the runner deformation. This way most of our multi-cavity trim dies can be trimmed successfully the first time. LINK TO: 1. What Is Die Casting Mold 2. Custom Die Casting In China 3. Die Casting vs Permanent Mold Casting 4. Steps Of Die Casting Die(HPDC Mold) Design 5. Technical Specifications Of Die Casting Dies 6. How Does Hot-chamber Die Casting Machine Work 7. Mold Making & Die Casting Mold Manufacturing Process 8. How Much Does a Die Casting Tool Cost? 9. What is Mold Maintenance?

The die casting mold‘s working environment is very harsh, especially since the mold cavity part is easily damaged. This leads to the die casting metal liquid drilling into these gaps, producing serious flying edges or even jammed sliding parts. These problems of die casting mold will cause casting defects, and even cause a lot of scraps. In order to ensure the quality of the die-castings and extend the service life of the mold, CAMEL recommends the die casting workshop to carry out mold maintenance work such as inspection and repair of the molds. Mold maintenance includes the following. Observation And Inspection Of The Mold There are 3 ways to check the mold, On-site inspection of the mold, that is, the mold repairer inspects the mold before it is used; The down-field inspection of the mold, that is, after producing a batch of castings, before the mold is put into storage, the mold repairer will check the condition of the mold; Weekly inspection of the mold, inspection, and maintenance cycle can generally be determined by the number of press shots, generally every 10,000 press shots, the need to remove the mold from the die-casting machine, disassemble the main parts for an inspection and maintenance work, the content of the following. (1) Observe the surface of the cavity to see if there are traces of strains and ablation of adhering metal chips, and polish the strains with abrasive cloth and polishing tools. (2) Observe all the top bar, core whether there is bending, cracking and fracture, if necessary, a copper or wooden hammer gently knocking check, bending, cracking and fracture of the Cores, projections, and top rods should be repaired or replaced immediately. (3) Check whether all the top bar is free to move in and out, whether there is a jamming phenomenon, the top bar hole and other mating surface drilled into the metal fluid, the top bar end surface is high, or lower than the mold surface. Problems found should be disassembled mold ejector parts for repair, the gap is too large for the top bar or sliding part to try to repair. (4) Use a magnifying glass to observe whether the surface of the cavity is cracked, cracks, scratches, and local collapse, and there are pits and barbs on the surface of the mold wall in the direction of the release. For minor mesh cracks on the surface of the cavity, they can be reinforced with a tungsten reinforcing machine and then polished. For larger cracks, collapses, and pits, the bottom metal must be removed and the mold steel welding rod must be used for welding (preferably with argon arc welding to ensure the welding quality). (5) Check if the exhaust system on the parting surface is clogged with grease or metal chips, and clean it up to ensure that the exhaust system is smooth. (6) Check whether the cooling system of the mold is smooth and free from blockage. Dimensional Accuracy Of Regular Identification Die casting mold use after a certain period of time will appear the naked eye can not detect the deformation and wear, thus affecting the dimensional accuracy of die-castings and make the processing volume change. Therefore, for the die-casting die with a high dimensional accuracy requirement, it is necessary to carry out the periodic identification of dimensional accuracy. The identification period is decided according to the specific requirements, the identification method can be used to periodically check the die casting or use three coordinate measuring instruments for measurement. Nitriding Treatment Die casting die after a certain period of time, the surface nitriding layer will be worn, thus reducing the surface hardness of the cavity, increasing the tendency of die casting sticky mold. For this reason, after every 30,000 die shots, the cavity should be disassembled, the surface should be polished and sent to the heat treatment workshop for nitriding treatment. Tempering Treatment Die casting die is used a certain number of times after the stress relief tempering treatment, According to improve the die casting die life of effective measures. Tempering temperature should be 30~50% lower than the original tempering temperature of die-casting material. During mass production, the aluminum residue is commonly found at the bottom of the mold, which needs to be cleaned up regularly to avoid mold collision. The stress-relieving tempering interval of aluminum alloy die casting mold is related to the die castings quality and the times of die casting shots, and usually: die casting mass less than 0.1kg, shots of 25000 times; die casting mass of 0.1kg-1kg, shots of 10000 times; When the casting mass is more than 1kg, shots of 5000 times. CAMEL deeply believes that good mold maintenance ensures a longer mold life and smooth production. Therefore, a quality mold must not only be stable during production but also easy to maintain. LINK TO: 1.What Is Die Casting Mold 2.Custom Die Casting In China 3.Die Casting vs Permanent Mold Casting 4.Steps Of Die Casting Die(HPDC Mold) DesignTechnical 5.Specifications Of Die Casting Dies 6.How Does Hot-chamber Die Casting Machine Work 7.How Much Does a Die Casting Tool Cost? 8.Mold Making & Die Casting Mold Manufacturing Process

The cost of a die casting tool has two main parts-mold and cavity processing. The cost of the tool is mainly controlled by the size of the die casting. The larger the part, the larger the tool and the higher the cost. The cost of machining the cavity is almost affected by all aspects of the part geometry. The Size Affects The Cost The main cost factor is the size of the cavity that must be processed, measured by the projected area and depth of the cavity. Any other elements that require additional processing will increase the cost, including the number of features, parting surfaces, edges, tolerances, and surface roughness. The Materials Affect The Cost The cost of the tool will be affected by the life of the die casting tool, and the life of the mold will be affected by the number of die castings and the materials we use. For example, a material with a high casting temperature, such as copper, will result in a short mold life. On the other hand, zinc can be cast at lower temperatures, which can lead to longer mold life. This effect will become more expensive as the number of production increases. The Side-cores Affect The Cost The last consideration is the additional cost for the side cores. However, the number of directions can limit the number of cavities that can be included in the mold. For example, a mold that requires 3 side core directions can only contain 2 cavities. There is no direct cost increase, but using more cavities may further save costs. Our capabilities CAMEL offer to die casting tool and high pressure die casting tool design; Our die casting tool solutions include tooling for aluminum, magnesium, and zinc die castings for complex products such as automotive components, medical equipment, and machinery parts industrial manufacturing. Accurate design and high-speed machining capabilities ensure superior die casting tool performance. LINK TO: 1, What Is Die Casting Mold 2, Custom Die Casting In China 3, Die Casting vs Permanent Mold Casting 4, Steps Of Die Casting Die(HPDC Mold) Design 5, Technical Specifications Of Die Casting Dies 7, How Does Hot-chamber Die Casting Machine Work 8, Mold Making & Die Casting Mold Manufacturing Process

LINK TO: 1, Die Casting Process Design and Die Casting Process 2, Design points of the inner gates in the gating system for die casting mold 3, Working principle of the die casting mold 4, Structure, classification, and design of pouring/gating systems 5, Temperature controller for Die-casting Production 6, The CASINO Machine Parts in Bulgaria made by CAMEL Manufacture