Die Casting Process Design Die casting process design is an important part of die casting production technology, mainly involving die casting process requirements for the shape and structure of the casting, the technical conditions of die casting (technical requirements), the process performance of die casting, and die casting parting surface determination. The Die-casting Process On The Requirements Of The Structure Of The Die Casting Die casting quality, in addition to the impact of various process factors, the structure of its parts process (reasonable) is also a significant factor, such as the location of the parting surface, the design of the gate, the layout of the launch mechanism, the accuracy of the guarantee, the type of defects. The type of defects and their degree, etc., are closely related to the structure of the die casting process itself (reasonable). Die casting structure affects the design of die casting mold structure and manufacture of difficulty, production efficiency and service life, and other aspects. The reasonable die-casting structure can shorten the product trial period, reduce production costs, ensure product quality, improve production efficiency. Therefore, the die casting shape structure should strive to be simple, especially to eliminate the inability or difficulty of lateral core extraction of the internal side concave, simplify the mold structure, and improve the service life of the mold. The main issues to consider when designing the structure of die casting are as follows: To help simplify the mold structure, extend the life of the mold 1) castings at the parting surface should try to avoid rounded corners Rounded corners increase the mold's processing difficulty and make the rounded corners of the mold strength and life have decreased. If the dynamic mold and fixed mold are slightly misaligned, die-casting rounded part of the easy form a step The appearance will be affected. If the structure changes to a flat shape, the parting surface is flat and easy to process, avoiding the above shortcomings. 2) to avoid internal side concave Die casting internal flange and bearing hole for the internal concave structure, core extraction difficulties, the need to set a complex core extraction mechanism or fusible core. As a result, it increases the complex shape of the mold and processing volume and reduces production efficiency. However, if the inner concave structure changes to a non-internal concave structure, the difficult core extraction can be solved, and the mold structure can be simplified. 3) Avoid crossed inaccessible Crossed not through the hole must use a higher tolerance fit of each other crossed cores, increasing the amount of mold processing and strict control of the order of core extraction. Once the metal liquid is in the gap of the crossed cores, it will make the core extraction difficult. If the crossed not through the hole to avoid crossing the inaccessible structure, you could avoid the core's cross, eliminating the shortcomings mentioned above. 4) to avoid partial thinning of the mold Casting structure because the hole edge from the flange distance is too small, easy to make the mold insert fracture. If the die casting to a local ≥ 3mm structure, the insert can be made with sufficient strength, thereby improving the service life of the mold. Conducive to reducing the extraction of core parts, improve the structure of the mold Reduce the parting surface is not perpendicular to the core part, reduce the complexity of the mold, and ensure the accuracy of die castings. The depth of the square hole in the center of the die casting is deep, the core distance is long, requiring a special core extraction mechanism, the mold is complex; plus the cantilever core into the cavity, easy to deform, difficult to control the sidewall wall thickness uniform. The use of an H-shaped section structure does not require core extraction, simplifying the mold structure. Conducive to core extraction, convenient casting mold release Die casting structure due to the core by the tab obstruction can not be smoothly extracted core. If the shape of the die casting suitably modifies to a structure conducive to core extraction, when can smoothly extract the core. LINK TO: 1, Design Of The Cross Sprue 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

The cross sprue is the passage from the end of the straight sprue to the front of the inner gate; sometimes, the cross sprue can separate into the main cross sprue and the transition cross sprue. The Cross Sprue Should Conform To The Following Requirements 1) Providing a stable flow of metal fluid. 2) Providing less resistance to the flow of the metal fluid. 3) Low amount of gas encapsulated in the metal fluid during the flow. 4) Provide suitable conditions for the heat balance of the cavity. 5) Make the metal liquid have a suitable solidification time, not hinder the transfer of complementary shrinkage pressure, and not extend the cycle of die-casting. 6) Heat loss should be minimized when the metal liquid flows through the cross sprue. The Layout Of Multi-cavity Cross Sprue The production of large and complex die casting, mainly using single-cavity die casting dies. While the shape of the simpler small dies casting and the production batch is more significant, to improve the efficiency of die casting production, reduce the total mold cost. Usually, using multi-cavity die casting dies. Multi-cavity die casting mold cavities can set the same but also can select different types. A mold multi-cavity die casting mold layout form of the cross sprue should be depending on the layout of each cavity. The structure of the multi-cavity position should base on the structural characteristics of each die casting, the flow condition of the metal liquid, and the heat balance of the mold temperature so that each cavity of the die casting process conditions as far as possible to achieve consistent. The Layout Forms Of Multi-cavity Cross Sprue Are Rough As Follows 1) Straight-line arrangement In general, when the metal press into the sprue, the metal liquid starts to divide, and the mainstream of the metal liquid flows forward. In contrast, a small stream of metal liquid flows from the transition cross sprue into the nearest cavity under a slight overpressure to form a pre-filled state. This situation repeats—the results in a small amount of fluid flowing into each cavity. When the mainstream of liquid metal reaches the front of the central cross sprue, the corresponding impact pressure generates, and the cavities fill in turn from top to bottom. Because the pre-filled metal liquid is in a minimal force into the cavity, and in an instant, its temperature will have a significant reduction or even close to the cooling state when they are not easy to fuse with the later entry of the mainstream metal liquid. This filling time difference will make the die casting molding effect reduce; close to the direct sprue die castings are usually easy to produce die-casting defects. 2) Symmetrical arrangement Symmetrically arranged cross sprue could use for larger die castings. The metal liquid pressed in from the straight sprue enters the cavity through the evenly bifurcated cross sprue. It can ensure that the double cavities have the same die casting process conditions, the mold body is also more balanced force. 3) Comb-style arrangements The comb arrangement cross sprue has the characteristics of the comb inner gate and the T-shaped cross sprue. 4) Surrounding arrangement The layout of each cavity is the same as the distance of the straight sprue; the cross sprue can arrange in the form of surround. This arrangement makes the metal liquid flow into each cavity under the same die casting condition, satisfying the principle of filling and cooling simultaneously. 5) Other forms of arrangement Depends on the structure of die casting, the layout of the multi-cavity mold cavity and the cross sprue also varies. The arrangement of the cross sprue is generally flat and branching, oblique branching, and circular branching. In practice, it depends on the structural characteristics of the die casting. What Are The Key Factor For Productivity And Part Quality? In the Die casting process, It is the Die that is key for productivity and part quality. Not only precision and dimensional accuracy is needed to produce high-quality castings efficiently. Especially in the casting, runner design and heat energy control prove to be essential factors for achieving the highest productivity and part quality. The CAMEL's job is 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. LINK TO: 1, Structure, classification, and design of pouring/gating systems 2, Maintenance of die casting mold 3, Working principle of the die casting mold 4, Mold debugging 5, Temperature controller for Die-casting Production 6, The CASINO Machine Parts in Bulgaria made by CAMEL Manufacture

Determination Of The Cross-sectional Area Of The Inner Gates The cross-sectional area of the gates directly determines the inner gates' speed and filling time. When the inner gates speed is selected, if the cross-sectional area of the inner gates, If the cross-sectional area of the gate is too large, the metal liquid fills the cavity too fast, so that the gas in the cavity is not discharged in time to produce pores and other die casting defects. If the cross-sectional area of the inner gates is too tiny, it prolongs the filling time, and in the filling process, part of the metal liquid cools too fast, resulting in the cavity filling is not satisfied with the phenomenon. In order to obtain the ideal filling time, the inner gates cross-sectional area remains unchanged, adjust the action on the liquid metal pressure and pressure injection punch speed, can also change the liquid metal filling time, but the adjustment range is minimal, in addition, to consider the bearing capacity of the die-casting machine. Therefore, in the design process, predetermine the inner gates' cross-sectional area is a critical design content. At present, in die casting practice, is the metal liquid at a certain speed and predetermined time to fill the cavity is the primary basis of calculation. Design Of The Thickness Of The Inner Gates In the inner gates cross-sectional area, the thickness of the inner gates has a more significant impact on the formation of a good filling flow state. Therefore, it is appropriate for thin-walled complex die castings to use thin inner gates to ensure the necessary speed of the inner gates. However, when the inner gate thickness is too thin, the metal liquid flow of tiny impurities, such as segregation, inclusions, oxides, and other impurities, will lead to local blockage of the inner gates, reducing the effective flow area of the inner gates. At the same time, the metal liquid entering the cavity is easy to produce an atomization phenomenon, thus blocking the exhaust channel, and then wrap the gas in the cavity to produce die casting defects. When the thickness of the inner gates is thicker, it helps to reduce the filling speed. At the same time, the inner gate's solidification time is the almost quadratic increase in the thickness of the inner gates, which is conducive to the transfer of the complementary shrinkage pressure. Therefore, without affecting the surface of die casting without increasing the cost of removing the inner gates, the thickness of the inner gates can be increased as much as possible. The width of the inner gates should also be selected appropriately, and the width is too large or too small will cause the metal liquid to rush straight to the opposite side of the wall, resulting in vortex flow to wrap the air and impurities and produce scrap. The length of the inner gates directly affects the quality of the casting. If the inner gates are too long, it will affect the pressure transfer, cooling, and casting surface will be easy to form a cold partition pattern. If the inner gates are too short, the temperature at the inlet will rise quickly and speed up the wear of the inner gate, and it is easy to produce a spraying phenomenon. Key Points For The Design Of The Position Of The Inner Gates When designing the inner gates, the most crucial thing is determining the inner gates' location, form, and direction. According to the shape and structure characteristics of die casting, wall thickness change, shrinkage deformation, and mold parting surface, and other factors, the flow pattern and filling speed change of metal liquid in the filling, as well as the expected filling process, may appear in the dead corner area, wrapped gas and complex partition parts, and arrange the appropriate overflow and exhaust system. CAMEL is a professional (HPDC) high-pressure die-casting dies manufacturer. Our design team specialized in Design, build, and production within over ten years of stable die casting tool and die manufacturing ​experience. Contact us if you have any die casting mold problems in all industries. LINK TO: 1, Structure, classification, and design of pouring/gating systems 2, Maintenance of die casting mold 3, Working principle of the die casting mold 4, Mold debugging 5, Temperature controller for Die-casting Production 6, The CASINO Machine Parts in Bulgaria made by CAMEL Manufacture

The metal die casting mold pouring system is the channel to fill the die cavity with the molten metal liquid inside the die casting machine press at high temperature, high pressure, and high speed. Gating System And Types It includes straight sprue, cross sprue, inner gate, and overflow exhaust system. In the process of guiding the metal liquid to fill the cavity, they play an important role in controlling and regulating the flow state of the metal liquid, the speed and pressure transfer, the exhaust effect, and the heat balance state of the die casting mold, etc. Therefore, the pouring system is an important factor in determining the surface quality of the die casting and the internal microstructure state. At the same time, the pouring system has a direct impact on the efficiency of die casting production and the life of the mold. The design of the pouring system is an important part of the die casting mold design; it is necessary to analyze the structural characteristics of the die casting from the theoretical point of view, but also to have the practical experience of the application of the die casting process. Therefore, the design of the pouring system must take the method of combining theory and practice. 1. The structure of the pouring system The channel where the metal liquid fills the cavity under pressure is called the pouring system. The pouring system is mainly composed of straight sprue, cross sprue, and internal gates. According to the form of die-casting machine and the introduction of metal liquid casting mold casting system composition form also has not hot room, vertical cold room, all vertical and horizontal cold pressure chamber several. 2. The main content of design of the pouring system ① according to the die casting size, quality (weight), and the positive projection area on the parting surface, and according to the actual situation of the field equipment, selected the type of die casting machine used, model, and diameter of the chamber. When the choice of vertical cold chamber die casting machine or hot chamber die casting machine, but also choose the appropriate nozzle so that the nozzle shape and pouring system to adapt. ② die casting dimensional accuracy, surface and internal quality requirements, bearing load conditions, pressure resistance, sealing requirements, etc., in order to carry out a comprehensive analysis to determine the location of the metal liquid into the cavity direction and flow state. ③Analysis of the complexity of the die casting, structural characteristics, and processing datum, combined with the selection of parting surface, determine the overall structure of the pouring system and the main dimensions of each component. ④Analyze the flow of metal liquid and determine the position of the overflow tank and exhaust channel. ⑤ Determine the suitable mold temperature adjustment measures according to the influence of the metal liquid flow on the mold temperature. Design Of Inner Gates The inner gate is a section of the sprue from the end of the cross sprue to the cavity, which is a channel to guide the molten metal liquid to fill the molding cavity at a certain speed, pressure, and time. The function of the inner gate is to introduce the metal liquid into the cavity in the best flow state according to the structure, shape, and size of the die casting to obtain a high-quality die casting. Therefore, when designing the inner gates, the main purpose is to determine the location and direction of the internal gate and the cross-sectional size of the inner gates, to anticipate the flow state of the metal liquid during the filling process, and to analyze the possible dead corner area or the air wrapping area, so as to set up effective overflow and exhaust slots in the appropriate areas. Since there are many factors affecting the internal gate, it has the greatest influence on the quality of die casting, so there are many design options. CAMEL is a professional (HPDC) high-pressure die casting dies manufacturer. Our design team specialized in the design, build, and production within over ten years of stable die casting tool and die manufacturing experience. Contact us if you have any die casting mold problems in all industries. LINK TO: 1, What is die casting? 2, What is die casting mold? 3, Steps Of Die Casting Die(HPDC Mold) Design 4, Glossary of die casting terms 5, How to choose steel for die casting mold? 6, How to Extend the Life of Die-casting Tools? 7, Failure Mode and Analysis Of Die-casting Dies 8, How to choose a die casting machine? 9, How does the cold-chamber machine work? 10, How does the hot-chamber machine work?

1. According to the principle of fluid mechanics, the theoretical analysis and some calculations of the movement of liquid metal in the pressure chamber of the horizontal cold-chamber die casting machine are based on the analysis that: the slow injection process of the horizontal cold chamber die casting machine punch is accelerated The combination of motion and uniform motion, the result of the combination directly affects the quality of die castings. The amount of air that the liquid metal is involved in the pressure chamber is related to the slow injection acceleration, slow injection speed, initial fullness, and pressure chamber diameter, and there is a critical slow injection speed and optimal acceleration, where the speed and acceleration It can minimize the amount of air involved and minimize the porosity of castings. 2. The filling process of liquid metal during die casting is a process in which many contradictory factors are unified. Among the many factors affecting filling, mainly pressure, speed, temperature and time, etc., time is the result of the coordination and synthesis of related process parameters, and each process factor influences and restricts each other, adjust a certain process Factors, it will inevitably cause the corresponding process factors to change, and may in turn affect the adjusted process factors to cause changes. Therefore, only by correct selection, control and adjustment of these process parameters, so that the various process parameters meet the needs of die casting production, can it be guaranteed that qualified die casting parts can be produced under other good conditions. 3. The basic characteristics of aluminum alloy die casting are filling under high pressure and high speed, and crystallization under high pressure. During the entire rapid injection stage, the molten metal enters the cavity in the form of a jet at a speed of 30 to 60 m/s, and the molten metal does not envelop the gas. It is impossible. In this case, by adjusting the process parameters and the process plan, the key is where and in what form the pores are distributed reasonably. Because the high-pressure jet breaks the gas into dispersed small pores and remains in the casting, the strength cannot be improved by heat treatment, and the elongation of the die casting is low. Therefore, die casting is generally suitable for the production of thin-walled shells and outer covers that do not need to bear large impact loads, and is not suitable for manufacturing important safety components. 4. According to the process characteristics of aluminum alloy die casting, it is difficult to form thin-walled large areas. If the wall thickness is too large or severely uneven, defects and cracks are easy to occur. It is hoped that the wall thickness of the die casting parts will be as uniform as possible. For large aluminum alloy die casting parts, Generally, the wall thickness should not exceed 6mm. Under normal process conditions, the wall thickness of die castings should not exceed 4.5m. The thickness of the die casting At the wall, in order to avoid shrinkage and other defects, the wall thickness should be reduced and reinforced ribs should be added. 5. Due to the characteristics of the aluminum alloy die casting process, the alloy used requires a small crystallization temperature range, a small thermal cracking tendency and a small shrinkage coefficient. 6. It is a feature of die casting process to be able to cast relatively deep holes well. For some holes with low precision requirements, they can be used directly without machining, thus saving machining man-hours. There is a certain relationship between the diameter and depth of the die cast hole on the part, and the smaller hole can only be die cast to a shallower depth. Generally, the hole diameter is not less than 2mm, and the hole depth is not more than 4~8 times the hole diameter. The threaded holes on the castings are often die cast to meet the requirements of the core hole, and then processed (mostly tapping) to make the threaded hole. 7. At the junction of the die casting wall and the wall, whether it is a right angle, an acute angle or an obtuse angle, it should be designed to be rounded. In order to facilitate the removal of die castings from the cavity and core of the mold, prevent surface scratches, and extend the life of the mold, the die castings should have a reasonable draft angle. Its size depends on the wall thickness of the casting and the type of alloy. The thicker the wall thickness of the casting, the greater the tightness of the alloy to the core, and the greater the draft angle. The greater the shrinkage of the alloy, the higher the melting point, and the greater the draft angle. In addition, the inner surface of the casting or the inner wall surface of the hole has a larger draft angle than the outer surface. Within the allowable range, a larger draft angle should be used to reduce the required pushing force or core pulling force. Generally, the draft angle is 0.5°-1.5. 8. In die casting process, threads can be directly die cast under certain conditions. 9. Various embossing, netting, text, signs and patterns can be die cast on die casting. 10. Metal or non-metal parts (inserts) can be embedded in the die casting mold first, and then cast together with the die casting parts. This can make full use of the properties of various materials (such as strength, hardness, corrosion resistance, wear resistance, magnetic permeability, conductivity, etc.) to meet the requirements for use under different conditions, and it can also make up for the poor processability of the casting structure. The lack of point, and solve the die casting problem of parts with special technical requirements. 11. Die castings have precise dimensions and good casting surfaces, and generally do not need to be machined. At the same time, due to the existence of internal pores in die casting, mechanical processing should be avoided as much as possible. However, after all, the die cast parts cannot be directly assembled and used in any situation. Therefore, in some cases, some surfaces or the parts are machined. The surface layer of the die casting is dense and uniform, with good mechanical and physical properties. The thickness of this surface layer is about 0.5~0.8mm, so the general machining allowance is preferably 0.3~0.5mm.

The Purpose Of Maintenance And Maintenance Of Die Casting Mold 1) The mold can maintain the best performance state and ensure normal production. 2) Extend the service life of the mold. Daily maintenance and maintenance methods of the die casting mold Whether the running mold is in a normal state 1) Whether the mechanism is operating normally and whether there are any wearing parts that need to be replaced. 2) Are the movable parts such as the guidepost, ejector rod, and row position worn and well lubricated? It is required to add high-temperature lubricating oil at least once per shift, and the special structure should increase the number of refueling. 3) Whether the sprue bushings and shunt cones are worn. 4) Clear the front of the slider (row position) position. Normal production conditions Check whether the defects of the product are related to the mold. A comprehensive inspection of the mold and anti-rust treatment should be carried out when the machine is off 1) Clean the mold face, clean the mold, especially the cavity. 2) Check the mold. If the parts or parts are damaged, make a record for replacement or repair. 3) Wipe dry the moisture in the cavity, core, ejector mechanism, and row position, and spray mold anti-rust agent or apply butter. The molds after getting off the machine for inspection should be placed in the designated place, and the specific conditions should be recorded and kept in the designated area. 1) Open the mold and check the internal anti-rust effect. If there is any abnormality, the anti-rust treatment must be performed again; the mold that is not used for a long time must be coated with butter. 2) Place the mold to be repaired in the area to be repaired, and store it in the storage area for standby after the repair is completed. 3) Regular mold maintenance: ①The mold needs to be tempered to relieve stress after wire cutting; ②After the mold trial is completed, it needs to be tempered before mass production; ③The mold needs to be tempered to relieve stress after using 5000 molds. 10000 molds, 20000 molds, follow-up can be tempered according to the situation; ④Other surface strengthening treatments (such as nitriding, etc.) can be treated at the same time during tempering according to the situation; ⑤Part replacement. 4) Routine inspections every season It mainly cleans and maintains molds that have not been used for more than two months. Put it back in place and make inspection records. Maintenance precautions 1) Non-professional maintenance personnel or without the permission of professional maintenance personnel can not dismantle the mold for maintenance. 2) A minor failure in the production process can be solved by the adjuster according to the situation, such as ①When the product sticks to the mold, Use a copper needle to knock out at the feed nozzle, do not use steel needles and other hard objects to hit the mold, such as burning with fire, be careful not to damage the surface of the mold; ②The cavity is slightly scratched, and the polishing material can be selected according to the finish of the cavity. Do not use sandpaper and other polishing materials, which should be done by professional maintenance personnel. 3) Professionals should not change the structure at will when repairing the mold, and the structure must be changed after the approval of the quality engineering department. 4) Ensure the quality of maintenance, select appropriate equipment, materials, tools, and methods to solve the problem, and complete it as quickly as possible. 5) The maintenance of the mold requires a record for easy traceability.

During die casting production, the die casting mold is installed on the die casting machine to form a whole with the die casting machine. Through the pressure of the die casting machine, the molten metal fills the mold cavity at high pressure and high speed, and the molten metal is cooled in the mold cavity under high pressure. Solidified and formed to obtain die castings. The die casting mold is mainly composed of two parts: a fixed mold and a movable mold. The fixed mold is fixed on the fixed mold mounting plate of the die casting machine. The sprue is connected to the nozzle or pressure chamber of the die casting machine. The movable mold is fixed on the mounting plate of the die casting motorized die and moves with the die casting motorized template to complete the opening and closing actions. The work of the die casting mold is a cyclical work process. When the mold is closed, the mold is closed to form a cavity, a gating system, and an overflow exhaust system. The liquid metal fills the cavity under high pressure and solidifies. When the mold is opened, the movable mold and the fixed mold are separated, and the casting is ejected under the action of the ejection mechanism. No matter what die casting mold, its working process includes the following actions: We illustrate the working process of a product die casting mold: 1) Mold closing: the mold is closed and waiting for pouring. 2) Pouring: The manipulator or the operator blows the material into the barrel from the furnace. 3) Injection: According to the set process parameters, carry out the injection. 4) Mold opening: The mold is opened, the core is pulled with the inclined guidepost, and the core is pulled simultaneously. 5) Core pulling: Under the action of the core pulling device, the mold exits from the side to facilitate ejection; if it is the front (fixed) mold core pulling, the core needs to be pulled first and then the mold is opened. 6) Ejector: Under the action of the ejection mechanism, the casting is ejected for easy removal. 7) Pick-up: Manually or automatically remove the casting from the mold; if there is a pin, pay attention to the direction and angle, and do not brutally beat and pull, otherwise the thimble will be easily damaged. 8) Spraying: Clean the mold cavity, the front, and back molds and spray the release agent evenly. 9) First reset mechanism: If there is a thimble under the core pull, you need to make a pull rod and another first reset mechanism to protect the mold. 10) Close the mold again and repeat the above process.

After the mold is installed, you need to do relevant inspections before you can open the mold for debugging. Be careful during the debugging process. The machine action should not be too large at a time, otherwise, the mold will be easily damaged when there is an abnormality, especially if there is a core pulling device and a reset mechanism Mold. 1) Adjust the clamping force according to the process regulations and the machine manual. 2) Select a reasonable machine action program according to process requirements. 3) If you need to pull the core first and then open the mold, check the hydraulic core pulling system, whether the oil circuit is smooth, whether the core-pulling action is smooth, and whether the core-pulling position sensor is working properly (after the core-pulling can be performed after the mold is opened an examination). 4) Check the overall installation and tightening status of the mold. 5) Open the mold slowly, and stop immediately if there is any abnormality (to avoid mold damage, you can click to open the mold). 6) When the movable template stops in place, adjust the ejection device of the machine tool to ensure that the ejection distance is reasonable. 7) If there is no abnormality, open and close the mold slowly several times. During the process, pay attention to observe whether the movement of the machine tool and the mold is smooth and normal. 8) After the reliability is confirmed, add lubricating oil to the movable parts, and then open and close the mold to check to ensure that it works normally.

Most of the sanitary ware products after die casting molding or machining also need to be polished and polished or after a variety of surface treatment addition and for a good finished product. What Surface Treatment Method Is Used Most Often For Our Sanitary Ware Products? What surface treatment method and means do we need to use to provide clean and clean for different sanitary ware products after all is most appropriate? It needs to combine different product base materials, different customer requirements, different grades of positioning, different surface treatment processing production costs, and other factors to make appropriate choices. The surface treatment method that defends the sanitary ware product industry uses most often has the following kind roughly: 1. Paint processing: This is one of the most familiar kinds of treatment method, low cost, simple treatment process, it is through the spray gun and with the aid of air pressure, scattered into a uniform and fine droplets, the coating applied on the surface of the sanitary ware pieces of a kind of method. It can be divided into air spray, airless spray paint, as well as the method of electrostatic spray painting. Lacquer, it is to have certain toxicity normally, have certain effect to the body, the paint of different brand because of composition content different toxicity also is different. Special attention should be paid to safety when using, avoid inhalation and skin contact. 2. Electroplating: Electroplating is to use the principle of electrochemistry to lay a layer of metal on the sanitary ware. In addition to copper, iron, zinc alloy, aluminum alloy, and other conductive materials, ABS plastic sanitary ware can also be processed by electroplating. It includes water electroplating processing and vacuum electroplating processing, sanitary ware and sanitary ware with water electroplating processing method is the most common, especially nickel and chromium plating processing for the most. Generally, we say electroplating is water plating processing, and vacuum plating is called coating. 3. Electrophoresis: It is electrophoretic paint, electrophoretic paint is the electrophoretic coating at the Yin and Yang poles, under the effect of applied voltage, the coating ions with charge are moved to the surface of the sanitary ware product, and the product surface is produced by the alkaline action to form insoluble matter, these substances it deposited on the surface of the product.

Optimization of Process Structure for Castings Abstract: In the design of die casting mould, more consideration is given to the curability of the mould itself, such as runner, overflow, temperature, ejection, etc. However, if the technological requirements of subsequent casting machining are not well considered in the design stage of the mould, the machining difficulty of the casting will increase. The production efficiency is reduced, which ultimately affects the machining production cost. Therefore, in the die design stage, not only the die casting process should be considered, but also the needs of subsequent machining should be considered more, so as to effectively optimize the die design scheme and improve the overall economic benefits of die castings. Die-casting has a series of characteristics such as high production efficiency, low cost, excellent appearance quality and long die life. In production, The rationality of mold design determines the quality of castings and the production efficiency. Therefore, the whole mold design process needs to be fully considered in combination with casting characteristics, die casting equipment capacity, material characteristics used, customer special requirements and other relevant factors. However, in actual production, most die-casting mould designer take that demand of blank die-casting as the key point of design concern. However, the special needs of subsequent machining are ignored, and problems such as difficult positioning, uneven blank allowance and shortened tool life often occur in the machining of die-casting blank, which seriously affect the production efficiency of machining and the stability of casting quality, and eventually lead to the decline of economic benefits of enterprises. The following is a brief discussion on the influence of the structural characteristics of die casting molds on machining and how to optimize them. 1st Influence of Gate Design on Die Casting The location of the ingate is one of the important links in the die design. The ingate design of the die casting mould is almost always based on the filling and forming of the casting. Quality and flow state are carried out without too much consideration of the influence of blank on subsequent machining. 1, Influence of ingate Position on Cutting Tools In many ways, the setting of the ingate location of die casting is the key and difficult point in the gating system design. Any negligence will cause unpredictable mistakes, which cannot be made up by the adjustment of die casting process. From the perspective of die casting production, the following basic principles should be followed in selecting gate position. (1)Avoid closing the venting passage immediately after liquid metal enters the mold cavity, which is beneficial to removing the air in the mold cavity. (2)As far as possible, branch ingates should be used less, so as not to interfere with each other and form eddy current and entrained air. (3)The ingates should not face the core and cavity wall directly to avoid direct impact of molten metal. (4)The ingates shall be placed at the thicker part of the casting to facilitate pressure transmission. (5)The molten metal flow is the shortest to reduce energy loss and avoid too much cooling. (6)The ingates shall not cause deformation during shrinkage of the casting. (7)Set the inner gate as close to the important parts of the work piece. If the setting of ingate location can meet the above conditions without considering the subsequent machining of the blank, then the setting of ingate location can be said to be perfect.However, most die castings need to be machined in production. If the actual demand of machining for casting blank is ignored, it will definitely bring some unnecessary troubles. The main manifestations are: the influence of the residue after gate removal on machining positioning and intermittent cutting during machining of gate parts. As we all know, intermittent cutting is a technological difficulty in mechanical machining, which can generate periodic vibration, make stripes or corrugated marks appear on the machined surface, resulting in an increase in the surface roughness value. Intermittent cutting in the cutting process makes the tool periodically stressed, which is easy to cause tool collapse and reduces the service life of the tool. In intermittent cutting, the operator has to adopt lower cutting speed spread and smaller feed, which affects the production efficiency of the machine and the worker. Relatively speaking, the influence on positioning is smaller. When designing machining fixtures, more understanding and communication should be done to confirm the gate form and position of the blank, estimate the approximate size of the gate residue in the future, and try to avoid using the gate position as the positioning benchmark for machining. Therefore, on the premise of meeting the die casting production, the ingate location setting also needs to take into account the technological requirements of subsequent machining, and reasonably arrange the ingate location of blank according to the actual technological process of machining. If you can't have both, it is recommended that the ingate be placed on an exposed and flat plane to facilitate polishing and reduce the allowance. Or the ingate location and size are placed evenly and continuously on the processing plane to reduce intermittent cutting. 1.As shown in picture 1, it is a common ingate location selection problem. Picture 1a that ingate is set on the movable die, and the ingate will remain on the circular plane in the future. From the perspective of die-casting technology, the ingate set on the movable die side is beneficial to the filling of molten metal and the die-casting production of castings. However, the ingate residue on the circular plane can be removed by subsequent machining, and the casting has beautiful appearance and no gate residue trace, but it will bring the problem of intermittent cutting. Fig. 1b is set at the fixed mold side, and the ingate will remain on the circumference of the casting in the future. In terms of die casting process, the metal liquid set at such ingate will directly impact the cavity wall of the mold, which is easy to adhere to the mold at the corresponding parts of the gate. After the ingate is removed in the future, ingate marks will remain on the circumference of the casting, affecting the appearance quality of the casting. However, the problem of intermittent cutting is avoided without machining the circumferential part. 2.The choice in actual production needs to be combined with the characteristics of their respective enterprises and comprehensively balanced with customer demand as the orientation. What should be emphasized here is that the design of die casting dies should take into account the needs of machining as much as possible. 2.Influence of Ingate Position on Machining Positioning Machining 1.Generally, a coarse reference on the blank should be selected for positioning, and then fine reference processing should be carried out. These coarse benchmarks require smoothness, reliability and consistency. There are mainly two selection methods for coarse benchmarks. (a)When the dimension chain on the machined casting pattern does not take a certain non-machined surface as the design benchmark, the determination of the coarse benchmark will often select the largest plane, outer circle or inner hole on the blank, because these features can obtain the maximum positioning limit and ensure the accuracy and consistency of positioning. (b)When the dimension chain on the machined casting drawing takes a non-machined surface as the design datum, the coarse datum must be selected, because the fine datum machined from this datum can represent the drawing in subsequent machining. The original design datum on is used as the process datum.If the gate appears in these areas, the casting positioning will be seriously affected. According to the machining positioning method, the corresponding optimization scheme is as follows: (1)As far as possible, the gate position should not be selected on a larger plane for positioning or on a very accurate design. (2)If the ingate must be placed on a larger plane for locating or on a design basis, consider multiple strands of feed and reserve the required position for positioning, as shown in Fig. 2. The middle area of the strand division is still a flat area, which can form a three-point-plane positioning (the same as the outer circle positioning) with other areas. (3) When the casting allows, add process positioning bosses (see Fig. 3) to optimize machining positioning coarse datum level. （a）The gate at the core side （b）The gate at the cavity side Picture 1 Different Design of Gate Position Through the above optimization scheme, the reliability of casting machining positioning can be improved. In addition, paying attention to the deformation at the gate and optimizing the gate removal process during die casting production can improve the machining positioning. 2nd Influence of Reserved holes 1.Influence of Reserved Holes on Position Tolerance It is generally believed that the hole should be reserved as far as possible for the hole shapes that can be formed in the mold, so as to reduce the machining allowance, protect the hardened layer of the casting and ensure the good air tightness of the casting. However, the reservation of bottom holes sometimes raises another question as to whether these pin holes can meet the position tolerance requirements of the casting and do not affect machining. If there is an out-of-tolerance position after machining, it is very likely that the out-of-tolerance position of the preset hole causes the tool to follow the wrong preset hole. The guide deviates from the preset machining size.The base of reserved hole is the manufacturing base of the mold, and in the process of machining the selection of the process base and mold manufacturing base is not consistent, reserved hole must also deviate from the process base, so it will lead to the position out of tolerance. This kind of problem can be solved in the following ways: (1)When designing the mold, the mold manufacturing benchmark is taken as the rough positioning benchmark for machining as far as possible. After the benchmark is unified, the position accuracy of hole machining will be improved. For example, the reserved hole with position requirement should be the same as the positioning surface of the process reference on the parting surface of the mold side, reduce the error influence of mold clamping dislocation. (2)Due to the diversity of products, it is sometimes difficult to unify the manufacturing standards. At this time, it is suggested to cancel the reserved hole with shallow processing depth. (3)The positioning and processing of the hole are completed by machining, thus eliminating the guiding effect of the preset bottom hole and improving the position accuracy. However, it should also be noted that a large margin of cutting will expose defects in the die casting. 2.Influence of Reserved Hole on Machining Positioning In machining, the reserved hole of the blank on the die casting is often used as coarse positioning, so the reliability of the reserved bottom hole is especially important for positioning. It is important, so it is suggested to consider the priority of preset hole positioning. (1)The core of the reserved hole of the mold should be integrated with the core as much as possible, avoiding the use of detachable separate body. The main reason is that the split detachable core is used-after a period of time, burrs will be formed on the pin hole assembly joint surface, and these burrs are very thin and soft. Even if they are removed, a small part of them will adhere to the hole wall, affecting the positioning accuracy. (2)Preset hole core for positioning The inclination of the mould is enlarged and the surface hardness is increased as much as possible, so that the mould can be released smoothly during die casting production, the possibility of sticking the mould and pulling the inner wall of the hole can be reduced, and the positioning accuracy can be improved. (3)When the reserved hole with small aperture and split type is used as coarse positioning reference, it is better to prepare more cores of the hole while making the mold, so as to ensure the stability and consistency of the hole size during mold maintenance and avoid unnecessary losses for subsequent machining. Whether the reserved hole is appropriate or not will affect the positioning and accuracy of machining. Therefore, in the die-casting production process, in addition to paying attention to whether the reserved hole is deformed or not, stick mold and other quality states, it is also necessary to strengthen the daily core maintenance, to ensure the consistency of positioning benchmark. 3rd Conclusion To sum up, from the perspective of casting machining, the mold design is more convenient to locate and the surplus distribution is more reasonable, especially the manufacturing standard of the mold should be in good agreement with the machining process, which is beneficial to improving the efficiency and quality of machining. Therefore, in the design of die casting molds, designers need to consider all aspects of factors comprehensively, which puts forward new requirements for the expansion of professional ability of die designers. An excellent die casting designer must be a compound technical talent with mold technology, die casting technology and machining technology.

The automatic control of die casting temperature controller is an indispensable means in modern die casting technology. What is the function of the die casting hot die machine in the temperature control of die casting? First, The Die Casting Temperature Controller In The Preheating Stage Of Die Casting 1. Preheating the mold can reduce the number of hot modules, improve production efficiency and reduce waste; 2. Preheating the mold can reduce the thermal impact of the alloy metal liquid on the die casting mold, prolong the time for the mold to generate thermal fatigue cracks, and extend the service life of the mold; 3.Preheating the mold can make the clearance of the sliding part of the mold expand and adjust, prevent the liquid metal from drilling into the sliding part, and block the mold; Preheating die by die casting temperature controller can effectively reduce the thermal modulus and thermal shock of molten metal. It is often used in gravity metal mold. The die casting hot die machine can preheat the die evenly and has the function of cooling the die to ensure the stability of the die temperature and minimize the thermal shock of the molten metal. It is the standard equipment for the production of aluminum alloy thin-walled parts and magnesium alloy casting dies. Second, The Die Casting Temperature Controller Of The Die Casting Mold Temperature Control If the mold temperature is too high or too low, it will cause disadvantages such as unstable casting size, high reject rate, and reduced output. When casting thin-walled castings, the heat sent to the mold is often less than the heat lost from the mold, so that the appropriate molding temperature cannot be reached, and the die casting hot mold machine needs to continuously add heat to maintain the mold temperature constant. As far as the mold temperature is concerned, the influence on the quality of die casting has the following items. Low mold temperature can cause: (1) The core sticking pressure is too large, and the casting is difficult to the mold; (2) The spray function of the spray agent deteriorates; (3) There is a cold lap on the casting surface; (4) The temperature difference between the mold and the liquid metal is too large, which accelerates the damage of the mold; (5) There are patterns or marks on the mold surface; (6) Undercast. Excessive mold temperature can cause: (1) Sticky mold and deformation; (2) The consumption of spray agent increases, and the decomposition is accelerated; (3) The cycle of die casting is prolonged; (4)The movable part of the mold is easy to break down and accelerate wear; (5) There are air bubbles on the surface; (6)There are shrinkage holes inside. Die casting temperature controller generally uses oil as the medium, and the working temperature can reach 320 ℃. But there are exceptions, such as the hot chamber die casting machine and the cooling of some cores. In order to prevent fire, pressurized water can be used as the medium, which does not vaporize at 140 °C. The non-pressurized water cooling system can only be used in places below 95 °C. In the die casting process, the pouring temperature, filling time, casting pressure, and mold temperature. These parameters are closely related to the quality, yield, and die life of die castings. In the production of die casting, the die casting temperature controller improves the quality and process of die casting by stabilizing the temperature, and its role and effect are self-evident.

From 10-2012 to now CAMEL DIE supplied EGT completed 48 sets of injection tools & die casting molds Premier Upright version. Mold Package Quantity 48 sets(32 injection molds and 16 die casting molds) Material ABS, PC and AL (Local) Mold Unit Weight From 1 ton to 5 tons Molds stay in China for mass production. From 05-2013 to 09-2013 CAMEL DIE supplied EGT completed 22 sets of tools for pillar parts of Murano new version. Mold Package Quantity 22 sets(15 injection molds, 5 die casting molds and 1 foaming mold) Material ABC, PC, PU and AL (Local) Mold Unit Weight From 1 ton to 5 tons Molds stay in China for mass production. From the cooperation to the present, customers will visit our company several times a year and have a very good relationship with CAMEL.