With the rapid development of the automobile industry, light-alloy materials are increasingly used in parts and components due to the requirements of lightweight bodies. Aluminum alloys (such as aluminum-silicon series alloys) have the characteristics of low density, low thermal expansion coefficient, and good friction properties, and are widely used in automobile engine covers, gearbox housings, and other castings. This topic uses Magma software to analyze the filling and solidification process of the aluminum alloy front cover of a family car engine; through the analysis of the results of numerical simulation, an optimization plan for the die casting process is proposed, which provides a reference for the production of similar products. Casting Model And Material 1. Casting model The outer dimension of the engine front cover is about 470 mm×310 mm×105 mm, the product mass is about 3.4 kg, the average wall thickness of the main body is 3.3 mm, and the maximum wall thickness reaches 26 mm (the part marked in the wireframe is the thicker wall). The product structure is relatively complex, with a considerable number of bolt holes and reinforcing ribs distributed inside; and the wall thickness of the casting is very different, and stress concentration is likely to occur during the die casting process, resulting in uneven density, resulting in casting deformation, shrinkage, and shrinkage porosity. . The casting product model is shown in Figure 1. 2. Casting materials The front cover of the engine is required to have good mechanical properties and high density, and no internal defects such as cracks, shrinkage porosity, pores, and shrinkage holes are allowed. Based on the above working environment and requirements, the AlSi9Cu3 aluminum alloy is selected, which has good fluidity and excellent die casting performance. Table 1 is its chemical composition and mechanical properties. Initial Die Casting Process Plan 1. Design of initial pouring system According to the characteristics of the product structure, it is planned to design 2 branches with a total of 6 inner runners for feeding, as shown in Figure 2. The aluminum alloy liquid is introduced into the sprue from the sprue cup, and then enters the 6-way internal gate through the 2-way branch, and finally enters the cavity for filling. 2. Determination of process parameters The casting material is AlSi9Cu3, and the mold is DIEVAR. According to the physical characteristics of the two materials, combined with the die-casting process design manual and production experience, and through calculations, the following die-casting process parameters are determined: the initial temperature of the casting is 670℃, and the initial temperature of the mold is 180℃ ; The casting mass is 3.4 kg, the pouring system mass is 2 kg, the overflow system mass is 850g, and the total mass is 6.25 kg. The projected area of the casting is 1 196 cm2, and the total projected area is 1 554 cm2; the injection specific pressure is selected as 60MPa, and the safety factor is 1.2. 3. Simulation analysis of the preliminary plan In order to understand the filling and solidification of the casting during the casting process, Magma software is used for numerical simulation, as shown in Figure 3. It can be seen that the filling time of the entire cavity is about 0.076 s. The initial filling speed of the molten metal entering the cavity is faster, and the filling speed of the middle area is significantly faster than the two sides. In the middle of filling, the molten metal gradually enters the thicker wall area. It was observed from time to time that the thicker-walled area was filled relatively slowly and gas stagnation was easy to occur. After the filling of the area was completed, due to higher temperature and longer solidification time, internal quality problems such as pores and shrinkage holes were prone to occur. Die Casting Process Optimization Design 1. Optimized design of gating system In view of the relatively slow filling of thick-walled areas, in order to ensure the quality of the castings and make the filling speed of each area basically the same during the forming process, it is proposed to add two gate feeds to the thick-walled areas to speed up the filling speed of this area, Which makes the entire filling process more stable and smooth, is more conducive to the elimination of gas and avoids shrinkage, shrinkage and other defects. Figure 4 shows the optimized scheme, and the wireframe part is a 2-way gate with added feed. Since the gate position has a large drop from the bottom of the casting, in order to make the feeding of this area smooth, a slider is added to the gate here, as shown in Figure 5, to ensure that the aluminum liquid fills the area well. 2. Simulation analysis of optimization plan In order to verify the filling effect and solidification of the optimized scheme, numerical simulation was performed again to observe the filling and solidification process of the optimized scheme. The simulation process is analyzed from the aspects of filling temperature field change, air pressure change, solidification situation, and so on. It is found through observation that the entire cavity filling process is about 0.071 s, which is very close to the theoretical estimate. During the filling process, the molten aluminum advances relatively smoothly, and the speed is basically the same; the gas discharge in the cavity is smooth, the air pressure is relatively stable, and within the risk control range, there is no obvious gas stagnation and entrainment. In the solidification process, except for the thicker areas, the cooling and solidification are slower, and the solidification and cooling of other areas are basically uniform and ideal. Local Area Cooling Scheme 1. High-pressure point cooling technology High-pressure point cooling technology has been increasingly used in the die casting industry in recent years. The cooling water is adjusted to the ideal pressure state by the high-pressure point cooler, and the corresponding pipe is quickly passed through the mold to achieve the purpose of cooling. Since the core cooling rate is fast in this process, shrinkage holes will not be formed near the core position. Therefore, the use of high-pressure spot cooling technology can achieve mold heat balance, effectively improve local pore defects, greatly increase mold life, and reduce core replacement and Overhaul rate, and better guarantee the quality of castings. 2. High pressure point cold in the local area In view of the slow cooling and solidification of the thicker part in the numerical simulation analysis process, high-pressure spot cooling is considered to be used to quickly cool the key areas to ensure the quality of the castings. Mold Development And Trial Production Die casting molds were developed according to the optimized process plan and trial production was carried out. The trial production was carried out on the DCC1250T horizontal die casting machine. The mold structure is shown in Figure 8. The initial temperature of the trial mold is 180°C. During the trial production process, as the injection progresses, in the low-speed injection stage, the molten aluminum enters the runner through the sprue, then enters the cavity smoothly from the inner gate, and quickly enters the high-speed injection stage. High-pressure spot cooling is performed in key areas to make the solidification time of each part of the casting basically consistent. Figure 9 is a photo of the trial product. It can be seen that the surface of the casting is smooth, the outline is clear, the quality of the inner hole is good, and there are no obvious defects. The product has been tested for airtightness and mechanical properties. After inspection, the pass rate of the product has reached 96%, and the test results meet the performance requirements. In Conclusion (1) Using Magma software, the filling and solidification process of the gating system and the overflow system of the aluminum alloy front cover of a certain family car engine were simulated. The corresponding problems were found through the simulation analysis, and the die casting process optimization program was proposed. (2)  After determining the relevant die casting process parameters, the optimized filling and solidification process was simulated again, and the temperature field changes, air pressure changes, and solidification conditions were analyzed, and the rationality of the optimized scheme was initially verified. (3)  Aiming at the problems of excessively high local temperature and long cooling time of castings, high-pressure spot cooling is used to speed up the cooling rate of local areas and improve the quality of castings.

CAMEL 's  factory has recently been upgrading and improving its facilities, such as building signs, logos and logos on packaging boxes. The logo of the main entrance of the CAMEL factory Workshop signs Close up of the sign CAMEL logo printed on the wooden box Install the logo and signs to facilitate customers to visit.

This is part of the showroom of CAMEL's die casting products. The products are casings of gaming machines and car parts. CAMEL has certain advantages in the production of products. This is the reason why we are constantly introduced to us by old customers. We are also very grateful to our customers for their continued trust in us. Our sales engineers also have high-level communication skills and are patient in responding to customer questions. Even if they cannot answer immediately, they will immediately consult technical engineers and respond to customers as soon as they reply.

Same as mentioned in the video above: SHENZHEN CAMEL DIE LIMITED, We have a company named CAMEL Because it is very suitable for the mold industry - “stable, like a CAMEL!" Good quality and lead time both are our advantages, and receive good reputation from many clients in the past 10 years. We export many tools to western Europe and North America every year. Here are 2 floors and 5,000 m2 for molds building only and 45 people as 2 shifts from Monday to Saturday. Last but not least, I hope my introduction can help you know more about CAMEL.

Abstract: High-pressure die casting is an important process for forming non-ferrous metal structures. The production elements of die casting are composed of a die casting machine, die casting mold, die-casting process, and die casting alloy. Low speed (hereinafter referred to as low-speed) is one of the key parameters of the die casting process. The low-speed setting has a more important effect on the quality of die-casting parts. This article will verify the impact of the low speed of die casting on the quality of parts while ensuring other parameters are not changed. Keywords: Die casting process; Low speed; Die casting parts. 1.Filling effect of casting at low pressure of 0.2m/s Figure 1.1  The filling state of the low-speed 0.2m/s shot sleeve ①  The filling of aluminum liquid is relatively stable, and no obvious entrained air is seen. Figure 1.2   Temperature distribution after low-speed 0.2m / s castings is filled. ② The overall temperature of the casting is about 570°C, which is slightly lower than the liquidus line of the A380 material at 574.4°C. The risk of defects such as the cold lab and flow marks on the surface is higher. Figure 1.3   Entrained air volume fraction after low-speed 0.2m / s casting is filled. ③ Entrained air is basically discharged into the overflow, and the risk of defects such as porosity and surface bubbles in the casting is low. 2.Filling effect of casting at low-speed 0.3m/s Figure 2.1   Filling state of the low-speed 0.3m/s shot sleeve. ① Molten aluminum filling smoothly, and no turbulence is seen, but the molten aluminum at the end of the die-casting is significantly lower than that at the front end, a local entrained air phenomenon is caused. Figure 2.2   Temperature distribution after low-speed 0.3m/s casting is filled ② The temperature distribution of the filled casting is shown in Figure 2.2. The overall temperature of the casting is about 590°C, which is slightly higher than the liquidus line of the A380 material at 574.4°C. The risk of defects such as cold lab and surface flow marks on the casting is low. Figure 2.3     Entrained air volume fraction after low-speed 0.3m/s casting is filled. ③Entrained air volume fraction of filled casting is shown in Figure 2.3. During the casting filling process, a small part of the entrained air remains in the casting area, and the casting has the risk of forming pores and bubbles. 3.Filling effect of casting at low pressure 0.5m/s. Figure 3.1   Filling state of the low-pressure 0.5m/s shot chamber ① The molten aluminum in the shot chamber is shown in Figure 3.1. The aluminum liquid filling the shot chamber stably, but the turbulence phenomenon occurs as soon as the aluminum liquid enters the runner, and the entrained air phenomenon is serious. Figure 3.2   Temperature distribution after low-speed 0.5m/s castings are filled ② The temperature distribution of the filled casting is shown in Figure 3.2. The overall temperature of the casting is about 610°C, which is higher than the liquidus line of A380 material at 574.4°C. With no defects such as cold lab and surface flow marks. Figure 3.3   Entrained air volume fraction after low-speed 0.3m/s casting is filled ③ The distribution of Entrained air volume fraction after the casting is filled is shown in Figure 3.3. There is more entrained air in the casting area during the filling process, with a higher risk of defects such as pores and bubbles. 4.Conclusion ①.The slower the low-speed, the less the volume of entrained air, but too low speed will reduce the temperature of the molten aluminum, and the casting will have problems occur such as cold lab and flow mark. ②.When the low-speed is too fast, the filling temperature of the casting is high, and the possibility of cold lab and flow marks is less, but the volume of entrained air will increase, and defects such as porosity and bubbles will appear. ③.To set the low speed, you must first determine the product requirements. If the casting is an appearance part, you can appropriately increase the low speed to avoid surface defects such as surface flow mark and cold lap to improve the surface molding quality. If the casting is air-tight, it is necessary to reduce the low speed as much as possible to ensure that the casting does not form a cold lap to achieve the best venting effect and ensure the casting sealing performance. 5. References [1] A Concise Design Manual for Die Casting Molds / Edited by Huang Yong. --Beijing: Chemical Industry Press, 2009.11

With a background of a profound understanding of the requirements of export quality molds to European and North American companies, and the observation of frustration which takes place when overseas purchasers encounter failure from negative experiences working with unprofessional suppliers in the south of China, as well as when quality did not match with pricing, projects being delayed, poor communication in English, lost contracts with suppliers, etc., CAMEL Engineering was born. Since 2009, Simon and Leo - as founders who established CAMEL Engineering as a professional engineering company in Hongkong and work place in Shenzhen city - have only one purpose, which is to provide international buyers the best engineering service for export molds without misunderstandings of the standards of mold making, and to offer the best quality and excellent lead time. The world financial crisis still affected many local companies seriously in 2009, causing the majority of their business to be reduced over 50-60%. Even more, some factories had to shut down in 3 months to avoid a cash flow break in this “economic winter”. During this time most customers slowed down their projects’ development, as it seems like everybody was waiting anxiously for the “spring” to arrive. CAMEL was not thinking of ideas to control operating costs like the other companies were, but rather stayed busy with improving and upgrading its own project management system and how to offer better service. We believe that opportunities always exist and favor the prepared company. CAMEL’s business was not affected too much during this time, not only because of good luck but also because our workers deeply realized the critical situation we were in and dared not to slack off in communication, manufacturing, and lead time, while doing our best to provide more solutions and analysis for uncompleted projects, supporting customers to win more trust from our hard work, etc. Finally, more and more projects commenced and were delivered successfully to different countries. In 2012, CAMEL invested 60% in one of the biggest mold suppliers in South China, aiming to take the opportunity to focus on the automotive, lighting, and communication industries, working more closely with some larger companies and stepping forward one step at a time to the big development of our company. Two years later, CAMEL was able to take over 100% of the shares and management in this mold shop and subsequently moved to the second location in Dongguan, China. In 2017, CNC quantities increased from 5 to 9 sets and we became an ISO certificated company. At that time, we had 60 workers, including 6 professional mold designers and 32 skilled mold operating workers. Certain of our long-time customers have kept working with CAMEL since 2009, and they became the most valuable assets for CAMEL’s growth. Staying focused on each step is still the working philosophy of our company - focusing on more professional investments in our project management system, employee internal training system, and customer service system. Any one of these areas determines the growth of CAMEL and our customers’ success. CAMEL considers these as a stable iron triangle, not afraid of any difficulties and the belief that the most brilliant future is within our reach, one step at a time.