Hardware Knowledge Base: Correct Use of Die Casting Dies

Formulating the correct die-casting process, the correct and skilled operation of the die-casting workmanship and the high-quality die repair are essential for improving the production efficiency, ensuring the quality of the die-casting, reducing the scrap rate, reducing the die failure, and prolonging the life of the die.

(I) Formulating the correct die casting process

The die-casting process is a demonstration of the technical level of a die-casting factory. He can correctly combine the production factors such as die-casting machine characteristics, die characteristics, casting characteristics, and die-casting alloy characteristics to produce die-casting products that meet customer requirements at the lowest cost. Therefore, we must pay attention to the selection and training of die casting process engineers. The die-casting process engineer is the general manager of the die-casting production site technology. In addition to formulating the correct die-casting process, the die-casting process is revised in time according to changes in the production factors, and it is also responsible for the training and improvement of die installation and adjustment workers, die-casting operators, and die maintenance workers.

Determine the most reasonable productivity and specify the cycle time for each injection cycle. Too low productivity is not conducive to improving economic efficiency. Excessively high productivity is often at the expense of die life and casting qualification rate. The economic benefit of GL can be even worse.

Determine the correct die casting parameters. To ensure that castings meet customer quality standards, injection speed, injection pressure, and alloy temperature should be kept to a minimum. In this way, it is beneficial to reduce the load on the machine and mold, reduce the failure, and increase the service life. According to characteristics of die casting machine, mold characteristics, casting characteristics, isosceles triangle characteristics of die casting aluminum alloy, determine the fast injection speed, injection pressure, boost pressure, slow injection stroke, fast injection stroke, punch out distance, launch Stroke, dwell time, push reset time, alloy temperature, mold temperature, etc.

With water-based coatings, a strict detailed spray process must be developed. The paint brand, the ratio of paint to water, the amount of spray (or spray time) and the order of spraying for each part of the mold, the pressure of the compressed air, the distance between the spray gun and the forming surface, the angle of the spray direction and the forming surface, etc.

According to the actual die casting mold to determine the correct mold cooling program. The correct mold cooling scheme has a great influence on production efficiency, casting quality, and mold life. The scheme shall provide for the method of opening up the cooling water, die-cast a few molds and start cooling. The cooling water valve shall be opened to the specified opening several times in several modules. The cooling intensity of the spot cooling system should be set by the die casting process engineer and matched to the thermal balance of the mold.

Specifies different lubrication frequencies for different sliding parts, such as punches, guide posts, guide bushes, core pulling mechanisms, push rods, reset rods, etc.

Formulate the die-casting operation procedures for each die casting, and train and supervise the die-caster to operate according to the regulations.

According to the complexity of the mold and the oldness, determine the appropriate mold preventive maintenance cycle. The proper mold preventive maintenance cycle should be a die casting mold that will fail in the mold and have not failed. Die failure has occurred in the use of the mold, can not continue production, was forced to repair, is not an advocated method.

According to the complexity of the mold, the oldness and the degree of risk of sticking, determine the module to eliminate the stress cycle (usually 5000-15000 die once) and whether the need for surface treatment. Such as nitriding, nitride layer depth. 0.33, maximum 0.55.

(B) the implementation of the correct die-casting operations die-casting workers should be qualified after training

Strictly enforce the operating procedures of die-casting workers and strictly control the cycle time of the first die. The error should be less than 10%. Stable die-casting cycle times are critical to the overall benefits of a casting plant. It has a decisive influence on product quality stability, mold life, and failure rate.

Strict implementation of mold cooling program, mold cooling is an effective way to improve production efficiency, casting quality, mold life, reduce mold failure. However, the wrong water cooling operation will do fatal damage to the mold. To stop the die-casting production, the cooling water must be turned off immediately.

The specifications of the pouring column, the aluminum sulphide, and the pouring column are such that the immersed metal fluid does not contain scale and the molten metal poured into the pressure chamber fluctuates at least. Hand pouring pouring error is controlled within 2-3%.

The clear mold timely removes the metal scrap accumulated on the parting surface, cavity, core, sprue, overflow channel, exhaust port, etc., to prevent the die surface from crushing when the mold is closed, and to block the exhaust passage, or Causes laxity. It is forbidden to use steel tools to contact the molding surface when cleaning.

Spray coating is one of the most important and most difficult die casting operations. It must be operated strictly according to the spraying process. Improper spraying can cause product quality instability and early die damage.

Lubricate the sliding parts as required.

Always pay close attention to the tightness of the mold, check the pressure of the mold platen and the support condition of the mold bracket frequently to prevent the mold from sinking or falling during use.

To complete a die maintenance cycle, or stop the production after the completion of the specified production batch, to retain the last die-casting product (preferably with pouring, drainage system), and repair with the mold.