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**1. Scope**
This procedure applies to all die casting molds used in the die casting workshop. It outlines the necessary guidelines for the proper use, maintenance, and care of these molds throughout their lifecycle.
**2. Reference Standards**
The following standards are referenced in this procedure and must be followed:
- GB/T 5611-1998: Casting Terminology
- GB 8844-88: Technical Conditions for Die Casting Molds
- GB 8847-88: Pressure Casting Mold Terminology
- GB 4678.1～15-84: Die-Casting Parts
- GB 4679-88: Technical Conditions for Die-Casting Parts
These documents provide essential definitions, technical requirements, and specifications that support the safe and effective operation of die casting molds.
**3. Use of Die Casting Molds**
Die casting molds are expensive to produce and require precise handling. They should always be operated according to established procedures to ensure longevity and performance.
**3.1 Preheating**
Before starting the die casting process, it is crucial to preheat the mold. The recommended preheating temperature is between 230°C and 280°C. If a mold temperature machine is available, it should be used for preheating. If not, an external electric heating plate can be used instead.
- When using a mold temperature machine, loosen the clamping force first to prevent excessive tightening due to thermal expansion after preheating.
- After preheating, re-adjust the mold’s locking mechanism to ensure proper fit and function.
**3.2 Mold Temperature Control During Production**
Molds equipped with a mold temperature machine should always be used for consistent temperature control. For molds without such equipment, the production rhythm can be adjusted, and the mold temperature can be controlled by applying a thin layer of paint or coolant spray. Proper temperature management is essential to maintain mold integrity and product quality.
**3.3 Pouring Temperature Control**
The pouring temperature significantly affects the lifespan of the mold. It must be strictly controlled according to the specifications provided in the process card. During the trial phase of a new mold, the pouring temperature can be determined based on the "General Process Specification for Die Casting."
**3.4 Surface Maintenance**
During the production process, the mold surface should be inspected regularly. Any dirt or debris should be cleaned immediately, and sliding parts should be lubricated as needed to ensure smooth operation and reduce wear.
**4. Maintenance of Die Casting Molds**
Regular maintenance is critical to ensuring the continued performance and longevity of die casting molds.
**4.1 Basis for Mold Repair**
Mold repairs should be based on the following:
- Mold design drawings
- Mold size inspection results
- Sample out-of-tolerance reports
- Operator feedback
Repairs are carried out according to the repair orders issued by the responsible craftsman.
**4.2 Repair of Cavity Parts**
Cavity parts can be repaired or replaced depending on the damage. The repaired section must be restored to its original dimensions, shape, and surface finish, and verified through testing.
**4.3 Repair of Non-Cavity Parts**
Non-cavity parts should be repaired or replaced as required, but the original structure, surface roughness, and hardness must remain unchanged unless otherwise specified.
**4.4 Post-Repair Inspection**
After repairs are completed, the mold must be inspected by a technician according to the design drawings and repair order. If test mode inspection is required, it should be arranged. Once approved, the mold is stored or put into production, and the repair order is archived.
**5. Ongoing Mold Maintenance**
Proper maintenance ensures that the mold remains in optimal condition over time.
**5.1 Record Keeping**
A detailed file must be created for each qualified mold, including:
- Date of qualification
- Manufacturer information
- Usage records
- Repair history
- Maintenance logs
**5.2 Usage Tracking**
Each time the mold is used, a usage log must be filled out, and production details should be accurately recorded. In case of any malfunction, production should be stopped immediately, and a technician should be notified to plan the necessary repairs.
**5.3 Storage Preparation**
After use, the mold should be cleaned, inspected, and properly oiled to protect it during storage.
**5.4 Periodic Stress Relief Annealing**
Stress accumulation during repeated use can lead to cracks and premature failure. To mitigate this, periodic stress relief annealing is required. The frequency depends on the mold size:
- Molds below 500 tons: First stress relief after 5,000 cycles, then every 10,000–15,000 cycles.
- Molds above 500 tons: First stress relief after 5,000 cycles, then every 6,000–10,000 cycles.
**5.5 Timely Grinding and Repair**
Early detection and repair of microcracks are crucial. Cracks often begin at stress concentration points such as gates, runners, corners, sharp edges, fillets, and around holes. These areas should be carefully inspected, and any signs of microcracks must be ground down promptly to extend the mold's life.
**Stay alert for unexpected issues.**
**Labels:** Die-casting mold, Die life, Micro-crack, Crack accident, Expansion rate
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**Stay alert for unexpected issues.**
**Labels:** Die-casting mold, Die life, Micro-crack, Crack accident, Expansion rate
**Previous:** Instrument structure principle and performance of electronic weighing instrument
**Next:** Several problems that can not be ignored when choosing CNC machine toolsTruss self-drilling screws,,Hex Self-drilling screw with EPDM Washer,Round head tapping screw,Flat head tapping screw
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