How To Make Higher Value For Die Casting Mold Application

Publish Time: 06/10 2021 Author: Site Editor Visit: 12230

The mold design manual has detailed the problems that should be paid attention to in the design of the die-casting mold, but when determining the injection speed, the maximum speed should not exceed 100m/S. If the speed is too high, it will promote the corrosion of the mold and the increase of deposits on the cavity and core; but too low will easily cause defects in the casting. Therefore, the corresponding minimum injection speeds for magnesium, aluminum, and zinc are 27, 18, and 12m/s, the maximum injection speed of cast aluminum should not exceed 53m/s, and the average injection speed is 43m/s.

In the process of processing, thicker templates cannot be superimposed to ensure their thickness. Because the thickness of the steel plate is doubled, the bending deformation is reduced by 85%, and the lamination can only play a superposition. The bending deformation of the two boards with the same thickness as the single board is 4 times that of the single board. In addition, when processing the cooling water channel, special attention should be paid to ensure concentricity in the two-sided processing. If the head corners are not concentric with each other, the connected corners will crack during use. The surface of the cooling system should be smooth, preferably without machining marks.

EDM is more and more widely used in mold cavity processing, but there is a hardened layer on the surface of the processed cavity. This is due to the self-carburizing and quenching of the mold surface during processing. The thickness of the hardened layer is determined by the current intensity and frequency during processing. It is deeper during rough machining and shallower during finishing. Regardless of the depth, the mold surface has great stress. If the hardened layer is not removed or the stress is eliminated, cracks, pitting and cracks will occur on the surface of the mold during use. To eliminate the hardened layer or stress relief:

①Remove the hardened layer with oil stone or grinding;
②Under the condition of not reducing the hardness, the stress is lowered below the tempering temperature, which can greatly reduce the surface stress of the mold cavity.

The casting process should be strictly controlled during the use of the mold. Within the scope of the process permit, try to reduce the casting temperature and injection speed of the molten aluminum as much as possible, and increase the preheating temperature of the mold. The preheating temperature of the aluminum die-casting mold is increased from 100-130°C to 180-200°C, and the life of the mold can be greatly improved.

Welding repair is a common method in mold repair. Before welding, you should master the model of the steel to be welded, and use machining or grinding to eliminate surface defects. The welding surface must be clean and dried. The welding rod used should have the same composition as the mold steel, and it must be clean and dried. The mold and the welding rod are preheated together (H13 is 450℃). After the temperature of the surface and the core are the same, they are welded and repaired under protective gas. In the welding process, when the temperature is lower than 260 ℃, it must be reheated. After welding, when the mold is cooled to the touch, it is heated to 475°C and the temperature is kept at 25mm/h. Finally, it is completely cooled in still air, and then the cavity is trimmed and finished. Heating and tempering after die welding is an important part of welding repair, that is, eliminating welding stress and tempering the thin layer under the welding layer that is heated and quenched during welding.

After the mold is used for a period of time, there will be deposits on the cavity and core due to the high injection speed and long-term use. These deposits are formed by the combination of release agent, coolant impurities and a small amount of die-cast metal under high temperature and high pressure.

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