Formulating the correct die-casting process, the correct and skilled operation of the die-casting worker and the high-quality mold maintenance are important for improving production efficiency, ensuring the quality of the die-casting parts, reducing the reject rate, reducing the mold failure and prolonging the life of the mold. Concerned about surprises Label: Die Casting Die Casting Process Die Life Cooling Solution Die Casting Production Previous: Structure and principle of temperature sensor Next: Daily maintenance and maintenance of automotive molds
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(1) Formulating the correct die casting process
The die-casting process is a manifestation of the technical level of a die-casting factory. It can correctly combine the production factors such as die-casting machine characteristics, mold 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 chief in charge 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 production factors, and it is also responsible for training and improving the mold installation and adjustment workers, die-casting operators, and mold repairers.
Determine the most reasonable productivity and specify the cycle time for each shot cycle. Too low productivity is not conducive to improving economic efficiency. Excessive productivity is often at the expense of die life and casting qualification rate, and the economic benefits of the general ledger account may be worse.
Determine the correct die casting parameters. Under the premise of ensuring that the casting meets the customer's quality standards, the injection speed, injection pressure, and alloy temperature should be minimized. In this way, it is beneficial to reduce the load on the machine and the mold, reduce the failure, and improve the life. According to the characteristics of die-casting machine, mold characteristics, casting characteristics, die-casting aluminum alloy characteristics, etc., determine the fast injection speed, injection pressure, boost pressure, slow injection stroke, fast injection stroke, punch-off distance, and push Stroke, dwell time, push reset time, alloy temperature, mold temperature, etc.
With water-based coatings, a rigorous and detailed spraying process must be developed. The paint brand, the ratio of paint to water, the amount of spray (or spray time) and the spray sequence for each part of the mold, the compressed air pressure, the distance between the spray gun and the molding surface, the angle of the spray direction and the angle of the molding surface.
According to the die casting mold, the correct mold cooling scheme is determined. The correct mold cooling solution has a great impact on production efficiency, casting quality, and mold life. The scheme should stipulate the method of opening the cooling water, start the cooling by die casting several times, and open the cooling water valve to the specified opening degree several times. The cooling strength of the point cooling system should be set on site by the die casting process engineer to achieve the mold heat balance with the spray.
Different lubrication frequencies are specified for different sliding parts, such as punches, guide columns, guide sleeves, core pulling mechanisms, push rods, reset rods, etc.
Formulate the die casting operation rules for each die casting, and train and supervise the die casting workers to operate according to the regulations.
Determine the appropriate mold preventive maintenance cycle based on mold complexity and age. A proper mold preventive maintenance cycle should be a die-casting mold that will fail during mold use without failure. There has been a failure in the use of the mold, it is impossible to continue production, and it is not recommended to be repaired.
According to the complexity of the mold, the old and the old and the degree of sticking hazard, determine the module to eliminate the stress cycle (usually 5000-15000 die once) and whether surface preparation is required. Such as nitriding treatment, the depth of the nitride layer. 0.33, maximum 0.55.
(II) Implementing the correct die-casting operation The die-casting machine should be strictly trained to perform the operation rules of the die-casting machine after strict training, and strictly control the cycle time of the first mode. The error should be less than 10%. The stable die-casting cycle time is for a casting factory. The overall benefits are crucial. It has a decisive influence on product quality stability, mold life, failure rate and so on.
Strict implementation of mold cooling scheme, mold cooling is an effective way to improve production efficiency, casting quality, mold life, and reduce mold failure. However, the wrong water cooling operation will cause fatal damage to the mold. To stop the die casting production, the cooling water must be turned off immediately.
The action of the pouring column, the bismuth aluminum, and the pouring column is standardized, so that the molten metal that is infiltrated does not contain scale, and the molten metal poured into the pressure chamber fluctuates at least. The hand pouring amount error is controlled within 2 to 3%.
Clearing the mold to remove the metal scale accumulated in the parting surface, cavity, core, runner, overflow tank, exhaust passage, etc., to prevent the surface of the mold from being collapsed when the mold is closed, and the exhaust passage is blocked, or Caused the mold clamping is not strict. It is forbidden to use steel tools to contact the forming surface during mold cleaning.
Spray coating is one of the most important and difficult die casting operations and must be handled strictly in accordance with the spray process. Improper spraying can result in unstable product quality and early mold damage.
Lubricate the sliding parts in time according to regulations.
Always pay attention to the tightness of the mold, often check the compression of the mold platen and the support of the mold bracket to prevent the mold from sinking or falling during use.
Complete the mold maintenance cycle, or stop production after completing the specified production batch, and keep the last die-cast product (preferably with the pouring and discharging system) and repair it with the mold. 