Introduction to die casting molds

Definition and basic process of die casting molds

Die casting molds are a method for casting liquid die forging, which is mainly completed on a dedicated die casting die forging machine. Its basic process includes: the molten metal is first cast and filled into the mold cavity at a low speed or high speed, and the mold has a movable cavity surface. As the molten metal cools, it is pressurized forged to eliminate the shrinkage and shrinkage defects of the blank and make the internal structure of the blank reach the broken grains of the forged state.

Three major elements of die casting molds

Die casting materials, die casting machines, and molds are the three major elements of die casting production, and none of them can be missing. The so-called die casting process is to organically combine these three elements to enable the stable, rhythmic and efficient production of qualified castings with good appearance and internal quality and dimensions that meet the requirements of the drawings or agreements, or even high-quality castings.

Die casting materials

The selection of die casting materials has a direct impact on the quality and production efficiency of castings. Different metal materials have different die casting temperatures and mold material requirements. For example, the die-casting temperature and mold material selection of non-ferrous metals such as aluminum alloy, magnesium alloy and zinc alloy will be different.

Die-casting machine

The die-casting machine is an important equipment for performing the die-casting process. Its performance and specifications directly affect the quality and production efficiency of die-casting parts. Choosing a suitable die-casting machine requires considering factors such as the type of mold, the melting point of the metal material, and the production batch.

Mold

The design and manufacturing quality of the mold directly determine the quality and production efficiency of the die-casting parts. The design of the mold needs to consider factors such as the shape, precision, parting surface, overflow system and pouring system of the product.

Common materials for die-casting mold steel

In the manufacture of die-casting molds, commonly used materials mainly include steel and alloy materials. Commonly used steel materials include:

H13 steel: has excellent heat resistance and wear resistance, suitable for high-temperature die-casting molds.

P20 steel: has good cutting performance and wear resistance, suitable for medium-temperature die-casting molds.

718 steel: has good heat resistance and wear resistance.

NAK80 steel: suitable for low-temperature die-casting molds.

8407 steel: has high hardness and wear resistance.

The selection of suitable materials depends on the die-casting process, metal materials and mold use requirements. In practical applications, it is necessary to comprehensively consider factors such as the hardness, toughness, wear resistance, heat resistance and cost of the material to ensure the stability, precision and durability of the mold.

Application areas of die-casting molds

Die-casting molds have been widely used in modern industry, and their application areas cover many important industries:

Automotive industry

Automotive parts are usually produced by die-casting, such as engine cylinder heads, steering housings, transmission housings, etc. Die-casting molds play a vital role in the automotive industry and directly affect the quality and performance of automobiles.

Electronic and electrical industry

Various electronic products such as mobile phones, computers, cameras, home appliances, etc. require the use of die-casting parts, such as housings, radiators, connectors, etc. Die-casting molds are widely used in the electronic and electrical industry, providing strong support for the lightweight and refinement of products.

Machinery manufacturing industry

Parts and accessories of various mechanical equipment are usually produced by die-casting. For example, engineering machinery, agricultural machinery, railway locomotives, etc. all require a large number of parts produced by die-casting molds.

Aerospace industry

The aerospace industry has extremely high requirements for the quality and precision of parts, so it is common for this industry to use high-precision die-casting molds to produce parts. Various aircraft engine parts, aircraft structural parts, etc. are inseparable from the manufacture of die-casting molds.

Railway transportation industry

The manufacture of railway vehicles is inseparable from various cast aluminum alloy parts and cast iron parts. These parts are usually produced by die-casting molds, which ensures the quality and reliability of the products.

Medical device industry

The medical device industry has extremely high requirements for product precision and hygiene, so high-precision die-casting molds are needed to produce rain parts and equipment. Medical devices such as surgical instruments and medical instruments are mostly produced by die-casting molds.

Precautions for die-casting mold design and manufacturing

When designing a die-casting mold, the following factors need to be considered:

Process analysis: According to the material type used in the product, the shape and precision of the product, etc., the product is analyzed and the process is determined.

Parting surface and overflow system: Determine the position of the product in the mold cavity, and analyze and design the parting surface, overflow system and pouring system.

Core and cavity design: Design the assembly and fixing methods of each active core.

Ejector mechanism design: Determine the design of the ejector mechanism.

Die-casting machine selection: Determine the die-casting machine, and design the mold frame and cooling system.

When manufacturing die-casting molds, it is also necessary to pay attention to the control of the mold surface temperature. Uneven or inappropriate die-casting mold temperature will also lead to unstable casting dimensions, deformation of ejected castings during production, and defects such as thermal pressure, mold sticking, surface depression, internal shrinkage holes and thermal bubbles.

Through the above introduction, we can see the importance and complexity of die-casting molds in modern industry. Reasonable design and manufacture of die-casting molds can effectively improve production efficiency and quality and meet the needs of various industrial applications.