Developing the right die-casting process, ensuring skilled operation by die-casting workers, and maintaining high-quality molds are essential for increasing production efficiency, guaranteeing part quality, reducing defects, minimizing mold failures, and extending mold life.
(1) Developing the Correct Die-Casting Process
The die-casting process reflects the technical capabilities of a die-casting facility. It should effectively integrate factors like machine characteristics, mold properties, casting features, and alloy behavior to produce cost-effective, high-quality parts that meet customer requirements. Therefore, it's crucial to select and train qualified die-casting process engineers. These engineers are responsible for managing on-site technology, revising processes based on changing conditions, and training workers such as mold installers, operators, and repair technicians.
Setting the optimal productivity level and defining the cycle time for each shot is important. Too low productivity can reduce economic efficiency, while excessively high productivity may compromise mold life and part quality, leading to worse overall results.
Choosing the correct die-casting parameters is key. Under the condition of meeting quality standards, injection speed, pressure, and alloy temperature should be minimized to reduce machine and mold stress, lower failure rates, and improve longevity. Parameters such as fast/slow injection speeds, boost pressure, punch-off distance, dwell time, and mold temperature must be set according to machine, mold, and alloy specifications.
Using water-based coatings requires a detailed and precise spraying process. This includes selecting the paint brand, paint-to-water ratio, spray quantity or duration, spray sequence, compressed air pressure, spray gun distance, angle, and surface orientation.
Establishing an effective cooling plan for the mold is vital for production efficiency, part quality, and mold longevity. The cooling strategy should define when and how to open cooling water, and adjust the cooling strength at the site to balance heat with the spray process.
Different sliding parts—such as punches, guide columns, cores, push rods, and reset rods—require different lubrication frequencies.
Creating clear die-casting operation guidelines and training workers to follow them strictly is essential for consistent performance and safety.
Setting a proper preventive maintenance schedule based on mold complexity and age ensures that molds do not fail unexpectedly. If a mold fails during use, it should not be repaired but replaced immediately to avoid further issues.
Considering mold complexity, age, and risk of sticking, determine the stress relief cycle (usually every 5,000–15,000 shots) and whether surface treatments like nitriding are required, specifying the nitride layer depth (typically 0.33 mm, maximum 0.55 mm).
(II) Implementing the Correct Die-Casting Operations
Die-casting machines must be operated strictly according to established rules after proper training. Controlling the initial cycle time with an error margin of less than 10% is critical for stable production and product quality. A consistent cycle time significantly affects mold life, failure rate, and overall profitability.
Strictly following the mold cooling plan is essential. Proper cooling improves efficiency, quality, and mold life, while improper cooling can cause severe damage. In case of an emergency, cooling water must be turned off immediately to prevent further harm.
Standardizing the pouring process ensures clean molten metal without impurities and maintains consistent filling levels. The hand-pouring error should be controlled within 2–3%.
Cleaning the mold regularly removes metal scale from the parting surface, cavity, runner, and other areas to prevent surface collapse, blocked vents, or poor clamping. Avoid using steel tools on the forming surface during cleaning.
Proper application of coatings is one of the most critical and challenging tasks in die-casting. Improper spraying can lead to unstable product quality and early mold damage. Always follow the defined spraying procedure carefully.
Regularly lubricating moving parts as per the schedule helps maintain smooth operation and prevents wear.
Always check the mold’s tightness and ensure the mold platen and bracket are properly secured to prevent sinking or falling during operation.
Completing the scheduled mold maintenance cycle or stopping production after finishing a batch ensures that the last cast part is preserved for future repairs, ideally including the gating system.
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Labels: Die Casting, Die Casting Process, Die Life, Cooling Solution, Die Casting Production
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