Establishing the correct die-casting process, ensuring skilled operation by die-casting workers, and maintaining high-quality molds are essential for improving production efficiency, guaranteeing the quality of cast parts, reducing defect rates, minimizing mold failures, and extending mold life.
(1) Developing the Correct Die-Casting Process
The die-casting process reflects the technical capability of a die-casting facility. It involves properly integrating factors like machine characteristics, mold properties, casting features, and alloy behavior to produce cost-effective products that meet customer requirements. Therefore, it's crucial to invest in the selection and training of die-casting process engineers. These engineers are responsible for overseeing on-site technology, revising the process as needed based on changing conditions, and training personnel such as mold installers, operators, and mold repairers.
It is important to determine the most efficient productivity level and define the cycle time for each shot. Too low a productivity rate can hinder economic performance, while excessively high productivity often comes at the cost of mold life and part quality, potentially leading to worse overall profitability.
Setting optimal die-casting parameters is also critical. Under the condition that the casting meets quality standards, injection speed, pressure, and alloy temperature should be kept as low as possible. This helps reduce machine and mold stress, minimize failures, and improve longevity. Parameters such as fast and slow injection speeds, injection pressure, boost pressure, punch-off distance, dwell time, alloy temperature, and mold temperature should be determined based on the specific characteristics of the machine, mold, and alloy.
A detailed and rigorous spraying process must be developed when using water-based coatings. This includes specifying the brand of paint, the ratio of paint to water, spray quantity or duration, spray sequence for different mold areas, compressed air pressure, spray gun distance from the molding surface, spray angle, and surface angle.
Developing an appropriate mold cooling plan is vital for production efficiency, casting quality, and mold lifespan. The plan should include how and when to open the cooling water, the number of times to start cooling after a certain number of casts, and the degree of valve opening. The cooling intensity of the point cooling system should be adjusted on-site by the die-casting engineer to achieve heat balance with the spray process.
Different lubrication frequencies should be set for various sliding parts, such as punches, guide columns, guide sleeves, core-pulling mechanisms, push rods, and reset rods.
Die-casting operation rules should be established for each casting, and workers must be trained and monitored to follow these procedures strictly.
The preventive maintenance cycle of the mold should be determined based on its complexity and age. A proper maintenance schedule ensures that the mold doesn't fail during use. If a failure occurs, production must stop immediately, and repairs may not be feasible.
Depending on the mold’s complexity and risk of sticking, the stress relief cycle (typically 5,000–15,000 shots) and whether surface treatment is required should be determined. For example, nitriding depth should be between 0.33 and 0.55 mm.
(II) Implementing the Correct Die-Casting Operation
Operators must undergo strict training to follow die-casting machine operating procedures. Cycle time accuracy should be controlled within 10%. A stable cycle time is crucial for overall factory performance, directly affecting product quality, mold life, and failure rates.
Strict adherence to the mold cooling plan is essential. Proper cooling improves efficiency, quality, and mold life while reducing failures. However, incorrect cooling can cause serious damage to the mold, requiring immediate shutdown and cooling water cutoff.
Standardizing the pouring column and bismuth aluminum operations ensures clean molten metal without impurities and consistent pouring. Hand-pouring errors should be kept within 2% to 3%.
Cleaning the mold thoroughly is necessary to remove metal scale from the parting surface, cavity, core, runner, overflow tank, and exhaust channels. This prevents mold collapse, blockage, or improper clamping. Steel tools should never be used on forming surfaces during cleaning.
Applying the coating is one of the most critical and challenging steps in die-casting. It must be done strictly according to the spray process to avoid quality issues and early mold damage.
Sliding parts should be lubricated promptly according to the defined schedule.
Always check the mold's tightness and regularly inspect the mold platen compression and bracket support to prevent mold sinking or falling during operation.
Complete the mold maintenance cycle or stop production after finishing the specified batch. Keep the last casted part (preferably with the gating system) for inspection and repair along with the mold.
Stay alert to unexpected issues
Tags: Die Casting, Die Casting Process, Die Life, Cooling Solution, Die Casting Production
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