Analyze and optimize unreasonable product structure
Aluminum Die Casting Manufacturer
30 Years of Experience in Manufacturing and Development of Die Casting Industry
Experienced Professional Team
Die Casting Mold
1. Optimize design and verify feasibility
2. Propose optimization solutions based on customer design (change wall thickness and structure, add Radius angle, rib angle, draft angle)
3. Analyze product feasibility (including product design, mold design (manufacturing), product production); such as: K4HA, 16 cavities, AP2, escalator steps
– The customer’s original mold is one mold with eight cavities, and feedback shows that 2-3 defective products are prone to appear. After Raidy Mold evaluated the full casting drawing, mold flow, and DFM(design for manufacture) report to confirm the solution of changing to one mold with sixteen cavities
– The customer provided three similar products of different sizes, and each product was assembled after die-casting of more than a dozen parts. After the solution evaluation, Raidy Mold integrated more than a dozen parts of each product into a whole, and used the replacement of sliders and inserts to allow the three products to be die-casted by the same set of molds, reducing product production costs for customers
4. Solve the problems of previous molds (extend mold life, improve product qualification rate (yield), and improve die-casting productivity)
Die Casting Part
1. Verify and analyze product feasibility, meet customer process and quality requirements, reduce product costs, and fast delivery.
2. Combine experience and data to adjust die-casting machine parameters including pressure, machine cycle time (how many bars to use, cycle time, spray time, blowing time, drying the moisture content of the mold surface and controlling the mold temperature) and use a reasonable proportion of release agent according to different aluminum materials.
3. Use auxiliary equipment to make product molding and internal quality better.
– Vacuum machine: reduce casting air porosity and improve product quality.
– High-pressure cooling of core pins: improve casting shrinkage, dispersed shrink, soldering mark, scuffing and other defects, and extend the service life of cores and core pins.
– Local pressurization: squeeze pins to eliminate shrinkage and dispersed shrink in thick-walled areas of castings.
– Sliding block technology: for structures that cannot be demolded locally on castings, solve the problem of this structure being unable to demold.
– Mold temperature controller: control mold surface temperature.
4. Use trimming machines, shot blasting machines, sandblasting machines, vibration grinders, impregnation treatment, robot automatic deburring and gas quenching heat treatment for product post-processing.
5. According to the requirements of parts, develop automatic or manual machining production lines, develop high-precision hydraulic and pneumatic clamps to meet the requirements of high-precision parts processing. Set up an air detection circuit for positioning points/positioning surfaces to detect whether they are accurately positioned.
If there are high requirements for cross holes in high-pressure oil channels, and the burrs of cross holes affect customer assembly, use ECM electrochemical processing appropriately, and discharge the electrodes through partial electrolysis to remove the burrs and sharp angles of the cross holes in the high-pressure oil channels.
6. According to the requirements of parts, develop pressure assembly, gluing, riveting, leak detection and testing and other process equipment with error-proofing functions.
Auxiliary Equipment
Solve problems that cannot be solved on molds and die-casting machines, such as reducing casting blow hole and improving casting quality.
1. Painting technology inside die-casting molds: painting on places that are difficult to paint, such as the bottom of the slider, to obtain good lubrication and cooling effects, improve product surface soldering mark, mold sticking and other problems, and improve the quality of blanks.
2. Vacuum machine: reduce casting pores and improve quality.
3. High-pressure point cooling machine: high-pressure cooling of core pins to improve casting shrinkage, dispersed shrinkage , soldering mark, scuffing and other defects, and extend the service life of cores and core pins.
4. High-pressure mold cooling machine: real-time monitoring of cooling water supply, and alarm information in case of abnormalities. Improve the quality of castings, achieve mold thermal balance, and speed up production cycle time.
5. Local pressurization device: solve the leakage problem of products with high air tightness requirements such as high-pressure oil channels. The squeeze density is high, stable and controllable, which reduces the failure rate of the mold squeeze pin and improves the product yield rate.
6. High-precision release agent liquid supply system: customized functions according to customer needs, mobile phone APP monitoring, with original liquid and mixed liquid delivery flow monitoring and real-time display of flow value function, real-time value of mixed liquid concentration, etc. The high-precision release agent ratio accuracy is ±1%. The output pressure value of the release agent mixed liquid is ≥5 kg.
7. Workshop pure water cooling system: design a pure water system that meets the needs according to the actual situation of the customer, cooling path layout, return water system layout, etc.
8. Pulse mold cleaning machine: solve the harm of scale, such as scale blockage of the mold water cooling pipe, resulting in product soldering mark, air leakage and other defects.
9. Mold temperature controller: When the mold temperature is higher than the set temperature, the control device will stop heating and automatically switch to the normal cooling system of the mold to control the mold surface temperature.
Die Casting Components
The main hardware structures in the whole injection system include: injection chamber, injection ram, sprue sleeve, sprue spreader, connector and injection rod, etc.. And its related auxiliary materials include release agent, plunger tip wax, etc. The implementation of the overall solution can effectively reduce the loss of die-casting production and improve the comprehensive benefits by more than 25%.
1. Injection chamber and sprue sleeve joint solution: the joint has no gaps, the concentricity is greatly improved, the resistance during injection is reduced, the punch stuck is avoided, and the punch strain is effectively controlled.
2. Injection chamber and sprue sleeve diverter nozzle water transport system solution: according to the principle of thermal expansion and contraction, the temperature of the accessories is reduced to reduce the damage, wear and even cracking and bursting of the metal structure of the accessories caused by excessive temperature.
3. Improvement of metal material requirements, optimization of heat treatment and processing technology, effectively improve the performance of accessories.
4. Standardization solution for die-casting accessories: collect customer feedback data, standardize and unify the inventory of accessories in combination with the actual production needs of the market. Reduce the types of accessories, avoid a variety of miscellaneous parts, and meet the urgent needs of customers’ production. Standardization of accessories provides you with faster and better services.
Injection Mold
1. Verify and analyze product feasibility, meet customer process and quality requirements, reduce product costs, and fast delivery.
2. Combine experience and data to adjust die-casting machine parameters including pressure, machine cycle time (how many bars to use, cycle time, spray time, blowing time, drying the moisture content of the mold surface and controlling the mold temperature) and use a reasonable proportion of release agent according to different aluminum materials.
3. Use auxiliary equipment to make product molding and internal quality better.
– Vacuum machine: reduce casting air porosity and improve product quality.
– High-pressure cooling of core pins: improve casting shrinkage, dispersed shrink, soldering mark, scuffing and other defects, and extend the service life of cores and core pins.
– Local pressurization: squeeze pins to eliminate shrinkage and dispersed shrink in thick-walled areas of castings.
– Sliding block technology: for structures that cannot be demolded locally on castings, solve the problem of this structure being unable to demold.
– Mold temperature controller: control mold surface temperature
4. Use trimming machines, shot blasting machines, sandblasting machines, vibration grinders, impregnation treatment, robot automatic deburring and gas quenching heat treatment for product post-processing.
5. According to the requirements of parts, develop automatic or manual machining production lines, develop high-precision hydraulic and pneumatic clamps to meet the requirements of high-precision parts processing. Set up an air detection circuit for positioning points/positioning surfaces to detect whether they are accurately positioned.
If there are high requirements for cross holes in high-pressure oil channels, and the burrs of cross holes affect customer assembly, use ECM electrochemical processing appropriately, and discharge the electrodes through partial electrolysis to remove the burrs and sharp angles of the cross holes in the high-pressure oil channels
6. According to the requirements of parts, develop pressure assembly, gluing, riveting, leak detection and testing and other process equipment with error-proofing functions.
Share Our Experience
The internal shrinkage of the M10 thread hole of the product column is serious.
Reduced risk of cavitation.
By increasing the diameter of the pin, the exhaust speed can be faster; by adding cooling to the pin, the cooling speed of the product can be accelerated and the risk of shrinkage cavities can be reduced.
Porosity on gate, coldshoot in various parts of the product.
The product has good appearance, no cold shut and material shortage.
By changing the pouring row design, the overall appearance of the product is good, there is no cold shut, material shortage, and no air holes and shrinkage holes are found.
After the product was cut, shrinkage cavities and shrinkage in the thick wall area were found.
Eliminate shrinkage cavities and porosity.
Eliminate shrinkage and porosity problems through local pressurization technology with auxiliary equipment.
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500 Sets Per Year, Up To 12000T Machines
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