Project Overview (Die Casting Mold Project Overview)
In high-pressure die casting production, porosity defects are one of the most significant issues affecting product quality and production costs . For die-cast parts that require machining, if internal porosity is exposed during processing, it will directly lead to product scrap.
The customer’s first batch of die-casting molds, produced by another supplier, had internal porosity issues.
For the second batch, they contacted Raidy Company to optimize the die-casting molds.
This case study demonstrates how the Raidy mold team successfully solved the porosity problem in fuel dispenser piston parts and significantly reduced the production scrap rate by optimizing the design of the die-casting mold gating system .
By redesigning the gate location of the die-casting mold and conducting Magama simulation analysis , we not only improved product quality but also helped our customers significantly reduce production costs and shorten product development cycles.
Ultimately, the project helped the client achieve:
- The scrap rate decreased from 30.1% to 2.3%.
- Annual cost savings of approximately 2.06 million yuan
- Project development cycle shortened by 40 days
This case fully demonstrates Raidy die casting mold supplier technical capabilities in high-pressure die-casting mold design and defect control .
Product Background: Development of Die-casting Molds for Key Components of Fuel Dispensers
The product involved in this project is a die-cast component of the core piston assembly in a fuel dispenser . This part is mainly manufactured using a high-pressure die-casting process for aluminum alloys, and requires multiple machining processes after die-casting.
This product has the following characteristics:
- There are multiple threaded holes and through holes.
- High machining precision requirements
- High internal structural density requirements
- Very sensitive to porosity defects
During the mass production of the customer’s first batch of products（(other die-casting mold suppliers)）, due to the unreasonable design of the die-casting mold gating system , the problem of exposed pores frequently occurred during the machining stage.
This problem led to a continuous decline in product yield and resulted in significant waste of materials and processing costs. Therefore, during the second phase of product development, the customer decided to redesign and optimize the die-casting mold .
After evaluating multiple suppliers, the client chose to partner with Raidy die casting mold supplier, hoping to solve this problem through their professional die-casting mold design and simulation analysis capabilities .
Project Challenge: Porosity Defects Caused by Die Casting Mold Design
The first batch from other suppliers, the appearance quality of the product was basically normal during the die casting stage, but internal pores were frequently exposed during the machining process.
Especially in the following areas:
- Threaded hole
- Through hole
- Key sealing structure
When machining tools drill or tap, the pores inside the die casting are exposed, causing the product to fail to meet quality standards.
According to customer production data statistics:
- The overall defect rate was as high as 30.1%.
- A large number of parts were scrapped after machining.
- Production costs continue to rise
After a comprehensive analysis of the product structure, die-casting process, and existing die-casting mold design by the Raidy die casting mold supplier engineering team , we found that the main problem stemmed from:
The gate location is poorly designed.
An improper gate location can cause the molten metal to form a complex flow path in the mold cavity, resulting in a gas stagnation zone.
These gases eventually form pores inside the product and are exposed during machining.
Raidy Die Casting Mold Solutions: Optimizing Gate Location
To address this issue, the Raidy mold team proposed a die-casting mold improvement solution centered on gating system optimization .
This optimization mainly includes the following three aspects.
1. Redesign the gate location of the die-casting mold
By redesigning the gate location, the molten metal can enter the cavity in a more stable manner, thereby reducing air entrapment.
The new gate layout makes the molten metal flow more uniform and reduces the generation of local eddies.
2. Optimize the metal liquid filling pat
In the new die-casting mold design, we adjusted the flow channel structure so that the molten metal can fill the cavity along a more rational path.
This improvement effectively reduces the accumulation of gas in critical machining areas.
3. Improve the venting conditions of die-casting molds
In addition to gate optimization, we also analyzed the mold venting system to allow air in the cavity to be discharged more smoothly during the filling process.
Through these optimization measures, the new die-casting mold design significantly improves the gas distribution during the molten metal filling process.
Verification of the Optimization Effect of Die Casting Mold
To verify the new mold design, we conducted dual verification through actual production testing and MAGMA simulation analysis .
Physical comparison verification
During the trial production phase of the new mold, we conducted detailed testing on products using both the old and new designs.
The test results show that:
- The original product had obvious porosity in the threaded hole area.
- The new solution significantly reduces internal pores in the product.
- The problem of exposed pores after machining has basically disappeared.
The scrap rate decreased significantly.
Statistical analysis of trial production data revealed that:
Original scrap rate:
30.1%
Optimized die-casting mold solution:
2.3%
This improvement has greatly increased the product qualification rate.
MAGMA die casting simulation analysis
During the mold design phase, Raidy die casting mold supplier used MAGMA simulation software to analyze the die-casting process.
Simulation results show:
- The air pressure inside the cavity decreased significantly.
- The flow of molten metal is more stable
- The gas retention area was significantly reduced.
The simulation results are highly consistent with the actual production data.
Project Outcome: The Commercial Value Brought About by Die Casting Mold Optimization
This project not only solved the problem of product porosity, but also brought significant economic benefits to the customer.
Cost savings
The customer’s monthly supply volume is approximately 80,000 units .
In the original plan, due to the high scrap rate, a large number of parts were scrapped after machining.
After optimization of the die-casting mold:
The scrap rate decreased from 30.1% to 2.3% .
Based on production data, this project saves the client approximately:
$290,000.
Improved product quality stability
By reducing porosity defects, the internal density of the product is significantly improved.
This not only reduces the scrap rate during machining but also improves the reliability of the final equipment.
Improve equipment production efficiency
With a reduced scrap rate, rework and downtime on the production line are significantly reduced, thereby improving the OEE (Overall Equipment Effectiveness) of the production equipment .
Shortened development cycle
Through die-casting simulation analysis and experience-driven mold design, we identify potential problems early in the development phase.
This ultimately shortened the project development cycle by approximately 40 days .
Key Application Areas of Raidy Die Casting Mold Solutions
Raidy high-pressure die casting mold solutions are widely used in multiple industries, including:
Automotive Parts
New Energy Vehicle Structural Components
Industrial Equipment Components
Refueling Equipment Components
Pump and Valve Bodies
Precision Mechanical Parts
Extensive project experience enables us to provide stable and reliable mold solutions for complex aluminum alloy die castings.
Why Choose Raidy Die Casting Molds?
Raidy Die casting mold supplier Die casting mold supplier has extensive experience in the development of high-pressure die-casting molds.
Our advantages include:
- Extensive experience in die casting molds for complex structural components
- MAGMA simulation-driven mold design capabilities
- Porosity and shrinkage cavity defect control technology
- Rapid mold development capability
- Complete quality control system
We not only provide mold products, but also offer customers complete die casting manufacturing solutions .
FAQ
Q1.Can the porosity problem in die-cast parts be completely avoided?
By designing appropriate die-casting molds, optimizing venting systems, and controlling processes, porosity issues can be effectively reduced and kept within acceptable limits.
Q2.Do all porosity issues require modification of the die-casting mold?
No. Some porosity issues can be resolved by adjusting process parameters. However, if the problem stems from the gating system design, then optimizing the mold structure is usually necessary.
Q3.Does Raidy offer die-casting simulation and analysis services?
Yes. We typically use MAGMA simulation software for analysis during the mold design phase to reduce the number of trial moldings and improve the mold success rate.
Contact Raidy for Die Casting Mold Solutions
If your die-cast parts encounter the following during the production process:
- Pore problem
- High scrap rate
- unreasonable mold design
- Development cycle is too long
Raidy mold team can provide you with professional die-casting mold design and optimization solutions .
Feel free to contact us for a free technical assessment and advice.
+86-13710657199
[email protected]
