In motorcycle high pressure die casting production, mold performance stability is paramount for maintaining consistent part quality over long production cycles. While many defects appear on the surface or inside the casting, some issues are directly related to mold design details that are often underestimated in the early stages. A typical example is erosion in the fixed-side gate area, which gradually affects the filling stability and part consistency of aluminum high pressure die casting molds.
This case study comes from a real motorcycle die casting mold project by Raidy Mold Manufacturer. By analyzing the problem and implementing targeted mold design and process optimization measures, the problem was effectively controlled, thereby improving casting stability and extending mold life.
Problem Identified
Based on the L-side of the motorcycle cover wall thickness and shape analysis, the part wall thickness of 2mm is a thin-wall part and an appearance part,which needs high-speed filling to ensure the part forming and appearance. According to the calculation of the mold runner, the gate ratio is 20 times, which is moderate for this part,it is not recommended to thicken the gate to reduce the filling speed.We will improve the erosion and filling end cold shut of the mold from below three aspects.
Problem Analysis
The Raidy mold technology team is currently improving mold erosion and sprue cooling in three ways:
Firstly, ABP strengthening will be applied to the movable and fixed mold inserts; Secondly, optimize the mold water line to increase the temperature of the filling end, please refer to the position of the diagram for details; Thirdly, adjust slag ladle of the filling end and replace the exhaust block, please refer to the diagram for details.
Problem Solving
- Remove the two coolings from the movable mold and replace them with one cooling at the red dot position.
- Cancel the three coolings of the filling end for the fixed mold.
- The direct cooling at the fixed mold gate is too close to the forming,needs to be moved downwards to the blue position.
- Replace the exhaust block and adjust the exhaust vent.
- These 6 slag ladle positions at the filling end has been adjusted, and the depth of the fixed mold side has been changed from 12mm to 18mm.
Our technical team at Raidy Mold Manufacturer ultimately concluded that the solution came from these aspects.
Early Risk Identification and Prevention Control for Motorcycle Die Casting Molds
Our Raidy technical team discovered that the customer’s original 20mm sleeve wall thickness posed a potential risk of cracking under actual die casting conditions. To reduce the risk of cracking and improve process safety, we increased the wall thickness from 20mm to 25mm.
Through this case study of high pressure die casting motorcycle parts, we clearly understand that even localized mold issues, such as gate erosion on the fixed mold side, can significantly impact long-term production stability. By optimizing the gate design and adjusting process parameters at the aluminum high pressure die casting mold level, we fundamentally solved the defect problem, not just addressed surface defects.
Contact Raidy Motorcycle Parts Die-Casting Mold Manufacturer
If you are developing or producing motorcycle die castings and facing issues related to mold design, corrosion, thermal control, or casting defects, Raidy Mold is ready to support your project. As a manufacturer specializing in aluminum high pressure die casting molds, we will work closely with you to assess risks early, optimize mold solutions, and provide reliable solutions for mass production. Welcome to contact us and tell us your high pressure die casting mold needs.
