Improve the quality and accuracy of precision die-casting products in Dalian?

Improve the quality and accuracy of precision die-casting products in Dalian?

Here are some effective methods to improve the quality and accuracy of precision die-casting products in Dalian:

1、 Mold design and manufacturing

Accurate design

Using computer-aided design (CAD) and computer-aided engineering (CAE) software, precise simulation and optimization design of the structure, flow channels, cooling system, etc. of the mold are carried out to ensure smooth and uniform flow of the metal liquid in the mold, reducing the occurrence of defects such as curling and inclusions.

According to the requirements of the shape, size, wall thickness, etc. of the die-casting product, the parting surface and demolding mechanism of the mold should be designed reasonably to ensure that the product can be demolded smoothly without problems such as pulling or deformation.

High quality material selection

Choose high-quality mold steel, such as H13 steel, which has good thermal fatigue resistance, hardness, and wear resistance, and can withstand high temperatures, high pressures, and frequent impacts during the die-casting process, extending the service life of the mold.

For some molds with special requirements, hot work mold steel surface treatment techniques such as hard chromium plating, nitriding, etc. can be used to improve the hardness, wear resistance, and corrosion resistance of the mold surface.

Precision machining

Using high-precision machining equipment such as CNC machining centers, EDM machines, etc., to ensure the dimensional accuracy and surface quality of the mold.

Strictly control the machining tolerance of the mold to ensure the precision of the fit between the various components of the mold, and reduce the deformation and wear of the mold during use.

2、 Optimization of Die Casting Process Parameters in Dalian

pressure control 

Reasonably adjusting the injection pressure, generally speaking, higher injection pressure can make the metal liquid fill the mold cavity more quickly and completely, reducing defects such as pores and looseness. However, excessive pressure may also cause mold damage and burrs, so optimization needs to be carried out according to the specific requirements of the product.

Controlling the pressurization pressure and time, applying appropriate pressurization pressure during the solidification process of molten metal, can improve the density and mechanical properties of the product.

Speed regulation

Optimize injection speed, including slow injection speed and fast injection speed. Slow injection speed is mainly used to remove gas from the pressure chamber and sprue to prevent air from being drawn in; The fast injection speed affects the filling time and filling effect of the metal liquid, and needs to be adjusted according to factors such as the shape and wall thickness of the product.

Control the flow rate of the molten metal in the mold to avoid local overheating or undercooling and ensure the uniformity of the product structure.

temperature control

Accurately control the temperature of the material cylinder of the die-casting machine to maintain the metal liquid within the appropriate pouring temperature range. Excessive temperature can lead to intensified oxidation of the molten metal and increased tendency to stick to the mold; If the temperature is too low, it will affect the fluidity of the metal liquid and increase the difficulty of filling.

Effective temperature regulation of the mold is achieved by controlling the temperature distribution of the mold through cooling channels or heating devices. For products with uneven wall thickness or complex structure, local heating or cooling can be used to improve product quality.

3、 Raw material selection and processing

Alloy selection

Select the appropriate die-casting alloy based on the performance requirements and usage environment of the product. For example, aluminum alloy has the advantages of light weight and corrosion resistance, and is widely used in fields such as automobiles and electronics; Zinc alloy has good casting performance and decorative properties, and is commonly used for die-casting of small precision parts.

Pay attention to the composition and impurity content of the alloy, strictly control the content of harmful elements such as iron, silicon, etc., to ensure the fluidity, mechanical properties, and corrosion resistance of the alloy.

Raw material pretreatment

Refine metal raw materials to remove impurities such as gases and inclusions, and improve the purity of the molten metal. Methods such as air blowing refining and solvent refining can be used.

Strictly inspect and classify the recycled materials, control the proportion of recycled materials, and avoid affecting product quality due to impurities and oxide scales in the recycled materials.

4、 Quality Inspection and Control

Online monitoring

Install a die-casting process monitoring system to monitor real-time parameters such as pressure, temperature, and speed during the die-casting process. Once any abnormal situations are detected, promptly sound an alarm and adjust the process parameters.

Using a visual inspection system, the appearance of die-casting products is inspected online to promptly detect surface defects such as burrs, cracks, sand holes, etc., and automatically sort them.

Offline detection

Use coordinate measuring instruments, metallographic microscopes, hardness testers, and other testing equipment to comprehensively inspect the dimensional accuracy, internal structure, mechanical properties, and other aspects of die-casting products.

Conduct destructive tests such as tensile tests, impact tests, etc. to evaluate the mechanical properties and reliability of the product.

Quality traceability

Establish a comprehensive quality traceability system, number and record each die-casting product, including raw material batches, die-casting process parameters, test results, and other information, in order to quickly trace and analyze the causes of quality problems when they occur.

5、 Personnel training and management

Skill training

Regularly provide professional skills training for Dalian die-casting operators, mold maintenance personnel, quality inspection personnel, etc., to familiarize them with the operation of die-casting equipment, maintenance of molds, quality inspection methods and standards, etc.

Carry out training on new technologies and processes to enable employees to timely grasp the latest developments in the industry, improve work efficiency and quality awareness.

Quality Assurance

Establish a strict quality management system, clarify the quality responsibilities and work processes of personnel in each position, and strengthen quality control over the production process.

Encourage employees to participate in quality management activities, such as quality improvement teams, rationalization proposals, etc., and create an atmosphere of full participation in quality management.