How to ensure the accuracy and quality of products in the production process of Dalian aluminum alloy die-casting?

How to ensure the accuracy and quality of products in the production process of Dalian aluminum alloy die-casting?

In the production process of aluminum alloy die-casting in Dalian, the accuracy and quality of the product can be ensured through the following aspects:

1、 Raw material process

Strictly control the quality of materials

Select high-quality aluminum alloy ingots to ensure uniform chemical composition and low impurity content. In the procurement process, collaborate with reliable suppliers and request material quality inspection reports.

Conduct random inspections on each batch of raw materials, such as using a spectral analyzer to detect whether the content of alloy elements meets the standards, in order to avoid affecting product accuracy and quality due to fluctuations in raw material quality.

Optimize material pretreatment

Uniform annealing treatment of aluminum alloy can eliminate internal stress and make the material structure more uniform, thereby improving the flowability and formability of the material during die-casting process, which helps to ensure product quality.

2、 Die casting mold process

High precision mold design and manufacturing

Use mold design software for precise design, fully considering factors such as mold shrinkage rate, parting surface design, demolding slope, etc. For example, based on the characteristics of aluminum alloy materials and the shape of the product, the demolding slope should be set reasonably, generally between 1-3 °, to ensure smooth demolding of the product and that the dimensional accuracy is not affected.

Using high-precision machining equipment, such as CNC machining centers, to ensure the dimensional accuracy of the mold. The machining accuracy of the mold cavity can be controlled within the range of ± 0.01- ± 0.05mm, improving the manufacturing quality of the mold.

Maintenance and upkeep of molds

Regularly inspect and maintain the mold, and promptly clean the residue and dirt on the surface of the mold. After each die-casting production is completed, use professional mold cleaning agents for cleaning to prevent residues from affecting the quality of subsequent die-casting products.

Monitor the wear of the mold, and when the wear of key parts of the mold exceeds a certain limit (such as cavity wear exceeding 0.1mm), repair or replace it in a timely manner to ensure the accuracy of the mold.

3、 Dalian Die Casting Process

Optimize die-casting process parameters

Accurately control the die-casting temperature, including furnace temperature and mold temperature. The furnace temperature for aluminum alloy die-casting is generally controlled between 650-720 ℃, and the mold temperature is adjusted between 150-300 ℃ according to the complexity and wall thickness of the product. Appropriate temperature can ensure the fluidity and filling properties of aluminum alloy liquid, reducing product defects.

Reasonably adjust the die-casting pressure and speed. The filling pressure is usually within the range of 30-100MPa, optimized according to the product structure and wall thickness. At the same time, control the injection speed to avoid product defects caused by being too fast or too slow. For example, when filling thin-walled parts, increase the injection speed appropriately to ensure complete filling.

Real time monitoring and adjustment

Install a die-casting process monitoring system to monitor real-time parameters such as pressure, temperature, and speed during the die-casting process. When there are abnormal fluctuations in parameters (such as pressure fluctuations exceeding ± 5MPa), adjust the process parameters or stop the machine for inspection in a timely manner to ensure the stability of the die-casting process.

Real time monitoring of the internal quality of products during the die-casting process is carried out through online detection equipment, such as X-ray flaw detectors, to promptly detect defects such as porosity and shrinkage, and take corresponding measures for adjustment.

4、 Post processing stage

Accurate post-processing technology

In the post-processing process, such as gate removal and trimming operations, high-precision cutting equipment is used, and reasonable cutting process parameters are formulated. For example, using laser cutting equipment, the cutting accuracy can be controlled within ± 0.1mm to ensure the dimensional accuracy of the product.

For products that require heat treatment, strictly control the heat treatment process parameters, such as aging temperature and time. For example, for ADC12 aluminum alloy, the aging temperature can be set at 150-180 ℃ and the aging time is 3-5 hours to ensure the mechanical properties and dimensional stability of the product.

Strict quality inspection

Establish a comprehensive quality inspection system and conduct multi process inspections on products. Including visual inspection, dimensional measurement, mechanical performance testing, internal defect detection, etc.

Use high-precision measuring equipment such as coordinate measuring instruments to test the dimensional accuracy of products, and the dimensional tolerance can be controlled within the range of ± 0.05- ± 0.5mm according to product requirements. For internal defect detection, non-destructive testing methods such as ultrasonic testing, magnetic particle testing, etc. are used to ensure product quality meets standards.