Parts processing inspection is the fundamental guarantee and basis of parts accuracy and mold product quality, mold parts inspection content and inspection means depending on different production conditions and production scale and different. Because the mold processing belongs to the single-piece production, processing processes, parts surface complex, its quality inspection, and conventional testing are slightly different. At the same time for the mold cavity hardness, corrosion resistance and ornamental processing requirements are difficult to achieve through the general testing methods, only through certain processing methods and process measures to ensure. Sometimes the test results of mold parts can not be evaluated by qualified or not, such as the cavity surface polishing usually indicates the quality of polishing. This is the difference between mold parts testing and ordinary parts testing. Mold parts inspection content Mold parts inspection content is mainly geometric inspection, including size tolerance, shape tolerance, position tolerance, surface roughness and threaded core, cavity tolerance, etc. Dimensional tolerance requirements are to ensure the accuracy of the size of the parts, with dimensional tolerance requirements, are to ensure the interchangeability of the parts, the accuracy of the fit of the motion vice, fit clearance, and deviation. There are two kinds of dimensional tolerances: linear dimensional tolerance and angular taper tolerance. Shape tolerance requirements are to ensure the accuracy and working performance of the mold. Shape tolerance is for a single element, including straightness, flatness, roundness, cylindricity, line contour, and surface contour, etc. Position tolerance is for the associated elements, including parallelism, perpendicularity, inclination, coaxial, position, and symmetry, etc. Surface roughness is an indicator that characterizes the microscopic morphological error of the workpiece surface. Thread inspection includes single-content inspection (such as pitch, tooth angle, mid-diameter, etc.) and comprehensive inspection. 1. Mold plate parts This type of parts mainly affects the closing accuracy and movement accuracy of the mold and is also an important reference surface in the process of processing and assembly, which needs to focus on the inspection of the surface roughness of the upper and lower plane, parallelism, flatness, perpendicularity with the side, cylindricity of the hole system, perpendicularity, hole size, and hole spacing size. 2. Cavity type parts These parts are directly related to the dimensional accuracy of the plastic parts, which is the core part of the mold processing but also needs to focus on the content of the inspection. The inspection of cavity parts includes almost all the contents of dimensional tolerance, shape tolerance, position tolerance, surface roughness and tolerance of threaded core and cavity, etc. At the same time, there are also requirements of release slope and surface quality inspection, such as the evaluation of polishing quality and the judgment of whether the plating is off. 3. Structural parts These parts have the function of guidance and movement, such as guide pillars, guide bushings, sliders, etc., the surface quality requirements are high. Guide pillar inspection indicators are the coaxial, cylindricity, radial dimensions of each step axis section. The guide sleeve is mainly to detect the coaxial, cylindricity, and radial dimensions of its internal and external cylindrical surface. The slider has high accuracy requirements for the parallelism, flatness, and angle of the locking bevel of the sliding fit surface. The tie rod mainly detects the consistency of the axial functional dimensions, and the pressure plate mainly detects the parallelism, perpendicularity, and consistency of the functional dimensions. For push rods, reset rods, and other outsourced parts mainly from the incoming channels to ensure quality, you can test the radial dimension, hardness. 4. Standard parts class parts The inspection of standard parts class parts needs special equipment, which is difficult to carry out in general enterprises, but the premature fatigue of screws and premature failure of reset springs may cause damage to the mold. So we should use some products from famous enterprises with good quality and high reputation to avoid similar problems.

In addition to the quality of die casting is affected by a variety of process factors, the structural design of its parts is also a very important factor, its structural rationality and process adaptability determine whether the subsequent work can be carried out smoothly. Die-casting production technology problems encountered, such as the selection of the parting surface, the design of the sprue, the layout of the launch mechanism, the mastery of the shrinkage law, the guarantee of precision, the type and degree of defects are related to the die-casting process of the die casting itself. 1, Die-casting Process Requirements For Die Casting Structure. Design die casting in addition to structure, shape, and other aspects have certain requirements, but also should make die casting adapt to the die-casting process. Die casting structure design directly affects the die casting mold structure design and manufacturing of the degree of difficulty, productivity and mold life, and many other aspects, so the design of die casting must emphasize the cooperation between the designer and die casting process personnel, so that die casting in the die casting process may appear many unfavorable factors to be considered in advance and to be excluded. If the designer is also familiar with the die-casting process, then the design of the structure of the die casting is usually more reasonable. The requirements of the die-casting process for die-casting structure design are as follows. Requirements To be able to easily remove the die casting from the mold; To try to eliminate the side concave, deep cavity; To minimize the core extraction part; To eliminate the crossed parts of the mold core; The wall thickness should be uniform; To eliminate sharp corners. Description All the obstacles that are not conducive to the die casting out of the mold should try to eliminate in advance when designing the die casting; Internal side concavities and deep cavities are the biggest obstacles to mold release. When it cannot be avoided, it should also facilitate the extraction of cores to ensure that the die casting can be removed from the die casting mold smoothly; Each additional core extraction makes the mold more complex and increases the risk of mold failure; When the core crosses, not only make the mold structure complex but also prone to failure; When the wall thickness is not uniform, the die casting will have shrinkage deformation due to the different solidification rates and will produce internal shrinkage and pores, and other defects in the thick part; Reduce casting stress. 1.1 die casting should simplify the mold structure, extend the life of the mold. 1) design die castings as far as possible to make the parting surface simple; 2) to avoid partial thinning of the mold, to ensure that the mold has sufficient strength and rigidity; 3) to prevent the die casting deformation. 2, The Structure Of The Die Casting Process Elements The basic structural process elements of die casting include wall thickness, ribs, casting holes, casting rounding, release slope, thread, gear, slot gap, rivet head, convex pattern, mesh, text, logo, pattern, embedded casting, etc. 2.1 Wall thickness and rib design Die casting reasonable wall thickness depends on the specific structure of the casting, alloy properties and die-casting process, and many other factors. The practice has proved that, as a rule, the mechanical properties of die casting with the increase in wall thickness and decrease. Thin-walled castings than thick-walled castings have higher tensile strength and denseness, thin-walled die casting wears resistance is also good. Die castings with the increase in wall thickness, its internal porosity, and loosening and other defects also increased, so in order to ensure that die castings have sufficient strength and stiffness of the premise, a reasonable wall thickness should be designed into a thin wall and uniform wall thickness, otherwise, it will lead to the uneven internal organization of die castings, but also to the implementation of the die-casting process increases the difficulties. In the usual process conditions, the wall thickness of the die casting should not exceed 4.5mm, the maximum wall thickness and minimum wall thickness ratio should not be greater than 3:1. The thick wall of the die casting, in order to avoid defects such as sparse, should be thinned wall thickness and additional reinforcement ribs.

With the progression of science and technology, the market competition is becoming more and more fierce, and the product renewal cycle is getting shorter and shorter, therefore, shortening the development cycle of new products and reducing the development cost are the urgent problems faced by every manufacturer, and the requirement of rapid mold manufacturing comes into being. Rapid mold making technology includes the traditional rapid mold making technology, such as low melting point alloy mold, electroforming mold, etc., and Rapid Prototyping (RP) for rapid tooling. Principles and characteristics of rapid prototyping technology There are many specific process methods of rapid prototyping technology, but the basic principle is the same, that is, the material addition method is the basic method to rapidly transform a 3D CAD model into a 3D solid prototype composed of specific substances. Firstly, a 3D CAD model is obtained in the CAD modeling system, or the shape and size of the entity are measured by measuring instruments and transformed into a CAD model, then the model data is processed and discretized in a plane layering along a certain direction, and then the embryo is processed by a special CAM system for layering forming and stacking into a prototype. Rapid prototyping technology opens up the way to rapidly manufacture various parts without any tool and provides a new manufacturing means for parts or models that cannot or are difficult to manufacture by conventional methods. It has shown good application prospects in the fields of aerospace, automotive design, light industrial product design, human organ manufacturing, architectural design, mold design, and manufacturing. In summary, rapid forming technology has the following application characteristics. 1, because rapid forming technology uses the mechanism of transforming three-dimensional shapes into two-dimensional planar layered manufacturing, it is insensitive to the complexity of the geometric structure of the workpiece, thus it can manufacture complex parts, fully reflect the design details, and directly manufacture composite parts. 2, rapid manufacture of molds ①Can manufacture metal molds from die castings with the help of electroforming, arc spraying, and other technologies. ②The rapid manufacturing prototype as a vanishing mold also can be used for batch manufacturing of vanishing molds for precision casting by prototype turning and manufacturing master molds. ③Fast manufacturing of high precision complex master molds for further casting of metal parts. ④Make graphite electrode by prototype, and then process the mold cavity from graphite electrode. ⑤ Direct machining of ceramic cavities for precision casting. 3, application in new product development, through the prototype physical model, the designer can quickly assess the feasibility of a design and fully express its conception. ①Shape design. Although CAD modeling systems can view the design model of a product from all directions, they are in no way as intuitive and visible as the prototypes obtained from RP, especially for complex shapes. Manufacturers can use conceptual prototypes as a promotional tool to sell their products, i.e., they can use RP prototypes to quickly allow users to compare and evaluate the new products they develop and determine the optimal appearance. ②Checking design quality. Taking mold manufacturing as an example, the traditional method is to open the mold on a CNC machine according to the geometric shape, which is too risky for expensive and complex molds, and any carelessness in the design may cause irreparable damage. Using RPM technology, the parts to be die-cast can be accurately manufactured before the mold is opened, and various subtle problems and errors in the design can be seen at a glance on the model, greatly reducing the risk of blind mold opening. the model made by RP can also be used as a CNC copy milling machine against the mold. ③ Functional inspection. Using prototypes to quickly perform functional tests of different designs to optimize product design. For example, the design of a fan, etc., can obtain the best fan blade surface and the lowest noise structure. 4, rapid forming process room is highly automated, long time continuous, simple operation can do day and night unattended, once the machine is turned on, can automatically complete the whole workpiece processing. 5, the manufacturing process of rapid forming technology does not require the input of tooling, and its cost is only related to the operating cost of the forming machine, material cost, and operator's salary, and has nothing to do with the batch of products, which is suitable for the manufacturing of the single piece, small-batch, and special and new trial products. 6, reverse engineering in rapid modeling has a wide range of applications. Laser 3D scanners, automatic tomography scanners, and many other measuring devices can quickly measure the internal and external contours of objects with high precision and convert them into CAD model data for RP processing. RP-based Rapid Tooling Technology In the field of rapid prototyping technology, the most rapidly developing and obvious growth of production value is Rapid Tooling, RT technology. By applying Rapid Prototyping technology to make Rapid Tooling RP+RT, we can greatly improve the success rate of product development, effectively shorten the development time and reduce the cost by conducting new product trials and small batch production before the final production mold. RP+RT technology provides a new concept and method of manufacturing molds directly from mold CAD models, which integrates the conceptual design and machining process of molds within one CAD/CAM system, creating good conditions for the application of parallel engineering. RT technology adopts RP multi-loop, rapid information feedback design, and manufacturing method, combined with various computer simulation and analysis means, forming a set of A new mold design and manufacturing system. The manufacturing of rapid tooling using rapid prototyping technology can be divided into two categories: direct rapid tooling manufacturing and indirect rapid tooling manufacturing. 1, Direct Rapid Tooling Manufacturing Direct rapid tooling manufacturing refers to the direct fabrication of a mold using different types of rapid prototyping techniques, followed by some necessary post-treatment and machining to obtain the required mechanical properties, dimensional accuracy, and surface roughness of the mold. Currently, the rapid prototyping processes that can directly manufacture metal molds include selective laser sintering SLS, shape deposition manufacturing SDM, and 3D Welding. Direct rapid mold manufacturing links are simple and can more fully exploit the advantages of rapid forming technology, especially in close combination with computer technology, to quickly complete mold manufacturing. For those injection molds that require complex shapes and internal runner cooling, the use of direct rapid mold manufacturing has advantages that cannot be replaced by other methods. Production injection molds can be produced in 5-10 days using the SLS direct rapid mold manufacturing process. 2, Indirect Rapid Tooling Manufacturing Using rapid prototyping master mold and pouring soft materials such as wax, silicone rubber, epoxy resin, or polyurethane, it can constitute a soft mold. The mold life of the injection mold made with this synthetic material can be up to 50-5000 pieces. A hard mold can be made by combining a rapid prototyping master mold or a soft mold with traditional processes such as investment casting, ceramic precision casting, electroforming, or cold spraying, which can produce plastic or metal parts in bulk. Hard molds usually have better machinability and can be partially machined for better accuracy and can be embedded with inserts, cooling parts, and sprue, etc.

Production of high-quality, economic die castings, in addition to a reasonable casting structure, perfect die casting die, and good die casting machine, but also must choose the appropriate die casting alloy. CAMEL dedicated designers in the selection of die casting alloy must consider the die casting stress state, working environment, production conditions, and economic 4 aspects, must also consider the alloy itself comprehensive properties. Die casting alloys selection generally follows the following principles. 1. Sufficient strength and plasticity at high temperatures, no or less thermal embrittlement. 2. Small crystallization temperature range. 3. Sufficient fluidity when the superheat is not high. 4. Small shrinkage. 5. Good physical and chemical properties - wear resistance, corrosion resistance, electrical conductivity, and thermal expansion, etc. 6. Good processability. Types of die casting alloys Die casting alloys are divided into non-ferrous alloys and ferrous alloys, currently widely used non-ferrous alloys, classified as follows Die casting non-ferrous alloys Low melting point alloy: lead alloy, tin alloy, zinc alloys. High melting point alloys: aluminum alloys, magnesium alloys, copper alloys. Properties comparison Comparison of the properties of various die casting alloys The property varies from "1" to "5". "1" means the most desirable, and "5" means the worst. Main alloy material of die casting Among them, the density of die casting aluminum alloy is about 2.7g/cm3, which can also be called light metal, and its property characteristics are very suitable for the die casting process. Aluminum alloys is the most used alloy for die casting. Die casting aluminum alloy has the characteristics of low density, high specific strength, good corrosion resistance, wear resistance, good thermal conductivity, good electrical conductivity, good cutting properties, etc. The die casting process is accompanied by a fast solidification rate, making the die casting alloy slightly better than gravity casting and casting alloys with the same chemical composition. yl112 alloy has better machinability. The 518 alloy with magnesium as the main alloying chemical element has the best machinability. The A390 alloy with high silicon content and incipient silicon phase have the worst machinability.

Optimization of Process Structure for Castings Abstract: In the design of die casting mould, more consideration is given to the curability of the mould itself, such as runner, overflow, temperature, ejection, etc. However, if the technological requirements of subsequent casting machining are not well considered in the design stage of the mould, the machining difficulty of the casting will increase. The production efficiency is reduced, which ultimately affects the machining production cost. Therefore, in the die design stage, not only the die casting process should be considered, but also the needs of subsequent machining should be considered more, so as to effectively optimize the die design scheme and improve the overall economic benefits of die castings. Die-casting has a series of characteristics such as high production efficiency, low cost, excellent appearance quality and long die life. In production, The rationality of mold design determines the quality of castings and the production efficiency. Therefore, the whole mold design process needs to be fully considered in combination with casting characteristics, die casting equipment capacity, material characteristics used, customer special requirements and other relevant factors. However, in actual production, most die-casting mould designer take that demand of blank die-casting as the key point of design concern. However, the special needs of subsequent machining are ignored, and problems such as difficult positioning, uneven blank allowance and shortened tool life often occur in the machining of die-casting blank, which seriously affect the production efficiency of machining and the stability of casting quality, and eventually lead to the decline of economic benefits of enterprises. The following is a brief discussion on the influence of the structural characteristics of die casting molds on machining and how to optimize them. 1st Influence of Gate Design on Die Casting The location of the ingate is one of the important links in the die design. The ingate design of the die casting mould is almost always based on the filling and forming of the casting. Quality and flow state are carried out without too much consideration of the influence of blank on subsequent machining. 1, Influence of ingate Position on Cutting Tools In many ways, the setting of the ingate location of die casting is the key and difficult point in the gating system design. Any negligence will cause unpredictable mistakes, which cannot be made up by the adjustment of die casting process. From the perspective of die casting production, the following basic principles should be followed in selecting gate position. (1)Avoid closing the venting passage immediately after liquid metal enters the mold cavity, which is beneficial to removing the air in the mold cavity. (2)As far as possible, branch ingates should be used less, so as not to interfere with each other and form eddy current and entrained air. (3)The ingates should not face the core and cavity wall directly to avoid direct impact of molten metal. (4)The ingates shall be placed at the thicker part of the casting to facilitate pressure transmission. (5)The molten metal flow is the shortest to reduce energy loss and avoid too much cooling. (6)The ingates shall not cause deformation during shrinkage of the casting. (7)Set the inner gate as close to the important parts of the work piece. If the setting of ingate location can meet the above conditions without considering the subsequent machining of the blank, then the setting of ingate location can be said to be perfect.However, most die castings need to be machined in production. If the actual demand of machining for casting blank is ignored, it will definitely bring some unnecessary troubles. The main manifestations are: the influence of the residue after gate removal on machining positioning and intermittent cutting during machining of gate parts. As we all know, intermittent cutting is a technological difficulty in mechanical machining, which can generate periodic vibration, make stripes or corrugated marks appear on the machined surface, resulting in an increase in the surface roughness value. Intermittent cutting in the cutting process makes the tool periodically stressed, which is easy to cause tool collapse and reduces the service life of the tool. In intermittent cutting, the operator has to adopt lower cutting speed spread and smaller feed, which affects the production efficiency of the machine and the worker. Relatively speaking, the influence on positioning is smaller. When designing machining fixtures, more understanding and communication should be done to confirm the gate form and position of the blank, estimate the approximate size of the gate residue in the future, and try to avoid using the gate position as the positioning benchmark for machining. Therefore, on the premise of meeting the die casting production, the ingate location setting also needs to take into account the technological requirements of subsequent machining, and reasonably arrange the ingate location of blank according to the actual technological process of machining. If you can't have both, it is recommended that the ingate be placed on an exposed and flat plane to facilitate polishing and reduce the allowance. Or the ingate location and size are placed evenly and continuously on the processing plane to reduce intermittent cutting. 1.As shown in picture 1, it is a common ingate location selection problem. Picture 1a that ingate is set on the movable die, and the ingate will remain on the circular plane in the future. From the perspective of die-casting technology, the ingate set on the movable die side is beneficial to the filling of molten metal and the die-casting production of castings. However, the ingate residue on the circular plane can be removed by subsequent machining, and the casting has beautiful appearance and no gate residue trace, but it will bring the problem of intermittent cutting. Fig. 1b is set at the fixed mold side, and the ingate will remain on the circumference of the casting in the future. In terms of die casting process, the metal liquid set at such ingate will directly impact the cavity wall of the mold, which is easy to adhere to the mold at the corresponding parts of the gate. After the ingate is removed in the future, ingate marks will remain on the circumference of the casting, affecting the appearance quality of the casting. However, the problem of intermittent cutting is avoided without machining the circumferential part. 2.The choice in actual production needs to be combined with the characteristics of their respective enterprises and comprehensively balanced with customer demand as the orientation. What should be emphasized here is that the design of die casting dies should take into account the needs of machining as much as possible. 2.Influence of Ingate Position on Machining Positioning Machining 1.Generally, a coarse reference on the blank should be selected for positioning, and then fine reference processing should be carried out. These coarse benchmarks require smoothness, reliability and consistency. There are mainly two selection methods for coarse benchmarks. (a)When the dimension chain on the machined casting pattern does not take a certain non-machined surface as the design benchmark, the determination of the coarse benchmark will often select the largest plane, outer circle or inner hole on the blank, because these features can obtain the maximum positioning limit and ensure the accuracy and consistency of positioning. (b)When the dimension chain on the machined casting drawing takes a non-machined surface as the design datum, the coarse datum must be selected, because the fine datum machined from this datum can represent the drawing in subsequent machining. The original design datum on is used as the process datum.If the gate appears in these areas, the casting positioning will be seriously affected. According to the machining positioning method, the corresponding optimization scheme is as follows: (1)As far as possible, the gate position should not be selected on a larger plane for positioning or on a very accurate design. (2)If the ingate must be placed on a larger plane for locating or on a design basis, consider multiple strands of feed and reserve the required position for positioning, as shown in Fig. 2. The middle area of the strand division is still a flat area, which can form a three-point-plane positioning (the same as the outer circle positioning) with other areas. (3) When the casting allows, add process positioning bosses (see Fig. 3) to optimize machining positioning coarse datum level. （a）The gate at the core side （b）The gate at the cavity side Picture 1 Different Design of Gate Position Through the above optimization scheme, the reliability of casting machining positioning can be improved. In addition, paying attention to the deformation at the gate and optimizing the gate removal process during die casting production can improve the machining positioning. 2nd Influence of Reserved holes 1.Influence of Reserved Holes on Position Tolerance It is generally believed that the hole should be reserved as far as possible for the hole shapes that can be formed in the mold, so as to reduce the machining allowance, protect the hardened layer of the casting and ensure the good air tightness of the casting. However, the reservation of bottom holes sometimes raises another question as to whether these pin holes can meet the position tolerance requirements of the casting and do not affect machining. If there is an out-of-tolerance position after machining, it is very likely that the out-of-tolerance position of the preset hole causes the tool to follow the wrong preset hole. The guide deviates from the preset machining size.The base of reserved hole is the manufacturing base of the mold, and in the process of machining the selection of the process base and mold manufacturing base is not consistent, reserved hole must also deviate from the process base, so it will lead to the position out of tolerance. This kind of problem can be solved in the following ways: (1)When designing the mold, the mold manufacturing benchmark is taken as the rough positioning benchmark for machining as far as possible. After the benchmark is unified, the position accuracy of hole machining will be improved. For example, the reserved hole with position requirement should be the same as the positioning surface of the process reference on the parting surface of the mold side, reduce the error influence of mold clamping dislocation. (2)Due to the diversity of products, it is sometimes difficult to unify the manufacturing standards. At this time, it is suggested to cancel the reserved hole with shallow processing depth. (3)The positioning and processing of the hole are completed by machining, thus eliminating the guiding effect of the preset bottom hole and improving the position accuracy. However, it should also be noted that a large margin of cutting will expose defects in the die casting. 2.Influence of Reserved Hole on Machining Positioning In machining, the reserved hole of the blank on the die casting is often used as coarse positioning, so the reliability of the reserved bottom hole is especially important for positioning. It is important, so it is suggested to consider the priority of preset hole positioning. (1)The core of the reserved hole of the mold should be integrated with the core as much as possible, avoiding the use of detachable separate body. The main reason is that the split detachable core is used-after a period of time, burrs will be formed on the pin hole assembly joint surface, and these burrs are very thin and soft. Even if they are removed, a small part of them will adhere to the hole wall, affecting the positioning accuracy. (2)Preset hole core for positioning The inclination of the mould is enlarged and the surface hardness is increased as much as possible, so that the mould can be released smoothly during die casting production, the possibility of sticking the mould and pulling the inner wall of the hole can be reduced, and the positioning accuracy can be improved. (3)When the reserved hole with small aperture and split type is used as coarse positioning reference, it is better to prepare more cores of the hole while making the mold, so as to ensure the stability and consistency of the hole size during mold maintenance and avoid unnecessary losses for subsequent machining. Whether the reserved hole is appropriate or not will affect the positioning and accuracy of machining. Therefore, in the die-casting production process, in addition to paying attention to whether the reserved hole is deformed or not, stick mold and other quality states, it is also necessary to strengthen the daily core maintenance, to ensure the consistency of positioning benchmark. 3rd Conclusion To sum up, from the perspective of casting machining, the mold design is more convenient to locate and the surplus distribution is more reasonable, especially the manufacturing standard of the mold should be in good agreement with the machining process, which is beneficial to improving the efficiency and quality of machining. Therefore, in the design of die casting molds, designers need to consider all aspects of factors comprehensively, which puts forward new requirements for the expansion of professional ability of die designers. An excellent die casting designer must be a compound technical talent with mold technology, die casting technology and machining technology.

Die Casting Process (Fully automatic die casting cycle) Mold cleaning Mold preheating Paint spraying Placement of inserts Mold closing Pouring Press injection Solidification Open the mold Push out and take the parts Die casting can be divided into two categories: hot chamber die casting machine pressure casting and cold chamber die casting machine pressure casting, of which cold chamber die casting machine pressure casting is divided into vertical, horizontal and full vertical die casting machine die casting. Commonly Used Die Casting Machine Die Casting Process 1, Hot press chamber die casting machine die casting process The pressure chamber of hot die casting machine is in the insulated crucible molten alloy, the press injection parts are mounted on top of the crucible, and when the press injection punch rises, the molten alloy enters the chamber through the inlet. When the die is closed and the press punch is pressed down, the molten alloy fills the die through the nozzle along the channel and cools and solidifies. When the die punch returns, the die is opened and the part is taken, completing a die casting cycle. 2, Die casting process of vertical cold chamber die casting machine The center of the vertical cold chamber die casting machine is parallel to the parting surface of the mold, which is called vertical side chamber. After closing the mold, the molten alloy poured into the chamber is held by the counter punch which has sealed the nozzle hole; when the press injection punch goes down to the molten alloy, the counter punch starts to descend to open the nozzle and the molten alloy is pressed into the mold cavity; after solidification, the press injection punch returns and the counter punch rises to cut off and push out the residual material; after the residual material is taken away, the counter punch descends to the original position and the mold is opened to take the parts, completing a die casting cycle, this die casting machine is especially suitable for This kind of die casting machine is especially suitable for the production of die casting machine with center gate. 3, Horizontal cold chamber die casting machine die casting process The center line of the horizontal cold chamber die casting machine is perpendicular to the mold parting surface, called horizontal chamber. After the mold is closed, the molten alloy is poured into the chamber, and the injection punch is pushed forward to fill the cavity through the sprue; when the mold is opened, the injection punch pushes out the remaining material, the die pushing out mechanism pushes out the die casting, and the punch is reset to complete a die casting cycle. 4, The die casting process of all vertical cold chamber die casting machine The die casting machine with vertical arrangement of die closing mechanism and press injection mechanism is called all-vertical die casting machine, which can be divided into the following two types. 1) The die-casting process of the punch head press type all-vertical cold chamber die-casting machine. The molten alloy is first poured into the chamber and then the die is closed, the pressurized injection punch rises to press the molten alloy into the mold cavity, and after cooling and solidifying, the die is opened and the die casting is pushed out, and the punch is reset to complete a die casting cycle. 2) The die casting process of punch down type all vertical cold chamber die casting machine. After the mold is closed, the molten alloy is poured into the mold, and when the pressurized punch goes down to the molten alloy, the counterpunch goes down to open the channel, and the molten alloy is pressed into the mold cavity through the sprue; after solidification, the pressurized punch returns, and the counterpunch goes up to cut off and push out the remaining material. After the remaining material is taken away, the counter punch is reset to complete a die-casting cycle. In the above die-casting method, horizontal cold chamber die-casting machine is most widely used. Global Brand Of Horizontal Cold Press Chamber High Pressure Die Casting Machine: China: LK, YIZUMI, HAITIAN, SANJI, ZITAI, RUIDA, YANHING, MULER Japan: TOYO ,TOSHIBA , UBE U.S.: HPM (Acquired by YIZUMI in 2011) Switzerland: BUHLER German: FRECH Italy: IDRA , ITALPRESSE

What is mold temperature control? and how to balance the heat energy in the mold processing program? Then we introduce the related MTC, heat energy balance, and cooling system to propose solutions. The Influence Of Mold Temperature On Mold And Die Casting Mold temperature is one of the important factors affecting the quality of die castings, but it is often not strictly controlled during the production process. Especially in the production of complex die castings, only the temperature is controlled within a certain range to produce qualified die castings, and this temperature range is relatively narrow. At this time, the mold temperature must be strictly controlled. In each die-casting cycle, the temperature in the mold cavity changes. The heat source to raise the temperature of the mold is the heat brought in by the molten metal, and the heat energy is converted into the part of the mechanical energy consumed by the molten metal to fill the cavity. When the mold receives heat, it also radiates heat to the surroundings. If the heat absorbed by the mold and the heat dissipated in a unit of time is equal and reaches an equilibrium state, it is called the heat energy balance of the mold. What is MTC(Mold Temperature Controller) The mold temperature controller controls the temperature of the mold during thermal equilibrium within the optimal working temperature of the mold. The temperature control of the mold is achieved through the heating and cooling system of the mold. In the continuous die-casting process, the mold temperature goes through a cycle of rising and falling for each injection. In order to avoid the thermal shock of the molten metal on the low-temperature die-casting mold and shorten the life of the die, the molten metal will be chilled to lose fluidity, increase the line shrinkage, cause cracks or cracks to affect the quality of the die-casting, the mold must be fully preheated before die-casting. In continuous production, especially when die-casting high melting point alloys, the mold heats up very quickly, causing the molten metal to stick to the mold, the die-casting part is pushed out and deformed, the mold is partially stuck or even damaged, and the mold opening time is prolonged, reducing the productivity, and the die-casting part cools slowly. And make the crystal grain coarse. Therefore, when the temperature of the die-casting mold is too high, cooling measures should be taken to keep the mold in thermal equilibrium. How Does CAMEL Balancing Heat Energy CAMEL designs ample cooling lines on the fixed side and movable side to control the heat energy balance to get the best cycle-time and part quality. The balanced heat energy also lowers the risk of die cracking.

When you first get involved in casting, especially die casting, one of the very important steps in the design process is mold flow simulation. But why we do mold flow analysis and what is mold flow simulation? We will start with these two aspects and introduce the reasons and methods. High Pressure Die Casting Simulation The die casting process designer is a complex and empirical creative job. In die casting production, the three main elements are die casting machine, die casting alloy and die casting mold. The die casting process is the organic combination of these three elements and the reasonable choice of settings. Therefore, to die casting process parameters for the correct selection, control, and adjustment, so that a variety of process parameters to meet the needs of die casting production, in order to produce qualified die casting under other conditions of quality. CAE Technology Make use of the powerful computing and graphic functions of computers to assist mold design, improve the design accuracy and design reliability, design reasonable mold structure and reasonable pouring system. Numerical simulation of the die casting process by CAE technology, commonly known as computerized mold testing, visualizes the whole process of flow and solidification of metal liquid in the cavity during casting generation and analyzes the factors of defect formation. Mold Flow Simulation and Analysis With the continuous development of simulation technology, computer hardware, and software, The needs of the casting market, the numerical simulation of the casting process is to establish the correct mathematical models, and through the appropriate values, use the computer to analyze these models and use them to guide the casting practice in terms of flow, temperature, organization, etc. The simulation results are observed through post-processing, and the flow and solidification process of the metal fluid in the cavity is animated through multiple angles and profiles to track the view and locate the defective parts inside the casting. To support our customers in getting the best productivity and part quality, CAMEL always provides flow simulation by designing various kinds of runner layouts. By doing this our T1 success rate is over 96%. In this preliminary flow simulation, it appears that the outermost feeders are not supplying hot metal directly to problem areas while the center section is filling well. CAMEL adjusted the runner layout as shown below for a successful T1. Step 1: Eliminate (2) end feeders and make them overflow. Step 2: Change the feeder angle and gate towards the outer edge of the part. ABOUT CAMEL CORE BUSINESS: Aluminum Alloy Die Casting Mold Magnesium Alloy Die Casting Mold Zinc Alloy Die Casting Mold Trim Die(Mold) Milling & Turning Design & Prototyping CUSTOMERS MAIN INDUSTRIES: Automotive Telecom Equipment Mechanical Electrical Lighting Furniture Medical Instruments

With a background of a profound understanding of the requirements of export quality molds to European and North American companies, and the observation of frustration which takes place when overseas purchasers encounter failure from negative experiences working with unprofessional suppliers in the south of China, as well as when quality did not match with pricing, projects being delayed, poor communication in English, lost contracts with suppliers, etc., CAMEL Engineering was born. Since 2009, Simon and Leo - as founders who established CAMEL Engineering as a professional engineering company in Hongkong and work place in Shenzhen city - have only one purpose, which is to provide international buyers the best engineering service for export molds without misunderstandings of the standards of mold making, and to offer the best quality and excellent lead time. The world financial crisis still affected many local companies seriously in 2009, causing the majority of their business to be reduced over 50-60%. Even more, some factories had to shut down in 3 months to avoid a cash flow break in this “economic winter”. During this time most customers slowed down their projects’ development, as it seems like everybody was waiting anxiously for the “spring” to arrive. CAMEL was not thinking of ideas to control operating costs like the other companies were, but rather stayed busy with improving and upgrading its own project management system and how to offer better service. We believe that opportunities always exist and favor the prepared company. CAMEL’s business was not affected too much during this time, not only because of good luck but also because our workers deeply realized the critical situation we were in and dared not to slack off in communication, manufacturing, and lead time, while doing our best to provide more solutions and analysis for uncompleted projects, supporting customers to win more trust from our hard work, etc. Finally, more and more projects commenced and were delivered successfully to different countries. In 2012, CAMEL invested 60% in one of the biggest mold suppliers in South China, aiming to take the opportunity to focus on the automotive, lighting, and communication industries, working more closely with some larger companies and stepping forward one step at a time to the big development of our company. Two years later, CAMEL was able to take over 100% of the shares and management in this mold shop and subsequently moved to the second location in Dongguan, China. In 2017, CNC quantities increased from 5 to 9 sets and we became an ISO certificated company. At that time, we had 60 workers, including 6 professional mold designers and 32 skilled mold operating workers. Certain of our long-time customers have kept working with CAMEL since 2009, and they became the most valuable assets for CAMEL’s growth. Staying focused on each step is still the working philosophy of our company - focusing on more professional investments in our project management system, employee internal training system, and customer service system. Any one of these areas determines the growth of CAMEL and our customers’ success. CAMEL considers these as a stable iron triangle, not afraid of any difficulties and the belief that the most brilliant future is within our reach, one step at a time.

Abstract: High-pressure die casting is an important process for forming non-ferrous metal structures. The production elements of die casting are composed of a die casting machine, die casting mold, die-casting process, and die casting alloy. Low speed (hereinafter referred to as low-speed) is one of the key parameters of the die casting process. The low-speed setting has a more important effect on the quality of die-casting parts. This article will verify the impact of the low speed of die casting on the quality of parts while ensuring other parameters are not changed. Keywords: Die casting process; Low speed; Die casting parts. 1.Filling effect of casting at low pressure of 0.2m/s Figure 1.1 The filling state of the low-speed 0.2m/s shot sleeve ① The filling of aluminum liquid is relatively stable, and no obvious entrained air is seen. Figure 1.2 Temperature distribution after low-speed 0.2m / s castings is filled. ② The overall temperature of the casting is about 570°C, which is slightly lower than the liquidus line of the A380 material at 574.4°C. The risk of defects such as the cold lab and flow marks on the surface is higher. Figure 1.3 Entrained air volume fraction after low-speed 0.2m / s casting is filled. ③ Entrained air is basically discharged into the overflow, and the risk of defects such as porosity and surface bubbles in the casting is low. 2.Filling effect of casting at low-speed 0.3m/s Figure 2.1 Filling state of the low-speed 0.3m/s shot sleeve. ① Molten aluminum filling smoothly, and no turbulence is seen, but the molten aluminum at the end of the die-casting is significantly lower than that at the front end, a local entrained air phenomenon is caused. Figure 2.2 Temperature distribution after low-speed 0.3m/s casting is filled ② The temperature distribution of the filled casting is shown in Figure 2.2. The overall temperature of the casting is about 590°C, which is slightly higher than the liquidus line of the A380 material at 574.4°C. The risk of defects such as cold lab and surface flow marks on the casting is low. Figure 2.3 Entrained air volume fraction after low-speed 0.3m/s casting is filled. ③Entrained air volume fraction of filled casting is shown in Figure 2.3. During the casting filling process, a small part of the entrained air remains in the casting area, and the casting has the risk of forming pores and bubbles. 3.Filling effect of casting at low pressure 0.5m/s. Figure 3.1 Filling state of the low-pressure 0.5m/s shot chamber ① The molten aluminum in the shot chamber is shown in Figure 3.1. The aluminum liquid filling the shot chamber stably, but the turbulence phenomenon occurs as soon as the aluminum liquid enters the runner, and the entrained air phenomenon is serious. Figure 3.2 Temperature distribution after low-speed 0.5m/s castings are filled ② The temperature distribution of the filled casting is shown in Figure 3.2. The overall temperature of the casting is about 610°C, which is higher than the liquidus line of A380 material at 574.4°C. With no defects such as cold lab and surface flow marks. Figure 3.3 Entrained air volume fraction after low-speed 0.3m/s casting is filled ③ The distribution of Entrained air volume fraction after the casting is filled is shown in Figure 3.3. There is more entrained air in the casting area during the filling process, with a higher risk of defects such as pores and bubbles. 4.Conclusion ①.The slower the low-speed, the less the volume of entrained air, but too low speed will reduce the temperature of the molten aluminum, and the casting will have problems occur such as cold lab and flow mark. ②.When the low-speed is too fast, the filling temperature of the casting is high, and the possibility of cold lab and flow marks is less, but the volume of entrained air will increase, and defects such as porosity and bubbles will appear. ③.To set the low speed, you must first determine the product requirements. If the casting is an appearance part, you can appropriately increase the low speed to avoid surface defects such as surface flow mark and cold lap to improve the surface molding quality. If the casting is air-tight, it is necessary to reduce the low speed as much as possible to ensure that the casting does not form a cold lap to achieve the best venting effect and ensure the casting sealing performance. 5. References [1] A Concise Design Manual for Die Casting Molds / Edited by Huang Yong. --Beijing: Chemical Industry Press, 2009.11

This is part of the showroom of CAMEL's die casting products. The products are casings of gaming machines and car parts. CAMEL has certain advantages in the production of products. This is the reason why we are constantly introduced to us by old customers. We are also very grateful to our customers for their continued trust in us. Our sales engineers also have high-level communication skills and are patient in responding to customer questions. Even if they cannot answer immediately, they will immediately consult technical engineers and respond to customers as soon as they reply.

With the rapid development of the automobile industry, light-alloy materials are increasingly used in parts and components due to the requirements of lightweight bodies. Aluminum alloys (such as aluminum-silicon series alloys) have the characteristics of low density, low thermal expansion coefficient, and good friction properties, and are widely used in automobile engine covers, gearbox housings, and other castings. This topic uses Magma software to analyze the filling and solidification process of the aluminum alloy front cover of a family car engine; through the analysis of the results of numerical simulation, an optimization plan for the die casting process is proposed, which provides a reference for the production of similar products. Casting Model And Material 1. Casting model The outer dimension of the engine front cover is about 470 mm×310 mm×105 mm, the product mass is about 3.4 kg, the average wall thickness of the main body is 3.3 mm, and the maximum wall thickness reaches 26 mm (the part marked in the wireframe is the thicker wall). The product structure is relatively complex, with a considerable number of bolt holes and reinforcing ribs distributed inside; and the wall thickness of the casting is very different, and stress concentration is likely to occur during the die casting process, resulting in uneven density, resulting in casting deformation, shrinkage, and shrinkage porosity. . The casting product model is shown in Figure 1. 2. Casting materials The front cover of the engine is required to have good mechanical properties and high density, and no internal defects such as cracks, shrinkage porosity, pores, and shrinkage holes are allowed. Based on the above working environment and requirements, the AlSi9Cu3 aluminum alloy is selected, which has good fluidity and excellent die casting performance. Table 1 is its chemical composition and mechanical properties. Initial Die Casting Process Plan 1. Design of initial pouring system According to the characteristics of the product structure, it is planned to design 2 branches with a total of 6 inner runners for feeding, as shown in Figure 2. The aluminum alloy liquid is introduced into the sprue from the sprue cup, and then enters the 6-way internal gate through the 2-way branch, and finally enters the cavity for filling. 2. Determination of process parameters The casting material is AlSi9Cu3, and the mold is DIEVAR. According to the physical characteristics of the two materials, combined with the die-casting process design manual and production experience, and through calculations, the following die-casting process parameters are determined: the initial temperature of the casting is 670℃, and the initial temperature of the mold is 180℃ ; The casting mass is 3.4 kg, the pouring system mass is 2 kg, the overflow system mass is 850g, and the total mass is 6.25 kg. The projected area of the casting is 1 196 cm2, and the total projected area is 1 554 cm2; the injection specific pressure is selected as 60MPa, and the safety factor is 1.2. 3. Simulation analysis of the preliminary plan In order to understand the filling and solidification of the casting during the casting process, Magma software is used for numerical simulation, as shown in Figure 3. It can be seen that the filling time of the entire cavity is about 0.076 s. The initial filling speed of the molten metal entering the cavity is faster, and the filling speed of the middle area is significantly faster than the two sides. In the middle of filling, the molten metal gradually enters the thicker wall area. It was observed from time to time that the thicker-walled area was filled relatively slowly and gas stagnation was easy to occur. After the filling of the area was completed, due to higher temperature and longer solidification time, internal quality problems such as pores and shrinkage holes were prone to occur. Die Casting Process Optimization Design 1. Optimized design of gating system In view of the relatively slow filling of thick-walled areas, in order to ensure the quality of the castings and make the filling speed of each area basically the same during the forming process, it is proposed to add two gate feeds to the thick-walled areas to speed up the filling speed of this area, Which makes the entire filling process more stable and smooth, is more conducive to the elimination of gas and avoids shrinkage, shrinkage and other defects. Figure 4 shows the optimized scheme, and the wireframe part is a 2-way gate with added feed. Since the gate position has a large drop from the bottom of the casting, in order to make the feeding of this area smooth, a slider is added to the gate here, as shown in Figure 5, to ensure that the aluminum liquid fills the area well. 2. Simulation analysis of optimization plan In order to verify the filling effect and solidification of the optimized scheme, numerical simulation was performed again to observe the filling and solidification process of the optimized scheme. The simulation process is analyzed from the aspects of filling temperature field change, air pressure change, solidification situation, and so on. It is found through observation that the entire cavity filling process is about 0.071 s, which is very close to the theoretical estimate. During the filling process, the molten aluminum advances relatively smoothly, and the speed is basically the same; the gas discharge in the cavity is smooth, the air pressure is relatively stable, and within the risk control range, there is no obvious gas stagnation and entrainment. In the solidification process, except for the thicker areas, the cooling and solidification are slower, and the solidification and cooling of other areas are basically uniform and ideal. Local Area Cooling Scheme 1. High-pressure point cooling technology High-pressure point cooling technology has been increasingly used in the die casting industry in recent years. The cooling water is adjusted to the ideal pressure state by the high-pressure point cooler, and the corresponding pipe is quickly passed through the mold to achieve the purpose of cooling. Since the core cooling rate is fast in this process, shrinkage holes will not be formed near the core position. Therefore, the use of high-pressure spot cooling technology can achieve mold heat balance, effectively improve local pore defects, greatly increase mold life, and reduce core replacement and Overhaul rate, and better guarantee the quality of castings. 2. High pressure point cold in the local area In view of the slow cooling and solidification of the thicker part in the numerical simulation analysis process, high-pressure spot cooling is considered to be used to quickly cool the key areas to ensure the quality of the castings. Mold Development And Trial Production Die casting molds were developed according to the optimized process plan and trial production was carried out. The trial production was carried out on the DCC1250T horizontal die casting machine. The mold structure is shown in Figure 8. The initial temperature of the trial mold is 180°C. During the trial production process, as the injection progresses, in the low-speed injection stage, the molten aluminum enters the runner through the sprue, then enters the cavity smoothly from the inner gate, and quickly enters the high-speed injection stage. High-pressure spot cooling is performed in key areas to make the solidification time of each part of the casting basically consistent. Figure 9 is a photo of the trial product. It can be seen that the surface of the casting is smooth, the outline is clear, the quality of the inner hole is good, and there are no obvious defects. The product has been tested for airtightness and mechanical properties. After inspection, the pass rate of the product has reached 96%, and the test results meet the performance requirements. In Conclusion (1) Using Magma software, the filling and solidification process of the gating system and the overflow system of the aluminum alloy front cover of a certain family car engine were simulated. The corresponding problems were found through the simulation analysis, and the die casting process optimization program was proposed. (2) After determining the relevant die casting process parameters, the optimized filling and solidification process was simulated again, and the temperature field changes, air pressure changes, and solidification conditions were analyzed, and the rationality of the optimized scheme was initially verified. (3) Aiming at the problems of excessively high local temperature and long cooling time of castings, high-pressure spot cooling is used to speed up the cooling rate of local areas and improve the quality of castings.