Die Casting Process Design Die casting process design is an important part of die casting production technology, mainly involving die casting process requirements for the shape and structure of the casting, the technical conditions of die casting (technical requirements), the process performance of die casting, and die casting parting surface determination. The Die-casting Process On The Requirements Of The Structure Of The Die Casting Die casting quality, in addition to the impact of various process factors, the structure of its parts process (reasonable) is also a significant factor, such as the location of the parting surface, the design of the gate, the layout of the launch mechanism, the accuracy of the guarantee, the type of defects. The type of defects and their degree, etc., are closely related to the structure of the die casting process itself (reasonable). Die casting structure affects the design of die casting mold structure and manufacture of difficulty, production efficiency and service life, and other aspects. The reasonable die-casting structure can shorten the product trial period, reduce production costs, ensure product quality, improve production efficiency. Therefore, the die casting shape structure should strive to be simple, especially to eliminate the inability or difficulty of lateral core extraction of the internal side concave, simplify the mold structure, and improve the service life of the mold. The main issues to consider when designing the structure of die casting are as follows: To help simplify the mold structure, extend the life of the mold 1) castings at the parting surface should try to avoid rounded corners Rounded corners increase the mold's processing difficulty and make the rounded corners of the mold strength and life have decreased. If the dynamic mold and fixed mold are slightly misaligned, die-casting rounded part of the easy form a step The appearance will be affected. If the structure changes to a flat shape, the parting surface is flat and easy to process, avoiding the above shortcomings. 2) to avoid internal side concave Die casting internal flange and bearing hole for the internal concave structure, core extraction difficulties, the need to set a complex core extraction mechanism or fusible core. As a result, it increases the complex shape of the mold and processing volume and reduces production efficiency. However, if the inner concave structure changes to a non-internal concave structure, the difficult core extraction can be solved, and the mold structure can be simplified. 3) Avoid crossed inaccessible Crossed not through the hole must use a higher tolerance fit of each other crossed cores, increasing the amount of mold processing and strict control of the order of core extraction. Once the metal liquid is in the gap of the crossed cores, it will make the core extraction difficult. If the crossed not through the hole to avoid crossing the inaccessible structure, you could avoid the core's cross, eliminating the shortcomings mentioned above. 4) to avoid partial thinning of the mold Casting structure because the hole edge from the flange distance is too small, easy to make the mold insert fracture. If the die casting to a local ≥ 3mm structure, the insert can be made with sufficient strength, thereby improving the service life of the mold. Conducive to reducing the extraction of core parts, improve the structure of the mold Reduce the parting surface is not perpendicular to the core part, reduce the complexity of the mold, and ensure the accuracy of die castings. The depth of the square hole in the center of the die casting is deep, the core distance is long, requiring a special core extraction mechanism, the mold is complex; plus the cantilever core into the cavity, easy to deform, difficult to control the sidewall wall thickness uniform. The use of an H-shaped section structure does not require core extraction, simplifying the mold structure. Conducive to core extraction, convenient casting mold release Die casting structure due to the core by the tab obstruction can not be smoothly extracted core. If the shape of the die casting suitably modifies to a structure conducive to core extraction, when can smoothly extract the core. LINK TO: 1, Design Of The Cross Sprue 2, Design points of the inner gates in the gating system for die casting mold 3, Working principle of the die casting mold 4, Structure, classification, and design of pouring/gating systems 5, Temperature controller for Die-casting Production 6, The CASINO Machine Parts in Bulgaria made by CAMEL Manufacture

LINK TO: 1, Die Casting Process Design and Die Casting Process 2, Design points of the inner gates in the gating system for die casting mold 3, Working principle of the die casting mold 4, Structure, classification, and design of pouring/gating systems 5, Temperature controller for Die-casting Production 6, The CASINO Machine Parts in Bulgaria made by CAMEL Manufacture

The cost of a die casting tool has two main parts-mold and cavity processing. The cost of the tool is mainly controlled by the size of the die casting. The larger the part, the larger the tool and the higher the cost. The cost of machining the cavity is almost affected by all aspects of the part geometry. The Size Affects The Cost The main cost factor is the size of the cavity that must be processed, measured by the projected area and depth of the cavity. Any other elements that require additional processing will increase the cost, including the number of features, parting surfaces, edges, tolerances, and surface roughness. The Materials Affect The Cost The cost of the tool will be affected by the life of the die casting tool, and the life of the mold will be affected by the number of die castings and the materials we use. For example, a material with a high casting temperature, such as copper, will result in a short mold life. On the other hand, zinc can be cast at lower temperatures, which can lead to longer mold life. This effect will become more expensive as the number of production increases. The Side-cores Affect The Cost The last consideration is the additional cost for the side cores. However, the number of directions can limit the number of cavities that can be included in the mold. For example, a mold that requires 3 side core directions can only contain 2 cavities. There is no direct cost increase, but using more cavities may further save costs. Our capabilities CAMEL offer to die casting tool and high pressure die casting tool design; Our die casting tool solutions include tooling for aluminum, magnesium, and zinc die castings for complex products such as automotive components, medical equipment, and machinery parts industrial manufacturing. Accurate design and high-speed machining capabilities ensure superior die casting tool performance. LINK TO: 1, What Is Die Casting Mold 2, Custom Die Casting In China 3, Die Casting vs Permanent Mold Casting 4, Steps Of Die Casting Die(HPDC Mold) Design 5, Technical Specifications Of Die Casting Dies 7, How Does Hot-chamber Die Casting Machine Work 8, Mold Making & Die Casting Mold Manufacturing Process

The die casting mold‘s working environment is very harsh, especially since the mold cavity part is easily damaged. This leads to the die casting metal liquid drilling into these gaps, producing serious flying edges or even jammed sliding parts. These problems of die casting mold will cause casting defects, and even cause a lot of scraps. In order to ensure the quality of the die-castings and extend the service life of the mold, CAMEL recommends the die casting workshop to carry out mold maintenance work such as inspection and repair of the molds. Mold maintenance includes the following. Observation And Inspection Of The Mold There are 3 ways to check the mold, On-site inspection of the mold, that is, the mold repairer inspects the mold before it is used; The down-field inspection of the mold, that is, after producing a batch of castings, before the mold is put into storage, the mold repairer will check the condition of the mold; Weekly inspection of the mold, inspection, and maintenance cycle can generally be determined by the number of press shots, generally every 10,000 press shots, the need to remove the mold from the die-casting machine, disassemble the main parts for an inspection and maintenance work, the content of the following. (1) Observe the surface of the cavity to see if there are traces of strains and ablation of adhering metal chips, and polish the strains with abrasive cloth and polishing tools. (2) Observe all the top bar, core whether there is bending, cracking and fracture, if necessary, a copper or wooden hammer gently knocking check, bending, cracking and fracture of the Cores, projections, and top rods should be repaired or replaced immediately. (3) Check whether all the top bar is free to move in and out, whether there is a jamming phenomenon, the top bar hole and other mating surface drilled into the metal fluid, the top bar end surface is high, or lower than the mold surface. Problems found should be disassembled mold ejector parts for repair, the gap is too large for the top bar or sliding part to try to repair. (4) Use a magnifying glass to observe whether the surface of the cavity is cracked, cracks, scratches, and local collapse, and there are pits and barbs on the surface of the mold wall in the direction of the release. For minor mesh cracks on the surface of the cavity, they can be reinforced with a tungsten reinforcing machine and then polished. For larger cracks, collapses, and pits, the bottom metal must be removed and the mold steel welding rod must be used for welding (preferably with argon arc welding to ensure the welding quality). (5) Check if the exhaust system on the parting surface is clogged with grease or metal chips, and clean it up to ensure that the exhaust system is smooth. (6) Check whether the cooling system of the mold is smooth and free from blockage. Dimensional Accuracy Of Regular Identification Die casting mold use after a certain period of time will appear the naked eye can not detect the deformation and wear, thus affecting the dimensional accuracy of die-castings and make the processing volume change. Therefore, for the die-casting die with a high dimensional accuracy requirement, it is necessary to carry out the periodic identification of dimensional accuracy. The identification period is decided according to the specific requirements, the identification method can be used to periodically check the die casting or use three coordinate measuring instruments for measurement. Nitriding Treatment Die casting die after a certain period of time, the surface nitriding layer will be worn, thus reducing the surface hardness of the cavity, increasing the tendency of die casting sticky mold. For this reason, after every 30,000 die shots, the cavity should be disassembled, the surface should be polished and sent to the heat treatment workshop for nitriding treatment. Tempering Treatment Die casting die is used a certain number of times after the stress relief tempering treatment, According to improve the die casting die life of effective measures. Tempering temperature should be 30~50% lower than the original tempering temperature of die-casting material. During mass production, the aluminum residue is commonly found at the bottom of the mold, which needs to be cleaned up regularly to avoid mold collision. The stress-relieving tempering interval of aluminum alloy die casting mold is related to the die castings quality and the times of die casting shots, and usually: die casting mass less than 0.1kg, shots of 25000 times; die casting mass of 0.1kg-1kg, shots of 10000 times; When the casting mass is more than 1kg, shots of 5000 times. CAMEL deeply believes that good mold maintenance ensures a longer mold life and smooth production. Therefore, a quality mold must not only be stable during production but also easy to maintain. LINK TO: 1.What Is Die Casting Mold 2.Custom Die Casting In China 3.Die Casting vs Permanent Mold Casting 4.Steps Of Die Casting Die(HPDC Mold) DesignTechnical 5.Specifications Of Die Casting Dies 6.How Does Hot-chamber Die Casting Machine Work 7.How Much Does a Die Casting Tool Cost? 8.Mold Making & Die Casting Mold Manufacturing Process

The standardized mold production process is one of the core competitiveness in mold manufacturing. From mold order to mold output, it takes about dozens of steps; The key steps of making die cast molds organized are as follows. Order Preliminary Review → Final Mold Structure Review → Design Review Of Die Casting Mold; Design Review Of Trim Mold → Manufacturing Review → Mold Components Inspection; Mold Steel Hardness Inspection → Mold Base Inspection Report → Cavity & Core Inspection After CNC → Mold Electrode Inspection → Cavity & Core Inspection After Wire Cut → Cavity & Core Inspection After EDM → Mold Pre-Assembly Inspection → Trial Review → Sample Inspection Report → Die Casting Die Checking List → Trim Die Checking List; Inspection Qualified Notice Read More Details Design Review Of Die Casting Mold In the molding process, it is the Die that is key for productivity and part quality. Both precision and dimensional accuracy are needed to efficiently produce high-quality castings. Particularly during the casting process, the runner design and heat energy control prove to be essential factors for achieving the highest productivity and part quality. It is the CAMEL’s job to develop, and build dies that support best-in-class cycle-time, part quality, and die life. Tempering must be done before the mold trial to guarantee the die life. Before mold production, The design of die casting dies is also a top priority. We always do flow simulation by designing many kinds of runner layouts to get the best productivity and part quality. This way most of our die casting dies can be sampled successfully the first time. The preliminary flow simulation below appears to show that the overflow speed is too fast and may cause a high risk of mold flush issues. We reduced the area of overflow to control the speed and ensure a better cast and mold quality. Balanced Heat Energy CAMEL designs ample cooling lines 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. Die Casting Parts Overflow is the essential factor for achieving the best part quality. We design all venting separately to ensure that venting can run smoothly and efficiently. This way parts will have a much lower risk of cold lap issues. Multi-cavity Trim Dies Trim dies are indispensable tools for high quantity production. Unprofessional mold makers need to adjust the multi-cavity trim die many times by welding. CAMEL designs all support blocks, cutters, guide pins, and guide bushes separately for each cavity. We also design separate locating components to control the runner deformation. This way most of our multi-cavity trim dies can be trimmed successfully the first time. LINK TO: 1. What Is Die Casting Mold 2. Custom Die Casting In China 3. Die Casting vs Permanent Mold Casting 4. Steps Of Die Casting Die(HPDC Mold) Design 5. Technical Specifications Of Die Casting Dies 6. How Does Hot-chamber Die Casting Machine Work 7. Mold Making & Die Casting Mold Manufacturing Process 8. How Much Does a Die Casting Tool Cost? 9. What is Mold Maintenance?

The Concept Of Die Casting Mold Qualification Rate Die casting mold qualified rate is a system concept, from die casting machine edge, die casting initial inspection, cleaning, post-treatment, machining, transportation, and other aspects of the qualified rate belongs to the composition of die casting qualified rate, which is also called straight through rate. For example, the problem of equipment, the problem of mold, the problem of spraying, and so on, the problem of these points has a significant impact on the qualified rate of die casting machine edge, the failure of equipment and mold will increase the number of cold mold parts; the instability of equipment and mold will increase the number of defective products of automatic identification, the unreasonable heat balance of mold and spraying will increase the appearance defects of castings. Die casting machine edge waste is the biggest part of die casting qualified rate scrap proportion, and also one of the biggest hidden points of die casting cost. Today we will discuss the qualified rate refers to the qualified rate of machining, mold circles often said the qualified rate is generally referred to in this data. Machined casting material waste is still attributed to the defects of die casting, there are often defects: porosity, shrinkage, leakage, inclusions, deformation, black skin, bruising, etc. The most important defect is the problem of gas shrinkage and leakage, which is also the most difficult to solve and continues to repeat. Die casting pass rate of 95% is a value that can be reached, as long as the die casting company has the basic management process and standard, excellent mold tooling, plus an excellent die casting process and continuous improvement team, 95% of the die casting pass rate is not difficult to achieve, in the real production process there are many cases in the mold is good enough under the premise of 95% pass rate is easier to achieve. However 99% pass rate is another concept, this discussion is a symbolic value, it represents a higher, more sustainable, and stable pass rate standard, it may be 97%, may also be 99.7%, the ultimate requirement is how we can pursue to excellence, it is how to step by step reality. How Does A Die Casting Mold Company Need To Do To Achieve A 99% Compliance Rate? CAMEL mold manufacturing process includes the following ways Establish a project team A high-standard project team is led or vice-led by the top management. As a senior manager, you must personally lead the core team through a few typical projects and then work together to develop effective processes and standards. Goal setting It is important to set a high target pass rate according to the difficulty of the casting. Goal decomposition and division of responsibilities Goal decomposition and division of responsibilities are particularly important, most of the problems that arise later are caused by the lack of comprehensive and careful analysis in the early stage; most of the implementation is not in place because of unclear responsibilities. Therefore, for the division of responsibilities must be designated the relevant responsible person, we must have more than one person to discuss the basic knowledge of a responsible, each thing is ultimately responsible for only one person. To avoid the emergence of localism and empiricism, and to designate the corresponding project management personnel to supervise. Casting feasibility analysis - DFM (ideally simultaneous design) Casting feasibility analysis is the most basic work because now many casting design engineers do not understand die-casting, the design of the casting is difficult to fully meet the process of die casting. Die casting problems and effective communication with customers (to solve the difficulties or apply for relaxation of standards) The feasibility analysis report of the casting is done is actually just the beginning, how to communicate effectively with the customer is very important. Mold design (pouring system design, heat balance system design, mold flow analysis, structure design, DFMEA) If you want to design a pouring system with a high pass rate, you should use the idea of process compensation to design the pouring system, which may increase the cost of post-processing, but it is worthwhile. Design of thermal balance Thermal balancing systems require strong logistical support, mold repair resources, and management capabilities. Mold review (checklist check) All important nodes in the process need to do the review, the review of mold design is the top priority, the key problems of solution A and alternate measures program B. LINK TO: 1.What Is Die Casting Mold 2.Custom Die Casting In China 3.Die Casting vs Permanent Mold Casting 4.Steps Of Die Casting Die(HPDC Mold) DesignTechnical 5.Specifications Of Die Casting Dies 6.How Does Hot-chamber Die Casting Machine Work 7.How Much Does a Die Casting Tool Cost? 8.Mold Making & Die Casting Mold Manufacturing Process 9.How to Make Die Cast Molds

CAMEL has served many well-known international companies for more than ten years and has been well received by customers. Next, I will show one of the original words of the customer: Dear Leo， I hope this message finds you and you are Okay！So, CAMEL made 6 complicated and significant tools for us and these molds were caught as a main at NOVA Project. I would like to make few conclusions about the last cooperation between us. First of all，thanks for the great support that I got from Delia，Emily and Cassie！ Each one assisted and assists us in the perfect way with a lot of patience，Professionalism and kindness. Cassie takes command and care in the middle of 2020 and continues to bestow us with an amazing approach- well done for entire great staff you have！ All of these tools worked very well at CAMEL and continue to work well here in Israel at our site. My and management are satisfied with the cooperation and will make it deeper with new future projects. I remember，Leo，during a mutual lunch I asked why did you called your company“CAMEL”，You have responded me that because of animal characters like endurance，survival，strength, etc. So，I am sure you have today a strong company as you imagined it due to the investments and professional staff you build and continue to build. Thanks again for all and have a nice day！ Regards to all team members that take part for Amiad Projects！ Alexey