New product development and the updating of old molds are often encountered in die-casting production. Generally speaking, the internal and external quality of die-casting parts depend on die-casting production process parameters such as molten metal temperature, die-casting pressure, speed, and speed switching point. But in most cases, it is also closely related to mold design and production. The factors that affect the mold include the number of cavities, the design of the gate system, the type (position and size) of the gate, and the structure of the casting itself. In order to avoid casting defects caused by mold design, and to inspect and correct some problems in mold making, it is necessary to test the finished mold.
1 Die-casting mold trial and process parameter optimization
The main purpose of mold trial is to find out the optimized process parameters and mold modification plan. It is required that even if the materials, machine settings or environmental factors have changed, it can still ensure that the mold can stably and uninterruptedly produce qualified products in batches. Improve the "adaptability" of the mold to the limit, not just to get a few good test mold samples.
1.1 Find out the problems in the mold
The molds made by the mold factory all hope to be a pair of molds with good "adaptability" (that is, wide molding parameters or process conditions). But often due to poor design considerations or improper processing in the production process, some problems often occur, such as over-tolerance in size, unsmooth local transitions, improper structure, etc., resulting in unqualified castings or trial production of molds. Unable to proceed. The trial mold is the simplest, direct and effective way to find out the mold problem.
1.2 Find the best forming conditions
In the mold trial process, the trial personnel can find a set of most suitable process data, and this set of data can be used as the default value of the set machine parameters during mass production. According to this set of data, the most suitable mold mass production can be adjusted. Optimal process conditions.
1.3 Verify the CAE-assisted design and improve the follow-up work efficiency
CAE analysis software is the result of computer simulation and simulation calculation based on the specifications of the real machine, the performance of the real alloy and the real external environment. The mold designer makes corresponding corrections to the mold design according to the simulation situation; the analysis data can be directly input as the preset value when the real machine is tested, and the mold tester can use this to check and analyze whether the mold design is lacking. The defects of the test module can be compared and analyzed with the simulation results to provide a basis for the subsequent process parameter setting.
