Die casting process parameter optimization: How to improve the molding accuracy and quality of castings by adjusting process parameters

In modern industrial production, die casting, as an efficient and precise casting method, is widely used in automotive, electronics, machinery and other fields. However, due to the multiple process parameters involved in the die casting process, such as pressure, speed, temperature, etc., the selection and control of these parameters have an important impact on the molding accuracy and quality of the casting. Therefore, how to improve the molding accuracy and quality of castings by adjusting the process parameters has become an urgent problem to be solved in the current die casting industry. From the point of view of die casting process parameters, the influence of die casting process parameters on casting accuracy and quality is discussed, and corresponding optimization strategies are proposed.

1、 Die casting process parameters and their impact on casting molding accuracy and quality

1.1、stress

Pressure is one of the most important parameters in die casting process. Reasonable pressure can ensure that the metal liquid is fully filled in the mold cavity to avoid defects such as under-casting or shrinkage. At the same time, the appropriate pressure can also improve the density and mechanical properties of the casting. However, too high pressure will lead to increased mold wear and reduce mold life; However, too low pressure may lead to the increase of pores inside the casting, affecting its molding accuracy and quality.

1.2、speed

Speed refers to the speed of die casting machine closing and opening die. The reasonable speed can ensure the uniform flow of metal liquid in the mold cavity, reduce the generation of bubbles, and improve the density and surface quality of the casting. At the same time, the appropriate speed can also shorten the production cycle and improve production efficiency. However, too fast speed will lead to unstable flow of metal liquid in the mold cavity, resulting in spatter and eddy current and other phenomena, affecting the molding accuracy and quality of castings; Too slow speed will make the metal liquid cool too fast in the mold cavity, resulting in an increase in the internal stress of the casting, easy to produce cracks and other defects.

1.3、temperature

Temperature is another important parameter in the process of die casting. Reasonable temperature can ensure that the metal liquid has good fluidity and filling in the mold cavity, and avoid defects such as cold insulation or insufficient pouring. At the same time, the appropriate temperature can also improve the crystallinity and mechanical properties of the casting. However, too high temperature will lead to serious metal liquid oxygenation, resulting in defects such as inclusions and pores. Too low temperature will make the metal liquid cool too fast in the mold cavity, resulting in an increase in the internal stress of the casting, easy to produce cracks and other defects.

2、Optimization strategy of die casting process parameters

2.1、Determine a reasonable pressure range

In the process of die casting, a reasonable pressure range should be determined according to the shape, size and material of the casting. Generally speaking, for castings with simple shape and thin wall thickness, lower pressure should be used; For castings with complex shapes and thicker walls, higher pressures should be used. In addition, the size and time of pressure should be reasonably selected according to the material and structural characteristics of the mold.

2.2、Adjust the appropriate speed parameters

In the process of die casting, the appropriate speed parameters should be adjusted according to the shape, size and material of the casting. Generally speaking, for castings with simple shape and thin wall thickness, a faster speed should be used; For castings with complex shapes and thicker walls, a slower speed should be used. In addition, the size and action time of the speed should be reasonably selected according to the material and structural characteristics of the mold.

2.3、Control suitable temperature conditions

In the process of die casting, the appropriate temperature conditions should be controlled according to the shape, size and material of the casting. Generally speaking, for castings with simple shapes and thin walls, lower temperatures should be used; For castings with complex shapes and thicker walls, higher temperatures should be used. In addition, the size of the temperature and the action time should be reasonably selected according to the material and structural characteristics of the mold.

2.4、The interaction between the parameters is considered comprehensively

In the process of die casting, there is a mutual influence relationship between the process parameters. Therefore, when adjusting a certain parameter, it is necessary to take into account the impact of changes in other parameters on the molding accuracy and quality of the casting. For example, when adjusting the pressure, it is necessary to pay attention to the impact of changes in speed and temperature on the molding accuracy and quality of the casting; When adjusting the speed, it is also necessary to note the impact of changes in pressure and temperature on the accuracy and quality of the casting. The optimum configuration of die casting process parameters can be realized only by considering the interaction between parameters comprehensively.

3、 Conclusion and Prospect

Through the analysis of die casting process parameters and the discussion of optimization strategy, it can be seen that reasonable selection and control of process parameters are of great significance to improve the molding accuracy and quality of castings. In the future research and practice, we should further explore the mechanism and law of the influence of each process parameter on the casting accuracy and quality; At the same time, strengthen technological innovation and research and development to promote the application and development of new technologies and new processes; In addition, we should also pay attention to personnel training and team building to provide a strong guarantee for the sustainable development of the die casting industry. It is believed that in the near future, with the continuous progress of science and technology and the continuous improvement of product quality requirements, the optimization of die casting process parameters will achieve more significant results and make greater contributions to the development of the manufacturing industry.