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<\/figure>\n\n\n\nThe core value of an aluminum die casting die: why it is the key to process success or failure<\/h2>\n\n\n\n
Die casting mold is not only the metal molding \"template\", but also production efficiency and product qualitydetermining factor<\/strong>The importance of this is threefold. Its importance is reflected in three areas:<\/p>\n\n\n\n Suggestions for selection<\/strong>:<\/p>\n\n\n\n challenge<\/strong>:<\/p>\n\n\n\n prescription<\/strong>:<\/p>\n\n\n\n results-based<\/strong>:<\/p>\n\n\n\n Q1\uff1aHow to evaluate the technical strength of mold suppliers?<\/strong><\/p>\n\n\n\n Q2\uff1aHow to choose the surface coating for mold?<\/strong><\/p>\n\n\n\n Q3: Best practices for mold maintenance?<\/strong><\/p>\n\n\n\n Aluminum die casting mold design is a combination of science and art, both require rigorous engineering calculations, but also rely on a wealth of practical experience. With the deep penetration of digital technology, mold industry is ushering in the \"intelligent design - precision manufacturing - predictive maintenance\" of the new paradigm. As a practitioner, the only way to take the lead in the triangle game of cost, efficiency and quality is to continue to embrace innovation.<\/p>\n\n\n\n\n
The cavity design of the mold directly determines the dimensional tolerance (usually \u00b10.1mm) and surface finish (Ra 1.6~3.2\u03bcm) of the casting. For example, in automotive engine block die casting, mold cooling system design if not reasonable, will lead to uneven local contraction, triggering porosity or deformation.<\/li>\n\n\n\n
A set of optimized multi-cavity mold can increase the production efficiency by more than 300%. Taking a new energy vehicle motor shell project as an example, after adopting a 4-cavity mold, the hourly output jumped from 15 pieces to 60 pieces, while the yield was stable at over 98%.<\/li>\n\n\n\n
Mold life has a direct impact on the cost per part. By using H13 hot-working steel to make molds, through the surface TD treatment (thermal diffusion method), the life of the molds can be increased from 100,000 to 500,000 molds, which significantly reduces the cost of apportionment.<\/li>\n<\/ol>\n\n\n\n
\n\n\n\nFive major types of aluminum die casting mold and selection strategy<\/h2>\n\n\n\n
Mould Type<\/th> Applicable Scenarios<\/th> cost cycle<\/th> Technical characteristics<\/th><\/tr><\/thead> Prototype Mold<\/td> Small lot validation (<500 pieces)<\/td> Low cost\/2-3 weeks<\/td> 3D printing + machining composite process<\/td><\/tr> Rapid Tooling<\/td> Pilot production (500-5000 pieces)<\/td> Medium cost\/4-6 weeks<\/td> Laser cladding additive manufacturing<\/td><\/tr> Unit molds<\/td> Multi-species and small batch<\/td> modular design<\/td> Quick change cavity inserts<\/td><\/tr> Production molds<\/td> High volume (>100,000 pieces)<\/td> High cost\/8-12 weeks<\/td> Multi-slider structure + point cooling system<\/td><\/tr> Trimming Mold<\/td> Deburring and runner separation<\/td> necessary for<\/td> Hydraulic servo drive + precision guidance<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n \n
\n\n\n\nThe six golden rules of aluminum die casting mold design<\/h2>\n\n\n\n
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The parting line should avoid critical functional surfaces. For example, a 5G base station radiator uses curved surface parting so that burrs are produced on non-contact surfaces, reducing post-processing costs.<\/li>\n\n\n\n
adoptionTapered cross sprue<\/strong>(Inlet 8mm \u2192 Outlet 4mm), together with the 30\u00b0 inner gate angle, can realize the smooth filling of aluminum liquid and avoid the oxidation slagging caused by turbulent flow.<\/li>\n\n\n\n
The core part is embedded with beryllium copper inserts (thermal conductivity 210 W\/mK), which can realize gradient temperature control with the mold thermostat (250\u2103 in the gate area\u2192180\u2103 at the end) and shorten the cooling time by 20%.<\/li>\n\n\n\n
Depending on the alloy shrinkage (about 0.6% for ADC12) and surface requirements, the outer wall slope is taken as 1\u00b0~1.5\u00b0 and increased to 2\u00b0~3\u00b0 for deep cavity parts. For example, the deep cavity structure of a UAV shell uses a 3\u00b0 slope, and the ejection resistance is reduced by 40%.<\/li>\n\n\n\n
A stepped overflow tank (depth 0.3mm\u21920.8mm) is set in the final filling area, and with the vacuum valve (vacuum \u226450mbar), the porosity can be controlled below 0.5%.<\/li>\n\n\n\n\n
\n\n\n\nCutting-edge technology in the industry: Digitalization and Intelligent Empowerment Mould Upgrade<\/h2>\n\n\n\n
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Through AnyCasting\/MAGMA software, the whole process simulation of filling-solidification-stress can be completed within 48 hours, and the risk of shrinkage can be predicted in advance. A gearbox shell project optimized the gate position through simulation, reducing the number of mold trials by 3 times.<\/li>\n\n\n\n
The use of Selective Laser Melting (SLM) technology to manufacture shaped waterways has enabled the mold temperature difference to be controlled within \u00b15\u00b0C, significantly reducing thermal joints. After the application of a LED lampshade mold, the cycle time was shortened by 18%.<\/li>\n\n\n\n
Temperature\/pressure sensors are implanted at critical locations in the mold to monitor the cavity surface condition in real time. When abnormal fluctuation of clamping force (>5%) is detected, a warning is automatically triggered to avoid batch defects.<\/li>\n<\/ol>\n\n\n\n
\n\n\n\nPractical case: a new energy vehicle battery tray mold optimization<\/h2>\n\n\n\n
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\n\n\n\nFrequently Asked Questions (FAQ)<\/h2>\n\n\n\n
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\n\n\n\nconcluding remarks<\/h2>\n\n\n\n