Die casting simplifies mold structure and filling molding
Simplifying the die’s structure and optimizing the filling and molding process complement each other. Reasonable simplification of the die structure not only reduces manufacturing cost and complexity, but also improves the filling of the molten metal into the cavity, enhancing casting quality and production efficiency. Simplifying the die structure primarily involves reducing the number of unnecessary parts and simplifying part shapes and assembly relationships. These simplifications often create more favorable conditions for the flow of molten metal and facilitate smooth filling and molding.
Reducing the number of mold parts is a key approach to simplifying mold structure. By integrating multiple parts into a single, integrated design, assembly steps and errors are reduced, improving the mold’s overall rigidity and stability. For example, designing a complex core and cavity as a single unit avoids the assembly gaps that can occur in separate designs, reducing the risk of molten metal overflowing from these gaps during filling. Furthermore, the integrated structure reduces turns and obstructions in the mold’s flow path, allowing the molten metal to flow more smoothly, reducing flow resistance and improving filling speed and efficiency.
Simplifying the mold’s core-pulling and ejection mechanisms can also have a positive impact on filling and molding. Complex core-pulling mechanisms often create more dead corners and narrow passages inside the mold. These areas can easily lead to poor flow of molten metal, resulting in eddy currents and air entanglement, affecting the quality of the casting. By optimizing the casting structure and reducing features such as side holes and undercuts that require core pulling, the core-pulling mechanism can be simplified or even eliminated, making the mold cavity more unobstructed, allowing the molten metal to fill the cavity in a shorter time, and reducing the chances of oxidation and air inhalation. Similarly, simplifying the ejection mechanism can avoid having too many ejector pins at the bottom of the cavity, reducing interference with the flow of molten metal and ensuring the molding quality of the bottom of the casting.
Simplifying the mold’s runner system is a key factor in improving filling and molding. A properly designed runner guides the molten metal to fill the mold cavity at an optimal speed and pressure distribution. Complex runner systems not only increase mold processing difficulty and cost but can also lead to excessive energy loss during the flow of the molten metal, resulting in uneven filling. A simplified runner system can employ short, thick main runners and fewer, straight branch runners, reducing runner length and the number of turns, thereby lowering the flow resistance of the molten metal. Furthermore, placing the gate in a thick, large area of the casting or in a location that facilitates metal diffusion allows the molten metal to flow quickly and evenly to all sides, avoiding localized underfilling or overpressure.
Simplifying the mold cooling system can also indirectly contribute to optimized filling and molding. A simplified cooling system utilizes evenly distributed, simple cooling channels, which can more effectively control the temperature distribution in the mold cavity, preventing localized overheating or underheating that can affect the fluidity and solidification rate of the molten metal. This uniform temperature field maintains good fluidity during the filling process, ensuring that every corner of the cavity is fully filled while reducing internal stress and deformation in the casting caused by temperature differences. Furthermore, a simplified cooling system is easier to process and maintain, ensuring the stability and reliability of the cooling effect, and thus ensuring continuous and stable production.
Finally, simplifying the mold structure can also improve its reliability and service life, reduce failures and wear caused by complex structures, and ensure the stability of the filling and molding process. The simpler the mold structure, the more uniform the stress distribution during the die-casting process, making it less susceptible to local damage or deformation and maintaining good working condition over the long term. This is crucial for ensuring consistent casting quality, especially in large-scale production. Stable mold performance can reduce production interruptions caused by mold failure, improve production efficiency, and improve product qualification rate. Therefore, in die-casting mold design, full attention should be paid to simplifying the mold structure to achieve better filling and molding results and a more efficient production process.
