Although advanced equipment is an indispensable factor in ensuring product quality, the role of molds in casting is also very important. Especially for aluminum alloy auto parts production companies, the precision and durability of the mold have a significant impact on product quality.
In ferrous metal casting, the mold is more to form a mold cavity. In general, the mold itself does not directly contact the molten metal. This is especially true for non-metal mold castings with complex shapes. The contact with the hot metal liquid is styling. Materials, mainly sand, make modeling materials a major factor affecting the quality of castings. Aluminum alloy gravity casting is different, because the lower melting point of aluminum alloy, casting performance is good, in mass production, the shape of the casting is generally formed directly by the mold, such as the engine aluminum alloy cylinder block, cylinder head, etc. It is beneficial to improve labor productivity, and more importantly, it controls the structure and grain size of castings by adjusting the temperature distribution in different parts of the mold, and improves the quality of castings. At the same time, it avoids the environmental pollution brought by the use of a large amount of modeling materials, and improves. The working conditions in the workshop.
With the different degrees of complexity of the casting shape, the aluminum alloy gravity casting molds are also different. Even if the same part uses different casting techniques, the form of the mold is often different, but in any case, the aluminum alloy gravity casting mold still has its common features.
First of all, we must choose a suitable casting process. The quality of the casting process is directly related to the quality of the casting and the rate of production. Some mold manufacturers in China have begun to use the solidification simulation to assist the design of the casting process. Through the computer simulation of the filling and solidification process, it is found that the hot junctions of the casting defects are easy to overcome and overcome, which improves the reliability of the casting process design. It is very important and effective to effectively prevent molds from being reworked during debugging.
Second, the mold must have good heat capacity. The thicker mold bases and modules that meet the requirements are not only an effective guarantee of mold life, but also play an important role in the adjustment of the temperature field during the continuous operation of the mold. Some mold factories, in order to reduce costs, save materials, blindly reduce the effective thickness of the mold to achieve the purpose of reducing weight, everyone does not know that this not only greatly reduces the life of the mold, but also makes the casting easy to deform, affecting the dimensional accuracy of the casting, serious It will cause the castings to be scrapped in batches, cause losses to the foundry, and more seriously damage the reputation of the mold factory itself.
Third, there must be a mold positioning device and a convenient mold mounting system that are compatible with the casting machine. The positioning device is not only the key to ensuring the size of the casting and reducing the seams and burrs, but also the key to ensure the normal operation of the casting machine. It can be said that there is no good positioning device for the mold, and there is no good qualified casting. The mold must be easy to install and remove. Because of aluminum alloy gravity casting, the mold must be removed and repainted and repaired at regular intervals. If it is inconvenient to disassemble, it will inevitably increase the labor intensity of the workers, occupy more labor time, and reduce Yield and efficiency.
Fourth, the mold must have a more reliable cooling system and a gas extraction system. Through cooling, it not only can effectively increase labor productivity, but also can adjust the temperature field of castings, control the cooling rate of castings, and then affect the internal structure and grain size of castings, and achieve the purpose of effectively controlling the mechanical properties of castings. As the name suggests, gas extraction means artificially venting the gas inside the cavity to the outside of the cavity to reduce the possibility of casting defects in the casting. At the same time, the installation of the vent plug can also adjust the mold temperature of the local small area, which plays an important role in preventing and overcoming the aluminum alloy cracking and shrinkage.
For foundries, high-quality molds mean high-quality castings, which means lower costs, higher output values and profits.
At present, the domestic mold industry is developing rapidly. There are no more than a few hundred aluminum alloy gravity casting mold manufacturers. With the development of the automobile manufacturing industry and the influx of foreign capital, both the scale and the technical strength of the mold manufacturing plant are increasing. With the popularization and application of numerical control processing equipment, the processing level of the mold industry has not much difference with foreign countries. Many mold factories also have more advanced testing equipment, but our management level, design concept, and business philosophy are also higher than foreign counterparts. Gaps, mold materials, and heat treatment enhancements also lag far behind developed countries. In the current situation, for casting mold manufacturing plants, there are practical experience, and engineering and technical personnel who know both the mold manufacturing and the casting process are also very scarce, and mold debugging and process verification are also inevitable steps in the mold production process. Successful molds and mature processes are the hope of many foundries that have weak technical capabilities.
The standardization of molds and the application of mold standard parts are inevitable trends in the future development of the mold industry. This is especially true for aluminum alloy gravity casting that started later. Only the standardization of molds can be implemented to standardize the behavior of the mold manufacturers, and it is possible to promote mold factories to provide molds that meet the standard of quality and low price. At the same time, the standardization of molds and the application of mold standard parts will make it easier for foundries to monitor the quality of molds and also make maintenance and maintenance of molds more convenient. The use of mold standard parts, production scale effect will help change the current mold industry, many varieties, small quantities, low production efficiency, will help reduce costs and increase productivity.
In short, the precise dimensions, high production efficiency, ease of use and maintenance are the eternal pursuit of the mold industry and the foundry industry.
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