Advantages and disadvantages of die casting production in terms

  • Die casting is one of the most widely used metal forming processes. It is a method for achieving both less chip and no chip. It has been widely used and has advanced rapidly in recent years. Die casting alloys are no longer limited to non-ferrous metals such as zinc, aluminum, magnesium, and copper, but are increasingly being used to die cast iron and steel castings as well. The size and weight of die castings are determined by the power of the die casting machine. As the power of the die casting machine increases, the shape and size of the casting can be varied from a few millimeters to 1-2 meters in length, and the weight can range from a few grams to dozens of kilograms. Die castings with a diameter of 2 meters and a weight of 50 kilograms are possible.

    Die casting is no longer restricted to the automobile and instrument industries, but has gradually spread to other industrial sectors, including agricultural machinery, machine tool industry, electronic industry, national defense industry, computer, instrument, clock, camera, daily hardware, and dozens of other industries, including: auto parts, furniture accessories, bathroom accessories (sanitary ware), and other dozens of industries. In the field of die-casting technology, there are several new technologies to consider, including vacuum die-casting, oxygen die-casting, precision die-casting, and the use of soluble cores.

     


    Die casting has a diverse range of applications. In fact, it has helped to create a number of market segments within the die casting services industry. At the moment, the majority of small and medium-sized die-casting manufacturers primarily produce common die-casting products such as hardware, household appliances, and lamps, on a small scale with low equipment levels, fierce price competition, and low efficiency. Furthermore, a few large-scale die-casting enterprises have relatively advanced equipment and technology, which allows them to produce high-precision die-casting products in accordance with the requirements of the automobile industry, the communication industry, and other industries. This type of manufacturer is able to establish a stable and long-term cooperative relationship with downstream customers, putting them in a favorable position in the market competition.

    Die casting production equipment has specific operating requirements.

    1. Before turning on the machine, check that the door is flexible and that the front and rear threshold switches (Jizhi, should be normal: turn on the machine power switch, close the front and rear doors, and observe the corresponding output signal lamp of the PLC in the electrical box; if the lamp is on, the machine is normal; if the lamp is not on, the machine should be stopped to check the corresponding circuit.

    (2) Inspect the emergency stop button to ensure it is operational, as well as the total pressure of the oil pressure system and the setting of various function parameters to ensure they meet the requirements of the job.

    (1) It is strictly prohibited to put your hand into the mold of die casting production equipment or to remove materials from it by hand.

    (2) It is prohibited to arbitrarily adjust the machine setting parameters without the permission of the machine's manufacturer. These parameters should only be adjusted by qualified personnel.
    (3) In the event of a machine failure or an alarm signal, stop the machine immediately, cut off the power supply, open the protective door, and then repair the machine.
    (4) When selecting a die casting alloy ingot, it is important to avoid putting alloy material containing moisture and oil into the furnace.
    (5) Before they can be reused, recycled alloy ingots must undergo special processing to demonstrate that their chemical composition meets the requirements. It is not permitted to place the slag directly into the furnace.

    Die casting has a number of disadvantages.

    (1) Die casting alloys are restricted
    It is still necessary to research the relevant materials, mold materials, and operation methods.
    (2) The equipment is very expensive.
    Die casting production equipment, such as die casting machines, melting furnaces, holding furnaces, and die casting dies, is extremely expensive.
    The air tightness of the castings is inadequate.
    When the molten liquid is poured into the die-casting die at a high rate, there will be turbulent flow, which will result in the formation of local pores or shrinkage holes, which will have an impact on the air tightness of the casting. At the moment, there is a method of immersion treatment that can be used to improve air tightness resistance.

    The following are the root causes of die casting undercasting:

    1) The filling condition is poor, and there is irregular condensed metal in the undercast part.
    When the pressure is insufficient or insufficient, and the metal in the active front solidifies prematurely, undercasting occurs in the corner, deep concave, thin wall (even thinner than the average wall thickness), and cylindrical hole wall.
    The mold temperature is too low; the pouring temperature is too low;

    The gate position is not optimal, resulting in a high level of resistance.
    2) The surface of the undercast part has been lubricated, but the shape is irregular.
    Where it is difficult to set up a drainage system, the gas will accumulate;
    When the molten metal moves, the turbulence becomes violent, and the gas is trapped.
    3) There is residue in the cavity of the plastic mold.

    Local coating deposition will result from the use of an insufficient amount of coating or the use of an insufficient spraying method.

    When the gap between the molding parts is too large, or the sliding cooperation gap is too large, the filling material will run into the metal. Once the cast aluminum parts have been removed, they will not be able to be replaced and will be clamped to the gap. When the type of sheet metal (the thickness of the metal sheet is the size of the gap) protrudes more on the surrounding mold surface, the height of the projection will be changed into the wall thickness of the casting under the condition of mold closing, resulting in the future casting having a groove through (for the wall thickness). This type of penetrating groove is referred to as a "special form of under casting."This type of undercasting phenomenon is frequently observed in the case of deep cavities made of inlay.