Die casting mold production process
Before designing the mold, we have to get the drawing of the casting provided by the customer, analyze the drawing first, including the structure, shape and accuracy of the casting, etc. After confirming that the casting can be made, feedback to the customer and get the customer’s confirmation, after completing the above steps, we can carry out the analysis of the process scheme, firstly determine the placement of the product in the mold, then carry out the design of the parting surface to facilitate the simplification of grinding, milling, CNC machining, and also determine the location of the gate and the number of cavities. CNC processing, also determine the location of the gate and the number of cavities, in addition, the discharge system and pouring system are completed by the process parameters, the shape and size of the pouring system, the size of the internal gate, for fine parts to use the method of mold insert, followed by the design of each active core assembly and fixed way, the next step is the design of the die-casting mold, including the determination of the ejector settings, according to the product The next step is the design of the die casting mold, including the determination of the ejector setting, the selection of the suitable ejector method according to the product type, and finally the general drawing of the die casting mold and the related design of the die casting mold parts.
A: mold frame processing: 1 numbering, 2 A/B plate processing, 3 panel processing, 4 ejector fixed plate processing, 5 bottom plate processing
B: mold core processing: 1 flying edge, 2 rough grinding, 3 milling machine processing, 4 clamping processing, 5 CNC rough machining, 6 heat treatment, 7 fine grinding, 8 CNC finishing, 9 EDM processing, 10 saving mold
C: mold parts processing: 1 slider processing, 2 compression block processing, 3 manifold cone gate sleeve processing, 4 insert processing
Mold frame processing details
1, playing number to unify, mold core should also play on the number, should be consistent with the mold frame on the number and the direction of the same, assembly can be aligned is not easy to make mistakes.
2, A/B plate processing (i.e. dynamic and fixed mold frame processing), a: A/B plate processing should ensure that the parallelism and perpendicularity of the mold frame is 0.02mm, b: milling machine processing: screw holes, water transport holes, ejector holes, machine mast hole, chamfering c: pincer processing: tapping, trimming burrs.
3, panel processing: milling machine processing boring machine mouth hole or processing material mouth hole.
4, ejector plate processing: milling machine processing: ejector plate and B plate with back pin connection, B plate facing up, from top to bottom drilling ejector holes, ejector countersunk need to reverse the ejector plate bottom up, correction, first rough machining with a drill, then finish machining with a milling cutter in place, chamfering.
5, base plate processing: milling machine processing: scribing, correction, boring, chamfering.
(Note: Some molds need strong pulling and strong top to add strong pulling and strong top mechanism, such as drilling screw holes in the thimble plate)
Mold core processing details
1） Rough machining of flying six sides: processing on the milling machine, to ensure verticality and parallelism, leaving a grinding allowance of 1.2mm
(2) rough grinding: large water mill processing, first grinding large surface, use the batch of Division clamping grinding small surface, to ensure verticality and parallelism in 0.05mm, leaving a margin of bilateral 0.6-0.8mm
3） Milling machine processing: the first milling machine head correction, to ensure that within 0.02mm, correction pressure workpiece, the first processing screw holes, ejector holes, threading holes, countersunk countersunk inlaid needle to open the rough, machine muzzle or muzzle hole, shunt cone hole chamfering and then do water transport hole, milling R angle.
4） Clamp processing: tapping, typing code
5） CNC rough machining
6） Heat treatment outside the hair HRC48-52
7） Fine grinding; big water grinding processing to negative 0.04mm than the mold frame, to ensure parallelism and perpendicularity within 0.02mm
8） CNC finishing
9) EDM processing
10） Mold saving, ensure the finish and control the cavity size.
11) Processing into the gate, exhaust, zinc alloy in general, the gate open 0.3-0.5mm, exhaust open 0.06-0.1mm, aluminum alloy gate open 0.5-1.2mm exhaust open 0.1-0.2, plastic exhaust open 0.01-0.02, try to be wider and thinner.
Slider processing technology
1, first milling machine rough machining six sides, 2 fine grinding six sides to the size requirements, 3 milling machine rough machining hanging table, 4 hanging table fine grinding to the size requirements and with the mold frame line position slip with, 5 milling machine processing bevel, to ensure that the slope and the pressure block consistent, leaving a margin of flying mold, 6 drilling water and oblique guide hole, oblique guide pillar hole than the guide pillar 1 mm larger, and chamfering, oblique guide pillar hole slope should be smaller than the slope of the slider bevel 2 degrees. The oblique guide pillar hole can also be machined again with the mold frame after the mold is closed in the fly, depending on the situation.