Aluminum Casting Die Casting Process

Aluminum casting process is not required to consider the following questions:

1) in the liquid metal in the filling system can clean, smooth flow, there is no vortex and.

2) there is no angular or dead?

3) if cross domain triggering system changes?

4) The performance of paint coatings produced gas analysis: the air to create porosity in aluminum castings have a direct impact. Projection process: the excessive, leading to significant evaporation of gas, too punch lubricant, or burns, are the source of gas.

5) The answer to the first aluminum casting porosity analyze the causes of pores again take appropriate action.

1) dry, clean alloy.

2) to control the melting temperature to prevent overheating and gas processing.

3) Melt a reasonable choice of process parameters, the extraordinary is the speed of injection. High speed switch for adjusting the starting point.

4) The order of the high pressure sodium lamp filled with the help of gas emissions, carrots and runner length sufficient to facilitate the free flow of gas and liquid alloy has the ability to download. Can change the thickness of a door, address, forming pores in the position set for the overflow reservoir, the discharge ducts. Sectional area of ​​the overflow of the product can not be less than the sum of the gate within 60% of the total cross-sectional area, or slagging poor results.

5) Selection and control of spray paint with good volume. Ideas to remedy the deficiencies that cause each fault from a number of different factors, so that the actual production to solve the problem, because in the face of many non-merits and demerits of the machine first transfer? Or before refueling? Or modified before the mold? We propose that the degree of difficulty, after the first dealing with the complex simplicity,

The order:

1) in the return surface, the cleaning of the cavity mandrel cleaning, the improved coatings to improve the sputtering process, increase the clamping force to increase the amount of molten metal. These operations can be implemented by simple measures.

2) adjusting the process parameters of the injection force, injection speed, fill time, the molding time, the casting temperature, mold temperature. 3) for materials, ingots select high quality aluminum alloy, the material again and again to change the ratio of filler to improve the process of fusion.

Cast aluminum produced flash of reasons:

1) Problem aluminum smelter: adjusts the clamping force not.

2) a technical problem: the injection speed is too high to form a peak pressure impact.

3) mold problems nonstick cookware deformation, type of surface debris, inserts, cursors used does not work, the model is not strong enough. Measures to resolve the flashing sequence: surface clean separation to improve the clamping force adjusting parameters of wear parts mold repairs to improve the rigidity of the mold.

The Classification Of Plastic Mold

Plastic mold is that used for the molding tool, this tool is composed of various parts. Plastic mold press molding method different, basically can be divided for injection mold, plastic compression mold, extrusion mold, blow mold, plastic mold and high foaming polystyrene molding.

1. Plastic injection mold

Plastic injection mold is mainly thermoplastic plastic products used in the production of one of the most common mold. Plastic injection mold corresponding processing equipment for plastic injection moulding machine. Plastic injection machine first in bottom heating barrel is melted by heating, and then in the injection machine screw or plunger drive below, the injection machine nozzle and mold's gating system into the mold cavity, plastic cooling hardening shaping, demoulding to obtain the products.

2. Plastic compression mold

Plastic mold includes compression molding and injection molding mold type structure of two kinds of. They are mainly used for molding thermosetting plastic in a mold, the corresponding equipment is pressure molding machine. Compression molding method according to the characteristics of plastic, the mold is heated to molding temperature, and then measuring the pressure plastic powder into the mold cavity and a feed chamber, closed mold, plastic in high temperature, high pressure is softened by viscous flow, after a certain period of time is solidified and shaped into a desired article shape.

3. Plastic extrusion mold

Plastic extrusion mold is used to produce continuous shape plastic products forming a mold, also called extrusion die, widely used in pipe, bar, sheet, film, filament, wire and cable coating layer, profile processing. The corresponding production equipment of plastic extrusion machines, the principle is in the heating and solid plastic extruder screw rotation under pressurized conditions melt, plasticizing, through the particular shape of the die and die shapes made of cross section and the same continuous plastic products.

4. Plastic blow mold

Plastic blow mold is used for molding plastic container type hollow products mould. Blow molded form according to the process principle mainly in extrusion blow molding, injection molding form. According to the process principle mainly in extrusion blow molding machine, injection blow molding, injection stretch blow molding, multilayer hollow blow molding, sheet blow molding. Hollow plastic products blow molding the corresponding equipment are often referred to as the plastic blow molding machine. Blow molding is only suitable for the hot varieties of plastic products production.

5. Plastic mold

Plastic mold plastic plates, sheets to molding materials some relatively simple plastic products mould. Plastic mold is to use the principle of vacuum bloom method or compressing air molding method which is fixed on concave or convex die plastic plates, sheets, in a heated and softened case of deformation and affixed to the mold cavity by the desired molded product.

6. High-foamed polystyrene mold

High foaming polystyrene mold is the application of expandable polystyrene raw materials to forming various needed shapes of foam packing material in a mold. Its principle is expandable polystyrene in the mold can into the steam forming, including simple manual operation tool and hydraulic pressure machine type foam mould two types.

Tooling Terminology

    Acute - Tooling with an angle less than 90°.

    Adapter - Intermediate tooling which converts an American Style punch holder to a European Style, or vice versa.  They can also be used to lengthen the punch holder.

    Adjustable - A die where the v opening can be changed by turning a screw mechanism to spread the two sides of the v.

    American Style - Tooling for press brakes comes in two main forms; American and European.

    Box - Tooling specifically designed to form boxes with flanges on 2, 3 and 4 sides.

    Channel - Tooling which is used to form sheet metal channels.

    Curling - Tooling which creates an open circular roll at the end of the sheet, this is different than hemming.

    Die - The bottom section of a press brake tool which typically features a v shaped groove.

    Die Holder - Attached permanently to the lower beam this clamping mechanism will hold the die or rail in position.

    Die Set - The term applied to a specific combination of holder, die, punch and any spacers or rails.

    European Style - Press brake tooling comes in two main forms, European and American.  European style tooling has an offset between the center of the tool and where it is clamped to the brake.

    Goose Neck Punch - A term for punches with deep profiles to allow for large return flanges when bending.

    Hemming - Tooling which is specially designed to produce hems in to stages, without tool change over.

    Offset - Offset tooling is a combination punch and die which has a Z shape and performs two bends in one stroke to produce a jog, or offset, in the metal.

    Punch - The upper section of tooling which generally features a v shaped profile matching the die.

    Punch Holder - A clamping mechanism which holds the punch, allowing for easy switching of punches.

    Radius - Tooling specifically designed for forming a larger radius in the work piece.

    Ribbing - Tooling which ads a round or v shaped grooved to the sheet metal in a single stroke.

    Sash Punch - A generally straight thin tool with a sharp relief offset at the bottom, used for bending special relief profiles.

    Sash Die - A thin single v die with a center tang, allowing for tighter profiles to be bent around the die.

    Seaming - Punch and Die sets which are designed to prepare and close seams on one or more pieces of sheet metal.

    Shimming - The act of adding material to the bend process in order to compensate for distortion along the bend line.

    Spacer Block - An intermediate piece of tooling which adds height to the die holder.

    Squaring Arm - A device which attaches to and moves with the press brake and work piece to hold work pieces square, or at a set angle.

    Straight Punch - Also known as sword punches these are characterized by long, straight, thin punches used for bending symmetrical profiles.

    Two, Three & Four Sided Die - A specialized die which has a square shape and a special profile cut into each side to allow for multiple setups from a single die.

    Rail - An intermediary holder which is seated in the die holder and adds height, or a special profile, to the die holder.  This also allows for quick accurate switching of dies.

    Rolla V - A specialized die which has two half cylinders which support the flanges as the work piece is bent.

    Rotary Die - Rotary dies have a cylindrical shape with v cut along its axis is seated in a saddle.

    Tang - A locating protrusion on a piece of tooling which fits into a matching groove.  Typically found at the center of American Tooling.

    Unbalanced - Tooling which does not evenly distribute the tonnage front to back and thus creates a thrust force on the punch holder.  Often seen in 30°-60° type tooling.

    Urethane Die - Press brake dies which incorporate a urethane pad to aid in the bending process.

    Window Punch - A bend setup which creates an open area above the punch to allow deep drawn parts to pass through.

    Wipe Die - Wiping die bending is performed by holding the sheet between a pad and die then sliding the wiping punch across the face bending the sheet metal which protrudes from the pad and die.

Forging and its types

Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in such a way that the required final shape is obtained. Forging is generally a hot working process through cold forging is used sometimes.

Type of forging

1.     smith forging

2.     drop forging

3.     press forging

4.     machine forging

1: Smith forging

This is the traditional forging operation done openly or in-openly dies by the village black smith or modern shop floor by manual hammering or by the power hammer. The process involves heating the stock in the black smith hearth and then beating it over the anvil. To get the desire shape the operator has to manipulate the component in between the blows.

The types of operation available are fullering, flattering, bending , upsetting and swaging.

 2: Drop forging

Basic definition:

This is the operation done in closed impression dies by means drop hammer here the force for shaping the component is applied in a series of blows.

      

Drop forging utilizes a closed impression die to obtain the desire shape of the component , the shaping is done by the repeated hammering given to the material in the die cavity. The equipment use for delivering for blows are called drop hammers. The drop forging die consists of two halves. The lower halve of the die is fixed to the anvil of the machine , while the upper halve is fixed to ram. The heated stock is kept in the lower die, while the ram delivers 4-5 blows on the metal spreads and completely fills in the die cavity. When the two die of halves closed the complete is formed. The typical products obtained in drop forging are cranks, crank shaft, connecting rods, wrench, crane hooks etc. The types of operations are fullering, edging, bending, blocking , finishing and trimming etc.

3: Press forging

Similar to the drop forging , the press forging is also done in closed impression dies with the expectation that the force is continuous squeezing type applied by the hydraulic press. Press forging dies are similar to drop forging dies as also the process in press forging, the metal is shaped not by means of  a series of blows as in drop forging , but by means of a single continuous squeezing action. This squeezing is obtained by means of hydraulic presses. Because of the continuous action of by hydraulic presses, the material gets uniformly deform through out its entire depth ,the press forging dies with the various impression , such as fuller, bender and finisher impression properly arranged .

4: Machine forging:

Unlike the press or drop forging where the material is drawn out , in machine forging the material is only upset to get the desire shape. As it involves the upsetting operation some time it is simply called as upset forging. Originally this was develop for making bolts head in a continuous fashion, but now there are fairly large number of diverse.

Uses of this process:

Because of the beneficial grain flow obtain from upsetting. It is used for making gears, blanks, shafts, excels, and similar parts. Upsetting machine called up setter are generally horizontal acting. The die set consists of die and corresponding punch or a heading tool. The die consists of two parts, one called the stationary gripper die which is fixed to the machine frame and the other movable gripper die which moves along with the die slide of the up setter. The stock is held then between these two gripper dies.

The upset forging cycle start with the, movable die sliding against the stationary die to grip the stock. The two dies when in closed position from the necessary die cavity then the heading tool advance against the stock and upset it to completely filled to the die cavity.

Having completed the upsetting the heading tool moves back to its back position. Then the movable gripper die releases the stock by sliding backward. Similar to drop forging it is not possible to get the final shape in a single pass in machine forging also. Therefore the operation is carried out in number of stages. The die cavities is required for the various operations are all arrange vertically on the gripper dies. The stock is the move from stage one to another in proper sequence till the final forging is ready. A heading tool each for every upsetting stage is arranged on the heading slide of the upsetting machine. A typical upsetting die and heading tool is shown:

Dies and its Types

Die:

The die may be defined as the female part of a complete tool for producing work in a press. It is also referred to a complete tool consists of a pair of mating members for producing work in a press.

Types of dies:

The dies may be classified according to the type of press operation and according to the method of operation.

(A): According to type of press operation:

According to this criterion , the dies may be classified as cutting dies and forming dies.

1: Cutting Dies:

These dies are used to cut the metal. They utilize the cutting or shearing action. The common cutting dies are : blanking dies , perforating dies , notching dies , trimming , shaving and nibbling dies.

2: Forming Dies:

These dies change the appearance of the blank without removing any stock. Theses dies include bending, drawing and squeezing dies etc.

(B) According to the method of operation:

According to this criterion, the dies may be classified as : single operation or simple dies , compound dies , combination dies , progressive dies , transfer dies and multiple dies.

1: Simple Dies:

Simple dies or single action dies perform single operation for each stroke of the press slide. The operation may be one of the operation listed under cutting or forming dies.

2: Compound Dies:

In these dies, two or more operations may be performed at one station. Such dies are considered as cutting tools since, only cutting operations are carried out. Figure shows a simple compound die in which a washer is made by one stroke of the press. The washer is produced by simulation blanking and piercing operations. Compound dies are more accurate and economical in production as compared to single operation dies.

3: Combination Dies:

In this die also , more than one operation may be performed at one station. It is difficult from compound die in that in this die, a cutting operation is combined with a bending or drawing operation, due to that it is called combination die.

4: Progressive Dies:

A progressive or follow on die has a series of operations. At each station , an operation is performed on a work piece during a stroke of the press. Between stroke the piece in the metal strip is transferred to the next station. A finished work piece is made at each stroke of the press. While the piercing punch cuts a hole in the stroke , the blanking punch blanks out a portion of the metal in which a hole had been pierced at a previous station. Thus after the first stroke , when only a hole will be punched , each stroke of the press produces a finished washer.

6: Transfer Dies:

Unlike the progressive dies where the stroke is fed progressively from one station  to another. In transfer dies the already cut blanks are fed mechanically from one station to other station.

7: Multiple Dies:

Multiple or gang dies produce two or more work piece at each stroke of the press. A gang or number of simple dies and punches are ganged together to produced two or more parts at each stoke of the press.