Analysis of the Die Casting Mold Manufacturing Process
Release time:
2020-01-09
Mold Manufacturing Process Flow: Review the Drawing—Prepare Materials—Machining—Mold Base Machining—Core Machining—Electrode Machining—Mold Component Machining—Inspection—Assembly—Trimming—Trial Molding—Production A: Mold Base Machining: 1. Assign numbering; 2. Process A/B plates; 3. Machine the panel; 4. Fabricate the ejector pin holder plate; 5. Manufacture the base plate B: Core Machining: 1. Remove flash; 2. Coarse grinding; 3. Milling machine processing; 4. Precision machining by hand; 5. Rough CNC machining; 6. Heat treatment; 7. Fine grinding; 8. Precision CNC machining; 9. Electrical discharge machining; 10. Finish mold polishing C: Mold Component Machining: 1. Slide block machining; 2. Clamp block machining; 3. Runner cone and sprue processing
Mold Manufacturing Process Flow:
Reviewing the drawing — Preparing materials — Machining — Mold frame machining — Core machining — Electrode machining — Mold component machining — Inspection — Assembly — Demolding — Trial molding — Production
A: Mold base machining: 1. Marking for numbering, 2. Machining of A/B plates, 3. Panel machining, 4. Ejector pin fixing plate machining, 5. Base plate machining
B: Core machining: 1 Deburring, 2 Rough grinding, 3 Milling machine processing, 4 Fitting and assembly work, 5 CNC rough machining, 6 Heat treatment, 7 Precision grinding, 8 CNC precision machining, 9 Electrical discharge machining, 10 Mold finishing
C: Mold Component Machining: 1 Slider Machining, 2 Clamping Block Machining, 3 Runner Cone Sprue Bushing Machining, 4 Insert Machining
Mold base machining details
1. Ensure that all part numbers are consistent, and also mark the core components with their corresponding numbers—these should match the numbering on the mold base and align in the same direction. This way, you can easily assemble everything correctly without mistakes.
2. A/B plate machining (i.e., moving and fixed mold frame machining):
a: A/B plate machining must ensure the parallelism and perpendicularity of the mold frame are within 0.02mm.
b: Milling machine operations: drilling screw holes, coolant holes, ejector pin holes, nozzle holes, and chamfering.
c: Hand tool work: tapping threads and trimming burrs.
3. Panel Processing: Milling machine processes boring tool holes or material nozzle holes.
4. Thimble Fixing Plate Machining: Milling Process – The thimble plate is connected to Plate B using return pins, with Plate B positioned face-up. Top-pin holes are drilled from top to bottom. For countersunk top pins, the thimble plate must be flipped over so its bottom faces upward, then carefully aligned. Begin with rough machining using a drill bit, followed by fine finishing with a milling cutter to achieve precise positioning, and finally chamfer the edges.
5. Base Plate Machining: Milling Machine Processing – Marking, Alignment, Boring, and Chamfering.
(Note: For certain molds requiring strong pulling and pushing actions, it’s necessary to reinforce the mechanism—for example, by drilling screw holes directly into the ejector plate.)
Mold Core Machining Details
1) Rough-machining the hexagonal flange: Perform machining on a milling machine to ensure perpendicularity and parallelism, leaving a grinding allowance of 1.2 mm.
2) Rough Grinding: Perform large-water grinding first on the larger surfaces, then clamp and grind the smaller surfaces using a fixture. Ensure that the perpendicularity and parallelism are maintained within 0.05 mm, leaving a margin of 0.6–0.8 mm on both sides.
3) Milling operations: First, align the milling machine spindle to ensure accuracy within 0.02 mm. Securely clamp the workpiece, then proceed with machining the screw holes, ejector pin holes, wire-passage holes, and countersink the cavity for insert pins. Next, drill the sprue or material-feed holes, chamfer the diverter cone holes, and finally create the cooling-water channels before rounding off the R-angles.
4) Machining: Tapping, lettering
5) CNC Rough Machining
6) Perform external heat treatment, HRC 48-52
7) Fine grinding: Perform large-water grinding until the surface is 0.04mm below the mold frame, ensuring that parallelism and perpendicularity remain within 0.02mm.
8) CNC Precision Machining
9) Electrical Discharge Machining
10) Polish the mold to ensure smoothness and carefully control the cavity dimensions.
11) For gating and venting during processing: For zinc alloys, the gate typically opens to 0.3–0.5 mm, while vents are set at 0.06–0.1 mm. For aluminum alloys, the gate should be 0.5–1.2 mm, with vents at 0.1–0.2 mm. For plastics, vents should be 0.01–0.02 mm wide—aim for them to be as wide and thin as possible.
Slider Machining Process
1. First, rough-machine all six sides on the milling machine.
2. Next, precisely grind all six sides to meet the dimensional requirements.
3. Then, rough-machine the mounting platform on the milling machine.
4. Finally, finish-grind the mounting platform to the exact dimensions and ensure a smooth sliding fit with the mold frame’s guide blocks.
5. Use the milling machine to cut the inclined surfaces, ensuring the slope matches that of the clamping blocks—leaving an appropriate margin for subsequent mold trimming.
6. Drill the coolant channels and the inclined guide pin holes. Note that the diameter of the guide pin holes should be 1 mm larger than the guide pins themselves, with chamfered edges. Additionally, the inclination angle of the guide pin holes must be 2 degrees shallower than the slope of the slider’s inclined surface.
Alternatively, the inclined guide pin holes can also be re-machined directly on the mold assembly after the mold halves are fully assembled, depending on the specific situation.
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