Die casting mold manufacturers often encounter new product development and updates to old molds. Generally speaking, the internal and external quality of die castings depend on production process parameters such as liquid metal temperature, die casting pressure, speed, and speed switching points. But in most cases, it is also closely related to mold design and production. The factors that affect the mold include the number of cavities, the design of the gating system, the type of gate (position and size), and the structure of the casting itself. In order to avoid casting defects caused by mold design, and to inspect and correct some issues in mold production, it is necessary to conduct trial molds on the completed molds.
Trial molding and process parameter optimization of die-casting molds
The main purpose of trial production by die-casting mold manufacturers is to find optimized process parameters and mold modification plans. It is required that even if factors such as materials, machine settings, or environment change, the mold can still ensure stable and uninterrupted mass production of qualified products, improve the adaptability of the mold, and not just to obtain a few good trial samples.
Identify the issues with the mold
The molds produced by die-casting mold manufacturers all hope to be a set of molds with good adaptability (i.e. wide molding parameters or process conditions). However, often due to inadequate design considerations or inadequate processing during the manufacturing process, problems such as size deviation, uneven local transitions, and unsuitable structures often occur, resulting in unqualified castings or inability to proceed with mold trial production. And trial molding is a simple and direct way to identify mold problems.
Identify better forming conditions
During the trial molding process, the trial molding personnel can identify a set of suitable process data, which can be used as the default values for setting machine parameters during mass production, and adjust the process conditions for mold mass production based on this set of data.
Verify CAE assisted design to improve subsequent work efficiency
CAE analysis software is the result of computer simulation and calculation based on the specifications of real machines, the performance of real alloys, and the real external environment. Mold designers make corresponding modifications to the mold design based on simulation results; During real machine trial molding, the analysis data can be directly inputted as preset values, which can be used by die casting mold manufacturers to verify whether there are any deficiencies in the analysis mold design. The shortcomings of the test specimen can be compared and analyzed with the simulation results, providing a basis for subsequent process parameter settings.
