Production factors in Diecast

Production factors in Diecast

The production of a piece depends on three factors that determine the melt, the machine and the mold, which we intend to examine the characteristics of each and express their impact on production.

1. Familiarity with furnaces, types of aluminum ingots in terms of analysis, smelting, degassing, furnace charging

Melt preparation

The melt is prepared in the following steps and transferred to the injection cylinder of the device

Mother furnace

Retaining furnace

Turn on the oven and prepare the melt

Stabilize the furnace temperature

Pull the load and turn off the furnace

Normally, 2 furnaces are installed next to each device, one of which is used to prepare the melt and separate impurities (mother furnace) and one is used to maintain the melt (holding furnace).

- To prepare the melt in the mother furnace, first turn on the furnace and when the temperature of the plant rises, a small amount of ingot is charged in the furnace and gradually, more ingots are added to the plant to fill the plant with melt.

- By turning the burner on and off, the temperature can be controlled.

- To turn off the furnace, first the melt inside it is emptied in ingot molds and then the furnace is turned off.

Effective parameters in melting

1- Type of alloy

Molten alloy is very effective on the appearance of the piece. The higher the fluidity, the better the appearance quality.

Alloys with higher silicon also have higher fluidity.

Iron reduces the adhesion of melt to the mold by 0.7-1%.

Silicon has a high latent melting point, so when it wants to solidify, it releases a lot of heat, which increases fluidity.

2. Melting temperature

The recommended temperature of molten aluminum in the holding furnace is about 687 degrees Celsius, but this temperature drops when entering the mold and reaches about 600-610, which is the desired temperature.

Excessive heat of the melt causes the following factors.

Melt spraying

Increased cylinder corrosion

Adhesion (soldering) to molds, cylinders and pistons.

The alloy of the mold loses its quality, for example, the magnesium of the mold is lost.

Increase contractile Macs

Note: Reducing the melt temperature is a good parameter, but this reduction should be done as long as it does not cause any apparent problems.

3- Existence of impurities

Impurities lead to the following problems:

Create Mac

Machining bugs

Below is an animation of the diecast casting steps

Ladle

Cover

First, mix the coating material with water in a certain ratio and heat the ladle and immerse it in the mixture and move it. This will evaporate the water and the coating will stick to the ladle.

The correct way to load

The ladle is slowly inserted into the melt from the wider part (back) and drained from the narrower part (front) into the injection cylinder.

This way we have less air trapping and melt spraying when loading.

Prevents the load from freezing during pouring.

Preheat

To prevent thermal stress from entering the ladle when it enters the melt, it must first be preheated.

Suggestion for ladle material: Steel ran fireproof

cooling

In general, the mold temperature is suitable around 204 ° C, but the temperature must be adjusted in different parts.

Areas of the mold that are hot should be cooled, such as:

Thin places.

Where soldering occurs.

Low diameter pins

Overflows should not be sprayed.

In spraying, in addition to the pressure and direction of spraying, the nozzle distance is also very important.

Properties of a lubricant

This material is able to lubricate the ejection pins and moving parts of the mold.

This material must prevent the casting piece from sticking to the mold.

It has safety and health properties and is not flammable.

Lubricant should not stick to the mold and damage its surface.

This material should not affect the casting and its smooth and sensitive surfaces.

This material must cause the casting piece to come out of the mold without damage and health.

Coating materials in the casting of aluminum alloys

Four types of coating materials are used for casting in die-cast aluminum alloy molds:

Color composition

Graffiti Grace

Colloidal graphite in oil

محل Water soluble compounds

Familiarity with the correct method of loading

1. Loading starts when the mold lock light is activated

2. Pour the solution into the cylinder at the appropriate speed

3. Pause for a few moments to prevent melt turbulence

4. Injection command

Familiarity with plunger and cylinder components

2-اجزای پلانجر و سیلندر (عوامل تولید در دایکست)

Types of pistons

3-انواع پیستون (عوامل تولید در دایکست)

Melt injection:

Melt injection is done in three working phases, the effective factors in the settings of each phase are given below.

Adjust the speed of phase 1 and start phase 2

To fine-tune the injection, you must first pay attention to how it is injected correctly. Note the following two figures.

4-تزریق مذاب (عوامل تولید در دایکست)

According to the figure above, the velocity of the piston should be such that the peak of the wave created in the melt is attached to the plunger. When it is molten, it traps air, and since the first places to be filled by the melt are overflows, they prevent air from escaping, creating a gas gap in the part.

Factors that cause the piston to move unevenly:

Failure to adjust the speed of phase 1 correctly

کلCylinder and piston shape (if they are lined up, they move step by step)

◦ Lack of proper cooling of cylinders and pistons

The minimum starting point of phase 2 is the beginning of the melt entering the passage and the maximum is the beginning of the melt entering the part.

The minimum starting point of phase 2 is the beginning of the melt entering the passage and the maximum is the beginning of the melt entering the part.

5-تزریق مذاب (عوامل تولید در دایکست)

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