The Selection Of Die Casting Machine

Publish Time: 07/01 2021 Author: Site Editor Visit: 15297

First, the selection steps of die casting machine

1) Calculate the technical parameters and manufacturability of the die-casting machine according to the technical requirements, use conditions and die-casting process specifications of the castings, and initially select the appropriate model.
2) According to the preliminary idea of die-casting mold (mold) technical parameters and process requirements, calculate the die-casting process parameters and die-casting mold (mold) dimensions, and select the appropriate model.
3) Evaluate the working performance and economic effects of the die-casting machine, including the yield, pass rate, productivity, and operational stability, reliability, and safety.

Second, the selection method of die casting machine

1) In actual production, the choice of die-casting machine is mainly based on the type of die-casting alloy, the contour size and weight of the casting to determine the use of hot-chamber or cold-chamber die-casting machines. For zinc alloy castings and small magnesium alloy castings, hot chamber die casting machines are usually used. For aluminum alloy, copper alloy castings and large magnesium alloy castings, cold chamber die casting machines are the main choice. The vertical cold chamber die casting machine is suitable for castings with central radial and cylindrical shapes and at the same time having the conditions for opening a central runner.

2) According to the material, outline size, average wall thickness, and net weight of the die-casting parts, select the model and specifications of the die-casting machine. The actual process parameters such as the value of the locking (mold) force, the amount of pouring each time, and the fullness of the injection chamber can be obtained by calculation as the basis for selecting the model.

3) The size of the die-casting mold (mold) should match the corresponding size of the mold (mold) installed on the die-casting machine. The main dimensions are the thickness of the die-casting mold (mold) and the distance between the parting surface of the mold (mold). Must meet the requirements of the basic parameters of the die-casting machine:

①The thickness H of the die-casting mold (mold) shall not be less than the minimum mold (mold) thickness given in the machine manual, and shall not be greater than the maximum mold (mold) thickness given, and the H setting shall meet the following conditions;Hmin+10mm≤ H set ≤ Hmax-10mm;Where H is set—the thickness of the designed model (mold) (mm);;Hmin—the minimum thickness of the given mold (mold) of the die-casting part, that is, "mold thickness" (mm);;Hmax—The maximum thickness of the mold (mold) given by the die-casting machine, that is, the "mold thickness" (mm).
②After the die-casting machine opens the mold (mold), the stroke (L) of the die-casting motorized mold (mold) seat plate, that is, the distance between the die-casting mold (mold) and the parting surface, should be greater than or equal to the minimum distance that can take out the casting.

L≥L take

Figure 1 shows the minimum distance for the die-casting mold (mold) pushed out by the push rod to take out the casting.

L takes ≥L core+L piece+K;In the formula, K generally takes 10mm.

3. Examples of the selection method of die casting machine;For example, a box-shaped casting is known, as shown in Figure 2. The following is a selection analysis based on the technical parameters of the horizontal cold chamber die casting machine produced by Lijin Machinery Factory Co., Ltd.The basic condition material is aluminum alloy; the overall dimensions (length×width×height) are 280mm×180mm×80mm; the average wall thickness is 3 mm; the net weight of the casting is 1240g

1. Calculate the projected area of castings

A1=280mm×180mm=50400mm2

Runner system A2=(0.15～0.30), 0.21 for A2

Then A2=0.21×50400mm2=10584mm2

Residual material (cake) A3=πd2/4, the diameter d in the pressure selection chamber is φ70mm (that is, the diameter of the punch is φ70), then A3=3847mm2

Discharge system A4= (0.1～0.2), if A1 chooses 0.12

A4=A1*0.12=6048mm2

Total projected area:

A=A1+A2+A3+A4=50400mm2+10584mm2+3847mm2+6048mm2=70879mm2

2. Calculate the bulging force, locking force, and select the initial type

(1) If the casting has only general requirements and belongs to ordinary parts, select boost pressure pbz=40N/mm2 (MPa), F expansion=40N/mm2×70879mm2=2835160N, F lock=F expansion/K, take K=0.85 F lock=2835160N/0.
85=3335482N=3335.482kn

The model with a locking force of 4000kn can be selected, and the DCC400 model is selected for the force machine.

2 mm2 (MPa) F expansion=70N/mm2×70879mm2

=4961530N, F lock=F expansion/K, take K=0.85 F lock
=4961530N/0.85=5837094N=5837.094 kn

The model with a lock force of 6300kn can be selected, and the DCC630 model is selected for the force machine.

3. Calculate the weight of the poured alloy liquid

The net weight of the casting is G1=1240g; the table shows that the liquid density of the aluminum alloy ρ=2.5g/cm3. Sprue system G2 set the average depth (thickness) of the sprue to be 7mm (0.7cm)

G2=V2 ρ=A2×0.7×2.5=186g

Residual material (cake) G3 Set the thickness of residual material to be 30mm (3cm) G3=V3

ρ=A3×3×2.5=288.5g

The overflow system G4 has an overflow groove depth of 6mm (0.6cm)

G4=V4 ρ=A4×0.6×2.5=90.8g total weight of molten metal

G=G1+G2+G3+G4 =1.81kg

4. Calculate the fullness of the pressure chamber

(1) When DCC400 is selected, the pouring amount of the punch diameter φ70 is 3.6kg. Fullness φ=1.81/2.6×100%=50.3% Usually the fullness is in the range of 40% to 75%. The above selection of DCC400 meets the requirements.

(2) When DCC630 is selected, the pouring amount of punch diameter φ70 is 4.3kg, and the degree of fullness is φ=1.81/4.3×100%=42.1%. DCC630 also meets the requirements.

5. The relationship between the die-casting mold (mold) and the size of the machine's mounting mold

machine's mounting mold is found out in the DCC400 and DCC630 models, the mold thinness, mold thickness, the stroke of the movable seat plate, the internal dimensions between the tie rods, and the technical parameters, which are designed by the accounting. Whether the corresponding size of the die-casting mold (mold) can meet the requirements.

6. To calculate the injection energy

use the maximum metal static pressure of the injection system and the flow P-Q2 relationship diagram to analyze, and calculate whether the injection performance of the selected die-casting machine can meet the required energy requirements. After calculating the various parameters of the machine, the die-casting machine model can be determined theoretically.

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