Die-casting applications in various industries

Die-casting applications in various industries

Aluminum die-casting is a pressure cast parts, pressure die cast by casting machine, a heated liquid aluminum or aluminum alloy is poured into the die casting machine feed inlet, the die-casting machine casting, casting mold limits the shape and size of aluminum parts or aluminum alloy parts, such parts usually called aluminum die-casting. Aluminum die-casting in different places have different terminologies, such as aluminum die-casting parts, aluminum die-casting parts, die-cast aluminum, die-cast aluminum, aluminum die casting, aluminum die-casting parts.

Casting is relatively early humans mastered a metal thermal processing,Is usually performed using gravity casting metal in a mold.However, aluminum die-casting is not done by gravity, but exert some pressure,A bit like "injection."But it has a high-tech pumping core cooling system.

Overall, a centralized entrance through the material to be cast, "Note" made in the cavity formed parts.

Since aluminum and aluminum alloy has good fluidity and plasticity, and the casting process is casting pressure die casting machine, die-cast aluminum and therefore can make a variety of more complex shapes can also be made high accuracy and finish and thus greatly reduce the amount of machining and casting of aluminum or aluminum alloy casting margin, not only saves electricity, metal materials, but also a significant reduction in labor costs; and aluminum and aluminum alloy with excellent thermal conductivity, and a smaller proportion of high workability;

Die-cast aluminum three major advantages:

1, good quality: high precision casting size, surface finish, high strength and hardness, dimensional stability, good interchangeability;

2, high efficiency: high productivity machine, small hot chamber die casting machine aluminum die-cast aluminum can on average every eight hours from 3000 to 7000; long life die-cast aluminum type, a pair of die-cast aluminum type, die-cast aluminum alloy bell, life of up to tens of million times, or even millions of times; easy to mechanization and automation.

3, the economic effect of the fine: As the die-cast aluminum precise size, smooth sheet pan and so on. Generally no longer be machined directly use or processing volume is small, so not only improves the utilization rate of the metal, but also reduces the amount of processing equipment and labor; casting cheap price; combination of die-cast aluminum with other metals or non-metallic materials may be used . Saving assembly work and save metal.

Therefore, aluminum die-casting is widely used in automobile manufacturing, engine production, motorcycle manufacturing, motor manufacturing, pump manufacturing, transmission machinery, precision instruments, landscaping, power construction, architectural decoration and other industries. Aluminum die casting can be manufactured as a die-cast aluminum auto parts, aluminum die-casting automobile engine fittings, aluminum die-casting engine cylinder, die-cast aluminum cylinder gasoline engine cylinder head, valve rocker aluminum die-casting, die-cast aluminum valve seat, aluminum die-casting power accessories, die-cast aluminum motor cover, die-cast aluminum housing, die-cast aluminum pump housing, aluminum die casting construction accessories, decorative accessories aluminum die-casting, die-casting aluminum fence parts, aluminum die-cast aluminum wheels and so on parts.

china plastic injection molding

Common types of plastics, advantages and disadvantages and main flaw

Plastic is a resin as a main component, at a certain temperature and pressure molded into a certain shape, and at room temperature can be maintained given the shape of the high molecular weight organic material. Plastic light weight, high strength. Usually density 0.9-2.3g / mm³ is 1 / 8-1 / 4, 1/2 of aluminum, iron and steel excellent electrical insulation properties, good chemical stability, anti-friction wear resistance, light transmittance and protective properties Good, good damping silencer performance. After heating the surface of the plastic according to the performance into thermosetting plastics and thermoplastics. Occur at a certain temperature over a period of time of heat, pressure or added hardener chemical reaction and hardened, hardened plastic chemical structure changes, hard, insoluble in solvents, no longer softened after heating, such as temperature: thermosetting plastic Features too high to decompose. Such as Bakelite (commonly known as bakelite), epoxy plastic (EP) and the like. Thermoplastic Features: biological state change hair after being heated to soften or melt into a sticky fluid state from a solid, but can harden after cooling from solid, and the process can be repeated many times. The molecular structure of the plastic itself is not changed. Plastics such as polyethylene (PE), polyvinyl chloride (PVC).

PC material (polycarbonate)

Advantages: 1 has high strength and elastic modulus, high impact strength, wide temperature range.

2. High transparency and freedom of dyeing

3. good fatigue resistance

The excellent electrical characteristics

5. low mold shrinkage, good dimensional stability.

Disadvantages: 1. hydrolysis resistance

2. chemical resistance, notch effect

3. The problem is easy to produce finished poorly designed internal stress.

Chemical and physical properties: PC is a non-crystalline engineering materials, with a particularly good impact strength, heat stability, gloss, inhibit bacterial properties, flame retardant properties and fouling resistance. PC de gap estimated impact strength in Iraq (otched Izod impact stregth) is very high and very low shrinkage rate, usually 0.1% to 0.2%. PC has good mechanical properties, but poor flow characteristics, so the injection molding process more difficult this material. PC quality in the selection of the material, we should expect the final product as a benchmark. If the plastic parts require high impact resistance, then use a low turnover rate of PC material; the other hand, you can use the high turnover rate of PC material, which can optimize the injection molding process.

Material ABS (acrylonitrile - butadiene - styrene copolymer, commonly known as: super glue is not broken)

Advantages: 1. hard, easy extrusion

2. Flame

3. easy to dye

4. Impact

5. The surface resistance

Disadvantages: 1. poor solvent resistance

2. Low Dielectric strength

3. Low stretch rate

Forming characteristics: 1. amorphous material, liquid medium, moisture large, must be fully dry, glossy plastic surface should take time to preheat the drying 80-90 degrees, 3 hours

2. should take high melt temperature high mold temperature, high precision mold, mold temperature should take 50-60 degrees, high-gloss heat-resistant plastic parts, mold temperature should take 60-80 degrees.

Chemical and physical properties: ABS is, butadiene and styrene of three monomers synthesized from acrylonitrile. Each of the monomers having different characteristics: acrylonitrile high strength, thermal stability and chemical stability; butadiene have toughness and impact resistance properties; styrene easy processing, high-quality finish and high strength. Morphologically, ABS is an amorphous material. Polymerization of three monomers produces a terpolymer having two phases, a styrene - acrylonitrile continuous phase, and the other is a polybutadiene rubber dispersed phase. The properties of ABS depends on the ratio of the monomers and the molecular structure of the two phases. This allows great flexibility in product design, and the resulting market hundreds of different quality ABS material. These different quality materials offer different characteristics, such as moderate to high impact resistance, from low to high finish and high heat distortion characteristics. ABS material with superior ease of processing, appearance, low creep and excellent dimensional stability and high impact strength.

Of course, various problems will be encountered in the injection molding project. The following is the solution.Plastic products cracking and deformation causes

The hot runner role in injection molding

80 %of life goods need to through the injection molding

Mold is closely related to our life, More than 90% of the life of the article to be processed through the die is made,While 80% of goods go through the plastic molding, plastic mold temperature should reach 300 ℃ or more. Due to the special shape of the plastic mold, with traditional insulation materials can not be insulated on the lower mold high temperature heat loss of a great, severe heat loss, high temperature metal mold thermal fatigue loss is large, and so on. Plastic mold heat great loss, not only directly increase the cost of production, but also due to frequent replacement of the mold caused by mass production line shut down frequently result in greater economic losses.

Hot runner injection molding is used in conjunction with the mold, and play a very important role, such as in the production of ultra-thin plastic injection parts, by using the runner can easily produce high-precision, high-quality products out; for illiquid injection molding material by using a runner can improve the flow of raw materials, to ensure smooth production of injection molding; for some large plastic parts such as car bumpers and door panels, rear shell TV, air conditioning and so on through the hot runner can shell very difficult injection molding becomes relatively simple.

Ues hot runner to reduce injection molding products cost

In the multi-cavity injection mold, the lack of hot runner molding is difficult, it can be said so far is to ensure the hot runner runner balance of the best technology. Because of the presence of plastic hang shear forces in the flow, regardless of the geometry of a mold having more than a reasonable balance, the weight of the molded product is difficult to come out of the same, especially in terms of multi-cavity molds.

For plastics processors, as long as there is a certain volume of injection molding using a hot runner it is quite economical, because the hot runner nozzle to help businesses get rid of in the production of injection molding, which not only saves raw materials, and to cut labor costs and make products more perfect appearance. We all know that in most cases the drain can not be reused, if not at times the weight of the hot runner nozzle and the weight of the product is almost, if the traditional way means that the injection nozzle producing a product must be a product of almost a waste of raw materials as waste, and therefore only this not only saves raw materials, and to cut labor costs, but also make the product more perfect and beautiful. In addition, the runner also help reduce mold wear, extend die life. In general, the hot runner mold life is twice as small inlet of the mold.Of course, there are many factors that affect the life of the mold.In addition to the hot runner, we also use the air poppet device

Our company offers a reasonable solution

Runner simple composition, but each component plays an important role. Generally good quality hot runner design and structure of the material requirements are very high. We can according to the customer's product, the design a reasonable solution, to ensure the hot runner injection molding system can play a maximum efficiency. As our company uses Han Guorui runner, the choice of heaters and temperature line all imported from South Korea, the steel used for all materials imported from Japan, which is to ensure the quality of these hot runner prerequisite.

Characteristics and development of rapid prototyping

Rapid Prototyping (Rapid PrototypingManufacturing, abbreviated RPM), high-tech manufacturing technology is based on a material deposition method, it is considered the last 20 years, a major achievement in the field of manufacturing. It combines mechanical engineering, CAD, reverse engineering, layered manufacturing technology, numerical control technology, materials science, laser technology in one automatically, directly, quickly and accurately convert design to prototype with a certain function or direct manufacturing of parts , so as part prototyping, calibration, etc. the new design provides a cost-effective means of achieving. That is, rapid prototyping technology is the use of three-dimensional CAD data, through rapid prototyping machine, the stacked layers of material into a physical prototype.

Rapid Prototyping Features

(1) prototyping materials used are not limited to, a variety of metallic and non-metallic materials can be used;

(2) prototype reproducibility, high interchangeability;

(3) regardless of the manufacturing process prototyping geometry, more favorable when machining complex surfaces;

(4) Processing cycle is short, low-cost, independent of the degree of cost and complexity of products, general manufacturing costs by 50%, saving more than 70% of the processing cycle;

(5) a high degree of technology integration, to achieve the integration of design and manufacturing;

The practical application of rapid prototyping technology, mainly in the following aspects:

(1) Application of the new product design process of rapid prototyping technology to build a new product development model for industrial product design and development staff. The use of RP technology to quickly, directly and accurately design ideas into physical model has a certain function (sample), which not only shorten the development cycle and reduce development costs, but also enable enterprises occupy the first in the fierce competition in the market machine.

(2) in the field of machinery manufacturing technology due to RP own characteristics, so that it is in the manufacture of machinery for a wide range of applications, used for manufacturing a single-piece, small batch manufacturing metal parts. Some special complex parts, because only single-piece production, or less than 50 small quantities, usually can be molded directly by RP technology, low cost, short cycle.

(3) rapid tooling traditional mold for a long time and high cost. The rapid prototyping technology with traditional mold manufacturing technology, can greatly shorten the development cycle of the mold manufacturing, increased productivity, it is an effective way to mold design and manufacturing weaknesses addressed. Rapid Prototyping technology in mold manufacturing can be divided into direct and indirect molding molding two types of direct molding is the use of RP technology directly stacked to create a mold, indirect molding is a rapid prototyping system first part, and then copy the parts obtain the desired mold.

Rapid Prototyping Development Direction

From the current status of research and application of RP technology point of view, further research and development of rapid prototyping technology, mainly in the following aspects:

（1）Rapid development of good performance molding material, such as low cost, easy to shape, small deformation, high strength, durability and non-polluting molding material.

(2) increase the processing speed RP system and open up a parallel process for manufacture.

(3) rapid prototyping systems to improve reliability, increase their productivity and production of large capacity, optimize the device structure, in particular to improve the forming precision, surface quality, mechanical and physical properties of the member, provide a basis for further mold and functional assays .

（4）RPM high-performance software the development of rapid prototyping. Improve the speed and accuracy of data processing, research and development of the use of the original CAD data directly slice of ways to reduce the STL format conversion generated by the slicing process and loss of accuracy.

IML (In Mold Label)technology introduction and development trends

IML's Chinese name: injection mold inserts its remarkable features is the process: the surface is a layer of hardened transparent film, the middle layer is printed patterns, the back is plastic layer, since the ink in the middle, the product can prevent surface scratches and abrasion, and can be difficult to maintain long-term bright colors fade.

                                                         

IML technology introduction

                                             

Keywords: IML IMD molding process

The concept of IML

IMD (In-Mold Decoration) Film is a film placed in the injection mold decorated plastic exterior surface of the new technology. Currently IMD has two manufacturing methods, one is to be made into a film Film printed circulation drum roll band, mounted in the injection molding machines and injection molds, as Label label affixed to the front surface of the mold fully automatic cycle with mobile production out; that is, people called IMD (injection transfer in the mold).

Another is to pass a good film printing Film Forming molding machine, then placed after the cut produced in the injection mold. That is called IML (in mold foil injection). This Film can generally be divided into three layers: a substrate (typically PET), an ink layer (INK), gluing material (mostly a special adhesive).

When the injection is completed, the adhesive effect makes plastic Film and closely integrated, because of their positive surface covered with wear-resistant protective film on the outermost layer of PET, there is abrasion and scratch effect, the surface hardness reach 3H, and will feel more brighter. Wherein the molding material is more PC, PMMA, PBT, and so on. As shown below:

IML process step

Conference materials --- --- flat printing ink drying protective film stickers fixed --- --- --- punching positioning holes cut peripheral shape thermoforming --- --- material injection molding process as follows: specific instructions as follows:

1) Conference materials: Film roll of the film has been cut into a square block sizes designed for printing, molding process used.

2) flat printing: according to the requirements of icons, text manufactured Philippine forest belt, cut a good film on the square block printing Film icon, text.

3) Fixed ink drying: The printed film Film square placed in a high temperature oven drying, aimed at fixing IML ink.

4) Protective Film: Avoid red when positioning hole step to get to spend a good film Film printed surface, and sometimes need to paste single or double layer of protective film.

5) positioning hole punch: positioning hole thermoformed certain quasi-hub. Positioning hole cutting operations sometimes also punched in advance.

6) Thermoforming (high or copper mold): After the printed film is heated with a high-pressure molding machine or mold in the warm-up state.

7) Cut the peripheral shape: the scrap molding good stereoscopic film cut off.

8) Injection material: the three-dimensional shape after molding die in front of exactly the same film placed on the front mold, injection molded IML products.

IML technology advantages and disadvantages

Advantages:

1) Film production cycle is short, the performance of multiple colors;

2) in the production of patterns and colors can be changed at any time;

3) IML outermost layer is FILM, silkscreen ink on the intermediate layer, smooth surface appearance, the more light touch, with excellent scratch resistance;

4) Number of IML production volume is very flexible and suitable for many varieties of small production

Disadvantages:

1) pre-long period;

2) easy to produce the film off, distortion, etc.;

3) poor product rate

In addition to this new technology, we also specialize in the production of Die-casting .

Injection mold manufacturing characteristics and requirements

Plastic mold production of general machinery products in common, and also that its particularity. Compared with the general machinery manufacturing, mold manufacturing is generally difficult, especially precision molds. As a special technical equipment, tooling and production process are the characteristics of the following aspects.

1. Precision mold manufacturing, high quality requirements, not only requires high precision, but also processing the surface of good quality. In general, the working part of the mold manufacturing tolerances should be controlled within ± 0.011mm, and some even claim within the micron range, surface defects after mold processing requirements are very strict, and the surface roughness of the working part of Ra <0.8 um.

2. The complex shape of the working part of precision molds are generally two or three dimensional complex surface (especially the cavity mold), rather than the general machining of simple geometric profile.

3. The mold as a single piece, production of many varieties of each pair of mold can only produce a certain shape, size and accuracy parts. In the manufacturing process as much as possible the use of common tools, common measuring tools and instruments, as much as possible to reduce the number of special tools. In the manufacturing process of the step arrangement requires relatively concentrated, in order to ensure the quality and accuracy mold, simplify management and reduce the process cycle time.

4. The high hardness of the material is actually a plastic mold machining tool, its high hardness, are generally made of hardened alloy tool steel or carbide and other materials, if manufactured using conventional machining methods, tend to difficult, so mold processing method different from the general machining.

5. Due to the short production cycle and accelerate the upgrading of increasingly fierce market competition, requiring mold production cycles are getting shorter. Mold production management, design and technological work should meet this requirement, to improve the mold design, manufacturing and standardization, in order to shorten the manufacturing cycle.

6. When a complete set of production parts need more deputy mold, a mold before the manufactured products are mutually implicated restrict Yi blank mold, mold parts, and only eventually qualified parts, which was a series of mold considered qualified. In the production and scheduling of the mold must take full account of this characteristic.