What are the advantages of die casting?

 

What are the advantages of die casting?

Die-casting applications in various industries

Aluminum Die-casting is a pressure-cast part, 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. Casting is relatively early humans mastered a metal thermal processing, It 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 molding” 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
the proportion of high workability; 

The Die casting 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, the 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; a combination of Die-cast aluminum with other metals or non-metallic materials may be used. Saving
assembly work and 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.

Troubleshooting for PC plastic molded parts

 

Focus on Polycarbonate Project success

We are very honored, for a Polycarbonate molded parts project between China and US injection mold company. We become the winner.

There is an American medical company needs 1 set of high precision injection molding part, the part we are going to mold is made in PC raw resin, also called Polycarbonate. Although the transparent plastics piece is our strength, in the actual production process, some problems. Our experts cost time and solve it finally, it should be we can learn and share.

Here’s a simple idea about the injection mold for PC medical products.

Deep Injection Molding Manufacturing Expertise

As you can see the transparent body is a hook surface.  The product surface needs to be transparent and no rod traces and dirty marks. We need to ensure that the plastic products will not stick in the side of the cavity during the injection molding process. So it is necessary to use a slider block structure. Because the customer needs all the wall thickness must be uniform, then the light reflection is the same. Look at the pictures and videos can know, for an elliptic shape, the problem is difficult to solve.

 

Another problem is the bubble inside, the product safety reason, customer have to design and make the wall thickness reaches 5 MM, PC accessories will have some bubbles, from the picture you are hard to find, but the actual existence, made a bubble in the PC material parts get cooling and sealing the door quickly,  there are some defects on the surface is easy to produce because of big thickness, to do the right thing, there are a few things you might want to check if the resin completely drying, a suitable mold temperature, injection speed, using multi-point hot runner feeding, etc. here is the final approved sample to see the clean off, there is no bubble at all!

 

“INCREASE YOUR COMPANY PROFIT WITHOUT SACRIFICING QUALITY “

Trusty Tooling & Mold Making, China Supplier– CNMOULDING.COM

Mold making in China is generally much more affordable than in the West .Cnmoulding.com will devise the appropriate tool and mold-making strategy for you.

China plastic injection molding and injection moulds will save your company 50% to 70% of the cost of U.S. Manufactured molds and we will produce them in half the time it takes to produce the same mold in the U.S.

Manufacture your injection molded products and injection molding with us in China. Send us your 3D solid model CAD drawings or sample or even only your idea. And we will provide you with the absolute lowest price for injection molds as well as your injection molded products with quality standards meeting or exceeding your expectations.

New energy vehicles put forward new requirements for plastics

 

New energy vehicles put forward new requirements for plastics

With the rapid development of the automotive industry, especially the rapid development of new energy vehicles (including hybrid, pure electric, and hydrogen energy). In recent years, the automotive industry has had a demand for lightweight, integrated, miniaturized, and electrified auto parts Also increasing day by day.

Plastic is an indispensable material in the automotive field, and its process and performance requirements are increasingly becoming everyone’s attention. At the same time, higher requirements are also placed on the R&D capabilities and rapid response capabilities of material suppliers.

Miniaturization of turbocharged engines requires high-temperature resistance of plastic materials

The latest development trend of internal combustion engines is miniaturization and intake supercharging (that is, turbocharged high). The huge benefits brought by these two technologies are a significant reduction in fuel consumption. An increase in engine power, and a reduction in overall engine mass. For example, The two-piece structure design of the previous engine intake manifold has been changed to an intake manifold with an integrated intercooler.

This design puts forward higher requirements for the high-temperature resistance and high strength of the material. It needs to withstand high temperatures of 190°C and 230°C for a long time and has excellent strength.

Electrification requires low precipitation and neutrality of plastic materials

As more sensors have been placed in various positions of the vehicle. The integration of electrification continues to improve, and the requirements for materials of this electrified equipment are more stringent than before. Such as low precipitation (not to block the oil circuit of the capillary structure), Electrically neutral (not to cause a short circuit in the circuit), and materials need to meet the requirements of relevant laws and regulations (not to contain prohibited substances), etc.

Polyamide (nylon) materials are widely used in the automotive industry for their excellent mechanical strength and long-term heat resistance. Its heat resistance is related to the heat stabilizer. Common heat-resistant stabilizers include metal salts (such as copper iodide/copper halide, metal stearate, etc.) and aromatic amines (such as aniline substances, etc.). With the increasing awareness of environmental protection, some of these heat-resistant stabilizers have been banned by relevant regulations due to their side effects. For example, the latest EU regulations strictly control N, N’-diphenyl-p-phenylenediamine (DPPD) substances.

New energy vehicle requirements for flame retardant properties of plastic materials

With the rapid development of new energy vehicles (including hybrid, pure electric, and hydrogen energy), related standards for parts and materials in this field are also rapidly refined. For example, requirements for different flame retardant systems, flame retardant systems Cover roughly 5 types, namely. Halogen flame retardant, nitrogen flame retardant, inorganic flame retardant, phosphorus flame retardant. And nitrogen-phosphorus synergistic flame retardant. Among them, the flame retardant mechanism is divided into gas phase flame retardant and corrosive” Carbonized” flame retardant. Such as red phosphorus, inorganic flame retardant, etc.

Different flame-retardant systems have different flame-retardant effects. At the same time have obvious changes in the physical properties of the material (such as density, rigidity, and toughness). So how choosing a flame-retardant system to match the flame-retardant effect and mechanical strength requirements of the components is a very complicated problem that must be solved.

New energy vehicle requirements for thermal aging stability of materials

In the high-voltage parts of new energy vehicles. According to regulatory requirements, bright orange materials are required to mark the relevant parts as high-voltage areas. The components in the high-voltage area tend to continue to heat up after the current is connected. Therefore, most vehicle manufacturers also put forward related thermal aging stability requirements for orange materials. For example, after 90℃+1000h thermal aging, the color change of RAL2003 shall not exceed Darker oranges such as RAL2008 and RAL2009.

In the future automotive industry, lightweight and weight reduction, electrification, high transmission efficiency, and miniaturization of turbocharged engines will surely become a whole. And become the indicators for the development and verification of most highly integrated auto parts. . Material manufacturers also need to actively respond to the market and improve material performance to meet the new requirements of the automotive industry.

Overview of China Auto Mould

 

Overview of China Auto Mould

China Auto Mould[/caption]

 

The rapid development of China's automobile industry has brought a broad development space for domestic automobile molds. In addition, due to cost and market factors. The focus of mold manufacturing in developed countries has gradually shifted to developing countries represented by China. Comprehensive factors at home and abroad have promoted the rapid development of the domestic automotive mold industry. And many emerging automotive mold companies have emerged. According to statistics, injection molds account for about 37%. China has become a veritable automobile mold manufacturing country.

 

China’s automotive mold production capacity is extremely advantageous in the world. However, due to the slow technological improvement of domestic high-end automotive mold companies, technical innovation capabilities. And insufficient capabilities in R&D and application of new mold technologies. The development capabilities of domestic high-end molds are not yet complete. To meet the supporting needs of the domestic automobile industry. A large part of high-end automobile molds still needs to be imported. Therefore, the domestic automobile mold industry needs to make up for this shortcoming as soon as possible to make up for a major shortcoming of my country's automobile mold industry.

 

As China's top ten industries for revitalization

China Auto Mould

China's automobile industry has been supported by national policies, coupled with the promotion of autos to the countryside. And China's major auto companies have increased their production, reaching 40 million vehicles in 2020, maintaining the world's first position in production and sales. It is understood that about 1,500 molds are needed to manufacture an ordinary car, among which are close to 1,000 stamping molds and more than 500 interior trim injection molds. Affected by the rapid development of China's auto industry. China's auto mold industry has shown rapid growth and its market capacity has continued to expand.

 

With the gradual increase of China's automobile production year by year. Domestic and foreign automobile mold companies have shown their talents in the Chinese automobile market. Meeting the hot domestic demand and export demand to a certain extent. And at the same time. It has created a new generation in my country's automobile mold industry. Good opportunity. It can be seen that the prospects of China's automobile mold industry are very broad.

 

Scientific management and informatization are the development direction of mold enterprises

 

Another important aspect of the development of automobile mold technology is scientific and information management. Scientific management has enabled mold companies to continue to develop in the direction of Just-in-Time Manufacturing and Lean Production. Enterprise management is more precise, production efficiency is greatly improved, and ineffective institutions, links, and personnel are continuously streamlined. With the progress of modern management techniques. Many advanced information management tools, including enterprise resource management systems (ERP), customer relationship management (CRM), supply chain management (SCM), project management (PM), etc., are used in mold companies It is widely used.

 

Refined manufacturing of molds is an inevitable trend

 

The so-called refined manufacturing of molds refers to the development process and manufacturing results of molds. It is specifically manifested in the rationalization of the stamping process and mold structure design. High precision of mold processing, high reliability of mold products, and strict technical management. Sex. Refined mold manufacturing is actually not a single technology, the second is a comprehensive reflection of design, processing, and management technology. The realization of refined mold manufacturing not only depends on technical excellence but also on strict management.

 

China is the world's largest country in automobile production and sales. The number of automobiles is also expected to be the largest in the world, but it has never been able to produce its own high-end cars. This has a lot to do with the lagging development of the automobile mold industry. Which is known as the "mother of the automobile industry". Auto mold refers to the mold used in the automotive field, known as the "mother of the automobile industry". More than 90% of the parts in automobile production need to be formed by molds, and automobile body molds, extensive huge and medium-sized panel molds. Are used for body manufacturing. An important part of technology is also a key link in the formation of autonomous vehicle development capabilities.

Automobile mold products include automobile cover molds, tire molds, interior, and exterior plastic parts molds, automobile lamp molds, automobile bumper molds, automobile dashboard molds, etc.

Rapid prototyping technology and development

Rapid Prototyping (RP) technology, also known as rapid prototyping technology, is one of the rapidly developing manufacturing technologies in the world today. Rapid prototyping technology is a computer-controlled, based on the principle of discrete, stacked with different methods of accumulation of materials, and ultimately complete the parts of the forming and manufacturing technology.

1, from the forming point of view, the parts can be regarded as "point" or "surface" superposition. The geometrical information of "point" or "face" is discretized from the CAD electronic model, and then combined with the information of the forming process parameters, the material is regulated to accumulate the parts from point to surface and from surface to surface.

2, from the manufacturing point of view, it is based on CAD modeling to generate parts of the three-dimensional geometric information, control multi-dimensional system, by laser beam or other methods of material layer by layer to form a prototype or parts.

The main features of RP technology are:

1, rapid RP manufacturing technology is the concurrent engineering of complex prototyping or parts manufacturing an effective means to enable product design and mold production simultaneously, thereby enhancing R & D efficiency, shorten the product design cycle, greatly reducing the cost of new product development And risk, for the smaller size, shaped products are particularly applicable.

2, CAD / CAM technology integration Design and manufacture of integration has been a difficult point, computer-aided process (CAPP) at this stage because it can not and CAD, CAM completely seamless docking, which is restricting the manufacturing information And rapid prototyping technology integrated CAD, CAM, laser technology, numerical control technology, chemical engineering, material engineering and many other technologies, making the concept of design and manufacturing integration to achieve a perfect one.

3, complete reproduction of three-dimensional data through rapid prototyping and manufacturing of complete parts, complete true reproduction of three-dimensional modeling, regardless of the outer surface of the contour or the cavity of the shaped hole, can be true and accurate completion of modeling, basically no longer need to help External devices to repair.

4, a wide range of molding materials So far, all kinds of RP equipment used in a variety of materials, resin, nylon, plastic, paraffin, paper and metal or ceramic powder, basically meet the vast majority of products on the material Mechanical performance requirements.

5, to create significant economic benefits Compared with the traditional mechanical processing, development costs to save more than 10 times, the same rapid prototyping technology to shorten the enterprise product development cycle, so that in the new product development process of repeated revisions to the design of the program greatly Reduce, and basically eliminate the problem of modifying the mold, to create economic benefits is obvious.

6, the application of industry-wide RP technology After years of development, technically has basically formed a system, the same can be applied to the industry has gradually expanded, from product design to mold design and manufacturing, materials engineering, medical research, Culture and art, construction, etc. are gradually using the RP technology, making RP technology has broad prospects.

Direction of development

From the current RP technology research and application status, rapid prototyping technology for further research and development work mainly in the following areas:

(1) the development of good performance rapid prototyping materials, such as low cost, easy to shape, small deformation, high strength, durable and pollution-free forming material.

(2) to improve the processing speed RP system and open up the manufacturing process of parallel methods.

(3) to improve the reliability of the rapid prototyping system to improve its productivity and the ability to produce large pieces of equipment to optimize the structure, especially to improve the accuracy of forming parts, surface quality, mechanical and physical properties, for further mold processing and functional experiments provide the basis .

 (4) the development of rapid prototyping of high-performance RPM software. Improve the speed and accuracy of data processing, research and development using CAD raw data direct slicing method to reduce the STL format conversion and slicing process generated by the loss of accuracy.

(5) the development of new forming energy.

6) rapid prototyping method and process improvement and innovation. Direct metal forming technology will become the future research and application of another hot spot.

(7) rapid prototyping technology and CAD, CAE, RT, CAPP, CAM and high precision automatic measurement, reverse engineering integration research.

(8) to improve network services research efforts to achieve remote control.

transparent plastic products in medical application

As the plastic has a lightweight, good toughness, easy molding. Low cost, so in modern and daily products, more and more use of plastic instead of glass, especially for optical instruments and medical aspects, the development is particularly rapid. However, due to the requirements of its transparency is better, high wear resistance, impact toughness is better, so the composition of the plastic, the entire process of injection molding equipment. Mold, etc., have to make a lot of work to ensure that the plastic used to replace the glass, the surface quality is good, to achieve the requirements.

Transparent plastic must first have a high degree of transparency, followed by a certain degree of strength and wear resistance, to impact, heat resistance is better, chemical resistance is excellent, water absorption is small, only to use, to meet the transparency requirements and long-term deformation

This is the main properties of plastic products

Injection molding process characteristics of three kinds of commonly used transparent plastics

1, PMMA

The viscosity of PMMA is large, the fluidity is little, so it must be high temperature and high injection pressure. The injection pressure is helpful to improve the shrinkage of the product.

The injection temperature range is wide, the melting temperature is 160 DEG C, the decomposition temperature is up to 270 DEG C, so the material temperature adjustment range is wide, and the process is better. Therefore, improve liquidity, from the injection temperature.

2, PC

PC viscosity, melting temperature is high, poor liquidity must be at higher temperature injection (270~320 DEG C), relatively speaking, the temperature range is narrow, the process is not as good as PMMA.

Injection pressure has little effect on the fluidity, but because of the high viscosity, the injection pressure is still larger. To prevent internal stress, the holding time should be as short as possible.

High shrinkage rate, stable size, but the product of large internal stress, easy to crack, so should be used instead of increasing the temperature pressure to improve the liquidity, and by increasing the mold temperature, improve the mold structure and postprocessing to reduce the possible cracking.

3, PET

PET molding temperature is high, the material temperature adjustment range is narrow (260 - 300 DEG C), but after melting, the fluidity is good, therefore the craft is poor, and often in the nozzle to be added to prevent the flow device.

The mechanical strength and performance of the injection is not high, must be through the stretching process and modification to improve performance.

The accurate control of mold temperature is an important factor to prevent warpage.

At the same time transparent plastic products, easy to produce blooming

Blister Mold material selection

1, the choice of blister c mold

Blister mold generally have plaster mold, copper mold and aluminum mold

Gypsum mold: plaster molding in the semi-wet state, and then drying mold, plaster mold low cost, easy to modify, but the plaster mold precision is not high enough, the surface is not smooth and fragile is not durable, so it is often used to fight To do the electroplating of copper mold or some of the requirements of small-batch production of plastic mold.

Aluminum mold: with aluminum ingots through the machinery (lathes, milling machines, CNC, etc.) from processing.

Aluminum mold high precision, smooth surface and durable, but the price is very expensive, aluminum mold is generally used in high precision copper mold not reach the blister products.

Electroplated copper mold: Plaster mold made of samples, the plating layer of copper shell is the electroplating copper mold, the cost of relatively high plaster mold, but much cheaper than aluminum mold, because of its smooth and durable surface, low cost, electroplating Copper mold is the most commonly used a plastic mold.

2， the choice of plastic material

Blister packaging products include: bubble shells, trays, plastic boxes, as well as: vacuum cover, blister, and so on.

Blister products are only plastic sheet material, film thickness is generally not more than 1.5MM, commonly used sheet: PVC, PET, PP, PS and on this basis, flocking sheet, gold-plated sheet and anti-static sheet .

PVC: the most commonly used plastic material, soft, toughness, good plasticity, can be made transparent and a variety of colors, commonly used transparent PVC packaging electronics, cosmetics, toys, gifts and other products.

PET (A-PET): hard, good toughness, high strength, bright surface, environmentally friendly non-toxic, transparent and a variety of colors of the sheet. Disadvantages of PET high-frequency heat more difficult, the price is much more expensive than PVC, this material is often required to replace high-end and environmentally friendly products, PVC

PS: small density (light), environmental non-toxic, plasticity is very good, toughness is not easy to brittle, can not be made of transparent material, it can only be made at the end of care plastic, because of its easy to crack,

PP: material is particularly soft, tough, environmentally friendly non-toxic, high temperature, often made of food containers or other high temperature packaging products; but its poor plasticity, processing difficulties, poor surface gloss, and the processing of color change shallow.

PET-G: physical properties with the A-PET almost, but high-frequency heat, the price is more expensive than A-PET 80%

3, The determinants of price of plastic products

Blister = unit material cost of materials + energy + labor + transport + profits

Energy consumption: Blister is through the thermal processing, power consumption relative to other industries larger, roughly for the material cost of 8%

Artificial: Blister mainly by machine production, less artificial, roughly 10% of the cost of materials,

Transportation: According to the customer from the factory and distance,

Profit: Plastic factory net profit is generally low, 12% -20%, depending on the payment period, 30 days checkout is 14%

Material cost: The material cost of the product is relatively complicated. Before the calculation, the following data should be clarified:

Raw material price: according to the use of the product, to determine what kind of material and grade of material, to find the lowest price of this material suppliers

Film Thickness: Extending The product must be made of thick film, according to the shape of the thickness and shape of the various parts of the

The number of typesetting: according to the size and shape of the product, the number of molds can be calculated in a version, the density will reduce the quality of products, thinning will increase the material loss, so that the cost of material loss rate: the main factor is the product shape, The number and size of the chassis fit with the degree of plastic, the shape of the more Founder, the greater the output, the smaller the loss rate

In addition to blister mold, we are also good at injection mould  and injection molding.