In the modern manufacturing industry, die casting technology is widely used in the production of various metal parts because of its high efficiency and precision. However, in order to achieve high quality die casting, the preheating and temperature control of the die are the key links. Let’s discuss the skills of die preheating and temperature control of die casting machine.

1、 The importance of preheating die casting mold

1.1、Purpose of preheating

Prevent thermal stress: Preheating can reduce the thermal stress caused by the temperature difference during the use of the mold, thereby extending the service life of the mold.

Improve fluidity: Preheating the mold can improve the fluidity of liquid metal, so that the metal liquid can better fill all corners of the mold, reduce casting defects.

Reduce mold sticking: Through preheating, the mold surface temperature is higher, which helps to reduce the adhesion between the casting and the mold and reduce the difficulty of stripping.

1.2、 The risk of not warming up

Hot cracking and cracking: The mold without preheating is in direct contact with high temperature metal liquid, which is easy to produce hot cracking and cracking, which seriously affects the life of the mold.

Porosity and cold insulation: too low mold temperature will lead to defects such as porosity and cold insulation in the casting, affecting the internal quality and appearance of the casting.

Unstable production: unpreheated mold will lead to unstable production process, casting size and performance are difficult to control.

2、Mold preheating method

2.1、Gas heating

Principle: Use the heat generated by gas combustion to heat the mold.

Advantages: Fast heating speed, suitable for small and medium-sized molds.

Disadvantages: low precision temperature control, easy to cause local overheating.

2.2、Electric heating

Principle: The mold is heated by resistance wire or electric heating rod.

Advantages: uniform heating, high temperature control accuracy.

Disadvantages: High energy consumption, need to be equipped with power equipment.

2.3、 Oil temperature machine heating

Principle: The use of high temperature thermal oil circulation heating mold.

Advantages: Good heating effect, can eliminate internal and external temperature difference, suitable for large complex mold.

Disadvantages: High equipment cost and complex maintenance.

3、Temperature control skills

3.1、 The use of temperature sensors

Layout: Temperature sensors are arranged in the key parts of the mold to monitor temperature changes in real time.

Calibration: Periodically calibrate the sensor to ensure measurement accuracy.

3.2、 Set the temperature control system

PID control: Proportional integral-differential (PID) control system is adopted to achieve accurate temperature control.

Segmented control: According to the heat load of different parts of the mold, the segmented control strategy is adopted.

3.3、Design of cooling system

Water cooling system: A cooling channel is designed inside the mold to carry away excess heat through the flowing water.

Wind cooling system: The use of fan forced convection, enhance the heat dissipation effect.

4、 Practical application case analysis

4.1、 Case 1: Aluminum alloy die casting mold preheating

Background: An auto parts manufacturing enterprise mainly produces aluminum alloy die casting parts.

Problem: The casting has porosity and sticky mold phenomenon.

Solution: The mold is heated with an oil temperature machine and the coating process is optimized.

Results: The casting quality was significantly improved, and the production efficiency was increased by 15%.

4.2、 Case 2: Temperature control of magnesium alloy die casting mold

Background: An electronics company that produces magnesium alloy casings.

Problem: Cold insulation and cracks appear on the surface of the casting.

Solution: High precision temperature control system was installed and injection parameters were adjusted.

Results: The defect rate of castings was greatly reduced, and the qualified rate of products reached 98%.

4.3、 Case 3: Heat balance of zinc alloy die casting mold

Background: A hardware factory, producing zinc alloy handles.

Problem: Mold temperature fluctuation, casting size is unstable.

Solution: Use gas heating combined with water cooling system and add thermal insulation.

Results: The mold temperature remained stable and the casting size was consistent well.

5、 Future Development Trend

5.1、 Application of intelligent temperature control system

Artificial Intelligence algorithm: Machine learning algorithm is introduced to automatically adjust temperature control parameters based on real-time data.

Remote monitoring: Remote monitoring and maintenance through network connection, improve production efficiency.

5.2、Application of new materials

New coating materials: Research and development of new coating materials with high temperature resistance and corrosion resistance to extend the service life of the mold.

High performance alloy: Develop high performance alloy materials more suitable for die casting process to improve casting quality.

5.3、Application of energy saving and environmental protection technology

Waste heat recovery: The waste heat of the mold is recycled to reduce energy consumption.

Green energy: The use of solar, wind and other renewable energy power supply, reduce carbon emissions.

6、Conclusion

Die preheating and temperature control of die casting machine play an important role in die casting process. Through reasonable preheating method and accurate temperature control technique, the casting quality can be effectively improved, the die life can be extended, and the production cost can be reduced. With the development of science and technology, intelligent and automated temperature control system will become the future development trend, bringing more opportunities and challenges to the die casting industry.