In the modern manufacturing industry, die-casting technology has become one of the important methods for the production of complex structural parts with its high efficiency, high precision and excellent surface quality. Because of the design characteristics of complex structural parts, higher requirements are put forward for the selection of die casting machines. Let’s discuss the selection strategy of complex structural die casting machines, which can help engineers and manufacturers make the best choice in different application scenarios.

Die casting machine types and characteristics

1、 the basic type of die casting machine

Hot chamber die casting machine: The press chamber of the hot chamber die casting machine is immersed in the liquid metal in the heat preservation crucible, and the injection mechanism is installed above the heat preservation crucible. Its structure is simple, easy to operate, easy to realize automatic production. Hot chamber die casting machine does not need pouring procedure, simple process, high production efficiency; The metal liquid is always in the closed channel, the oxidizing inclusions are not easy to get involved, the metal liquid entering the cavity is clean, and the casting quality is good. However, the injection ratio of hot chamber die casting machine is small, there is no pressurization section in the injection process, and the hot work parts such as pressure chamber, punch, gooseneck tube and nozzle have short life and are not convenient to replace. It is usually used for the production of zinc, tin, lead and other low melting point alloys and small, thin-walled magnesium alloy die-casting parts, and the mold closing force is generally less than 160T (1.6MN).

Cold chamber die casting machine: The press chamber of the cold chamber die casting machine is separate from the heat preservation furnace, and the metal liquid is taken out of the heat preservation furnace and injected into the pressure chamber for die casting. According to the position of the pressure chamber and the injection mechanism, the cold chamber die casting machine is divided into horizontal and vertical two kinds.

Horizontal cold chamber die casting machine: the pressure chamber and injection position are in a horizontal position. Horizontal cold chamber die casting machine has comprehensive specifications and models, wide range of product size and alloy types, simple production operation, high production efficiency, automatic production can be realized online with automatic peripheral equipment, and it is easy to realize the segmented control and adjustment of injection stroke. However, the heat loss of liquid metal during the injection process is large, and it is easy to get involved in oxidizing inclusions and air. Special technological measures should be taken for products with high density or requiring heat treatment.

Vertical cold chamber die casting machine: the press chamber and injection position are in a vertical position. The metal hydraulic injection process of the vertical cold chamber die casting machine involves less gas, which is convenient for the setting of the central pouring system, but the maintenance and operation are troublesome, and the production efficiency is relatively low. It is mainly used for the die-casting production of special products such as motor rotors. With the improvement of injection performance of horizontal cold chamber die casting machine, in order to improve production efficiency, more and more micromotor rotors have been produced by horizontal cold chamber die casting machine.

2、 the main parameters and selection basis of the die-casting machine

Locking force: The locking force is one of the most important parameters of the die casting machine, which must be greater than the expansion force generated by the product during die casting and reserve the safety factor. The clamping force is generally calculated by multiplying the projected area of the part of the die that bears the metal pressure by the specific pressure of the die casting. In the actual production situation, it is also necessary to consider whether the special position of the parting surface, the size of the slide core-pulling projection area, and the deviation between the center of the injection force and the center of the equipment.

Injection performance: For some large and high-performance products, it is necessary to analyze the characteristics of the injection system P-Q diagram to determine whether the mold gate area matches the injection capacity of the die casting machine. When the energy of the injection system is satisfied, the injection system is required to have good low-speed performance, acceleration performance and pressurization performance for dense and pressure-resistant castings. For products with thin walls or high appearance requirements, the injection system is required to have good high-speed and acceleration performance.

Other parameters: including mold thickness, mold opening stroke, guide post inner distance, ejection distance, etc., these parameters need to be confirmed according to the mold plan of the specific product.

Selection strategy of die casting machine for complex structural parts

1、analyze product characteristics and requirements

Structural complexity: Assess the complexity of the product structure, including whether it has deep holes, thin walls, complex internal channels or external shapes. These features will have a direct impact on the required die casting technology and model selection.

Material selection: Different materials (such as aluminum alloy, zinc alloy, magnesium alloy, etc.) have different physical and chemical properties, which affect the flow, cooling rate and shrinkage rate during the die casting process. Therefore, material selection is one of the key factors in determining the selection of die casting machine.

Precision requirements: Complex structural parts often have higher requirements for dimensional accuracy and surface quality. High precision requirements may require more advanced die casting machines and more precise control systems to meet.

Production demand: According to the size of the production batch, choose the appropriate die casting machine model and production efficiency. High-volume production may require die-casting machines that automate continuous production, while low-volume production may focus more on flexibility and rapid mold change capabilities.

2、evaluate the performance and parameters of the die casting machine

Clamping force: Ensure that the clamping force of the selected die casting machine is sufficient to overcome the expansion force generated by the product in the die casting process, and reserve a certain safety factor. Insufficient clamping force may lead to instability of flying material or casting size.

Injection system: The performance of the injection system directly affects the filling speed and efficiency of the liquid metal. For complex structures, it is necessary to ensure that the injection system can provide sufficient pressure and flow to meet the needs of rapid filling and precise control.

Temperature control: Accurate temperature control is essential to ensure casting quality and stability. Evaluate the temperature control system of the die casting machine, including heating power, temperature control accuracy and stability.

Degree of automation: A highly automated die-casting machine can increase production efficiency, reduce labor costs and reduce human error. Consider whether you need automated functions such as robot automatic fetching, spraying, cutting, etc.

3、 Consider costs and benefits

Equipment cost: Different types and specifications of die casting machine prices vary greatly. According to the budget and economic benefit analysis of the enterprise, choose the cost-effective die-casting machine.

Operating costs: including energy consumption, maintenance costs, mold costs, etc. Evaluate the energy efficiency and durability of die casting machines and select equipment with lower operating costs.

Return on investment period: Estimate the return on investment period by considering factors such as equipment cost, operating cost, expected output and market demand. Preferentially choose die casting machine with short investment return period and good economic benefit.

 4、Market research and supplier evaluation

Market research: Understand the current technical level, development trend and mainstream brands of die casting machines in the market. Get the latest information by attending exhibitions and reading industry reports.

Supplier evaluation: Select die casting machine suppliers with good reputation and service track record. Inspect the supplier’s technical strength, after-sales service, customer feedback, etc., to ensure that the equipment can get timely technical support and maintenance services during use.

Conclusion and suggestion

When choosing a die casting machine for complex structural parts, factors such as product characteristics, die casting machine performance, cost effectiveness and market demand should be considered comprehensively. Through in-depth market research and supplier evaluation, choose the die-casting machine models and specifications that best suit your needs. At the same time, pay attention to the installation and commissioning of equipment, personnel training and maintenance work to ensure that the die-casting machine can run stably for a long time, and bring the greatest economic benefits to the enterprise.