overflow trough
Many people in the design of die-casting molds tend to overlook the overflow groove, thinking it is "redundant" and saving as much as possible, but in reality, they are completely wrong. The overflow groove is equivalent to the "cleaner" of the die-casting mold, mainly used to collect impurities, oxide scales, and gases generated during the filling process in the metal liquid, to prevent these impurities and gases from staying in the mold cavity, causing defects such as pores, slag inclusions, and shrinkage holes in the product.
The key to the design of overflow channels lies in their "position" and "size". The location is not selected correctly, impurities and gases cannot be discharged, which is equivalent to a white design; The size is too small to accommodate impurities and gases, and defects may still occur; The size is too large, which will waste raw materials and increase production costs.
Yurun designs overflow channels that accurately control two key points: firstly, the position is selected at the end of the metal liquid filling, the dead corners of the mold cavity, and places where gas is prone to gather, such as the corners of the parting surface and the thick walled parts of the product, to ensure precise collection of impurities and gases; Secondly, the size is determined based on the product size and the flow rate of the metal liquid. It should be able to accommodate impurities and gases while avoiding waste. At the same time, an exhaust channel should be designed to allow gases to be smoothly discharged from the mold.
And the overflow groove also needs to cooperate with the pouring system and the parting surface: the overflow groove should be close to the end of the gate, so that impurities and gases can be naturally pushed towards the overflow groove during the flow of the metal liquid. At the same time, the position of the overflow groove should be coordinated with the parting surface, which is convenient for subsequent demolding and trimming without additional processes.
cooling system
During the die-casting production process, the metal liquid is in a high-temperature state. After being injected into the mold cavity, it will bring a large amount of heat to the mold. If the mold temperature is too high, it will not only cause unstable product molding and shrinkage deformation, but also accelerate mold wear and aging, shorten the mold life; If the mold temperature is too low and the metal liquid cools too quickly, problems such as material shortage, cold insulation, and surface roughness may occur.
The cooling system is a magical tool for "cooling" the mold. Its core function is to control the temperature of the mold, keeping it within a stable and reasonable range, which can ensure the quality of product molding and extend the life of the mold. Many people design cooling systems and blindly increase the number of cooling water pipes, thinking that the faster the cooling, the better. However, this is not the case. Uneven cooling can cause mold deformation, which in turn affects product dimensional accuracy.
Yurun designs a cooling system that follows the principle of "uniform cooling and precise temperature control". Based on the shape and thickness of the product, the position and quantity of cooling water pipes are reasonably arranged to maintain consistent temperature in various parts of the mold, avoiding local overheating or undercooling. For example, in the thick walled areas of the product, the cooling water pipes should be arranged more densely to accelerate cooling; For thin-walled areas, the cooling water pipes can be sparser to avoid defects caused by rapid cooling.
At the same time, the cooling system also needs to coordinate with three other systems: the layout of the cooling water pipes should not affect the fit of the parting surface, the smoothness of the pouring system, or block the exhaust channel of the overflow groove. It is necessary to achieve uniform cooling without affecting the normal operation of other systems, ensuring stable product molding and longer mold life.