Working pressure forging, commonly known as aluminum die casting, is a forging method in which molten aluminum alloy liquid is poured into a pressure room to fill the concave mold of steel abrasive tools at a high speed, and the aluminum alloy liquid is condensed under working pressure to produce castings. . The main features of aluminum die casting different from other forging methods are high pressure and high speed.

Two forms of aluminum die casting

• The metal material liquid is filled with the die under the working pressure, and the crystals condense under the higher working pressure. The general working pressure is 15-100MPa.

• The metal material liquid fills the die at a high speed, generally 10-50 m/s, and some can exceed 80 m/s. Therefore, the filling time of the metal material liquid is very short, and the concave mold can be filled in about 0.01-0.2 seconds (depending on the size of the casting).

Aluminum die-casting is a high-precision forging method. The standard tolerance of the castings made of aluminum die-casting is very small, and the surface precision is very high. In most cases, the castings can be installed without milling and processing. Using, parts with external threads can also be cast immediately. From general digital camera parts, printing parts, electronic computing devices and decorations and other small parts, as well as the complicated parts of cars, electric locomotives, airports and other means of transportation, most of them are produced using the aluminum die-casting method.

How die casting designs its structure

The overall design of the casting is a step in the aluminum die-casting work. The rationalization of the design plan and the adaptability of the processing technology may jeopardize the smooth development of the next step, such as the difficulty factor of mold design and manufacturing, the accuracy of castings, and the types of defects, etc., are based on the quality of the casting itself's technological performance as a prerequisite. In order to avoid the quality defects of the castings from the source, and to continuously produce the castings at a low cost rate, the structure of the castings must be suitable for the casting process. The overall design of the casting is to make the structure and appearance of the casting meet the various requirements of the casting process and die casting as much as possible under the premise of considering its processing technology.

Process performance of casting construction:

• As far as possible, remove the inner side concave of the casting to make the mold design simple.
• Make the wall thickness of the castings as uniform as possible, and use ribs to reduce the wall thickness to prevent the castings from causing defects such as blow holes, shrinkage porosity, and deformation.
• Try to remove deep holes and deep cavities on castings. Because the small, medium and small cores are easy to bend and break. Inadequate filling and venting in deep cavities.
• The casting of the design plan should be conducive to mold release and core pulling.

Aluminum die casting is a unique forging method. Compared with other forging methods, its basic feature is that the shape memory alloy is filled and filled with the abrasive tool at a high speed and high pressure. The surging caused by the mold and the rapid cooling of the metal material and the damage to the abrasive tool caused by the high productivity make the castings unavoidable and cause many shortcomings. However, some disadvantages are not easy to damage the characteristics of the casting, so it is not easy to cause the casting waste, and some other defects will damage the characteristics of the casting and become scrap.

Conclusion

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