1.1 die-casting process

Die casting process is refers to the use of high pressure effect, the metal liquid quickly added to the die casting mold cavity, the metal liquid cooling condensation casting parts produced after the process way. The die-casting process mainly includes two basic methods: cold chamber die-casting and hot chamber die-casting. In the contemporary industrialized production, die casting process is mainly used for manufacturing all kinds of metal parts, the application of die casting process production process is very little or no need to carry out metal cutting, production and manufacturing work efficiency is high, with significant economic benefits.

1.2 aluminum alloy profile die casting production process

Aluminum alloy profile die casting production process contains die casting machine adjustment, die casting mold assembly, abrasive heating, building coating, mold locking, pouring pressure injection, test pressure, out of the mold, fine grinding, fine casting and other processes (such as figure 1).

1.3 Die casting process principle

Die casting process will environment temperature, working pressure, length, rate and other process elements for flexible use, die casting faster, high efficiency, in parts production industry has relative advantage:

(1) die-casting process can produce complex metal parts; molten metal under the influence of high pressure, can maintain a relatively high degree of mobility, so in the appearance of complex, clear contours, thick-walled deep cavity of the metal parts production process, die-casting process is more widely used than other processing technology.

② die-casting parts of high precision, cost-effective; general die-casting processing precision in IT9-IT13 level, die-casting parts appearance roughness in Ra0.8-3.2um, parts of the organization of high density, hardness and toughness are very high, exchangeability is very good.

③ die-casting process in the material utilization rate is high; because of the high precision of the die-casting parts, the production of only a little mechanical processing manufacturing can start to install the application, and thus the material utilization rate is usually in six to eighty percent, the embryo use rate can even be achieved above ninety percent.

④ die-casting process manufacturing efficiency is high; metal liquid filling speed is faster, shorter time, condensation fast, compression chamber die casting machine one hour die casting in four hundred to one thousand times, cold compression chamber die casting machine one hour die casting in eighty to one hundred times, compared with other production process, die-casting processing process manufacturing efficiency is high, more suitable for mass production.

⑤ Easy to achieve parts part of the unique performance test program; In the die-casting abrasive set up positioning organization, can be embedded casting embedded parts, can be better to achieve the parts of the local special requirements.

All processing technology method is very difficult to achieve the best to the best, die-casting processing technology is no exception:

① out of gas holes and casting defects; liquid metal quickly filled to the concave mold and rapid cooling, this process is very short, the concave mold gas if not quickly discharged, die casting will have out of gas holes or air oxidation inclusions exist, jeopardizing the quality of die casting.

② high cost, not suitable for small batch; die casting production process die casting machine, die casting mold, metal liquid, three elements are indispensable, in which the die casting machine, die casting mold cost is high, is not suitable for carrying out small batch.

③ die casting aluminum alloy type is relatively limited, die casting specifications are restricted; By die casting abrasive application environment temperature limitation, at this stage can be used to carry out die casting operation aluminum alloy mainly includes aluminum alloy profile, zinc alloy material, copper-nickel alloy and die casting aluminum. In addition, by the die-casting machine and die-casting mold specifications, can not carry out large and medium-sized parts of the die-casting.

④ The use period of abrasives is slightly shorter; restricted by technical conditions, cracks, brittle fracture and leaching often occur in the use of die-casting abrasives, which greatly shorten the use period of abrasives.