Development of China's die-casting molds has gone through several stages of growth. The first stage is that everyone feels state of crossing river by stone. This is road that rise of every industry is bound to take.
The second stage is driven by development of theoretical knowledge system of older generation of experts represented by Chen Jincheng and Gu Jinsheng. They went abroad to study and exchange, introduced foreign advanced die casting technology into China, which made great contributions to theoretical knowledge system of die-casting and mold in China. Many books published in the 1980s now seem to be very valuable. Many books do not tell you specific knowledge, but a way for you to learn the best people to do things. This is also another person. Mr. Liu Guangfu is now 80 years old. He went to United States to study the most advanced mold technology, especially application of pouring system. Liu is one of the most knowledgeable experts in domestic practice knowledge. He recently compiled knowledge he had learned in his life into a book <<Design Practice of Die Casting Sprue System>>. From perspective of practice, content must be very grounded, combination of theory and practice is the most precious.
The third stage should be high-speed development stage of private die-casting and mold enterprises. Some advanced foreign replica mold developments have brought great improvement to China's die-casting mold technology, but final management and technological breakthroughs are still step by step by itself, no advanced innovation is based on imitation. For a while, trial mold of large mold is a bit of luck. If you can successfully test sample for the first time, it will be basically successful. It takes a lot of effort to design a large mold. You must consider all aspects. A bias of inverted hole will lead to failure of trail mold. This failure is the most stupid behavior, it will bring a serious blow and can not bring atmosphere of discussion to the whole team, leaving a sense of failure.
Nowadays, proportion of mold manufacturing costs is getting higher and higher. High price will inevitably lead to a substantial increase in wages. Increase in customer requirements does not increase price of molds. Therefore, it is necessary to achieve a trial success from perspective of finance, management and technology. From a technical point of view: behind success of a trial success, there must be a large amount of data accumulation, standards, strict design process and an efficient team with core values. From a management perspective: a successful mold trial reflects determination of core management team, which can greatly reduce workload of mold repair, put more energy into manufacture of new molds, reduce internal friction between departments, making the whole company closer. It is normal for some mold enterprises to test 7-8 times of complicated molds. Therefore, cost of repairing many molds will account for 20%-30% of contract cost. From perspective of finance, if you can achieve a successful trial, profits of company will be greatly improved.
Then how to achieve a successful mold trial, you must have the ability to decompose a complex system. First, impetuous heart of the entire manufacturing industry is getting more and more serious. Second, because scope of work usually limits difficulty of comprehensively thinking about problems. I share a mind map that I have already applied, hope to provide some ideas to those who are interested.

To do a complicated thing, the most important condition is never from dominance of technology. First of all, establishment of the whole system is the most crucial. Determination of management has made establishment of the whole system have core soul, management's determination and promotion from top to bottom let the whole mold enterprises understand that establishment of this system is not as simple as a performance appraisal in the past. It will be a strategic move of company. All members must treat operation of the whole system with core business until repeated and continuous improvement. Establishment of processes and standards is complementary. Process is to teach everyone how to go down. Standard is to prevent process from drifting away. It must be step by step according to standard steps.

 

System is not technology-oriented, but technology is basis of the entire system, no technical support management will enter chaotic internal friction. The first point is input stage. It is the most important prerequisite to get a product that is compatible with die casting. This preliminary work will affect the whole life cycle of entire project, so we must stand on customer's side and make reasonable suggestions on technical requirements, dimensions, wall thickness and slope of 2D and 3D drawings without affecting structure and function of products. As far as current state of industry is concerned, it is generally technical level of one person is assessed by level of pouring system technology. In a system, if you are too biased towards one problem, then other problems will be ignored more or less. However, operation of the whole system is not maintained by one point. System works together by many points. Charm of gating system has its unique features. It has strong theoretical data support and professional software support for CAE simulation analysis. It can be studied alone in a small room. All data calculations and flow analysis are demonstrated at that moment, which is a perfect combination of theory and practice. Area of runner is the most popular in all the research. In fact, Chen Jincheng's die-casting gate technology and its development--PQ~2 maps are very clear. Flow area can be obtained by flowmeter algorithm. According to calculation method, the two factors related to flow rate are speed and time. In a reasonable speed range, it can calculate time without surface defects when casting is filled. Then inner gate area is basically reasonable. Description of speed and time can be found in any of die casting manuals. Problem of gate scouring is the most troublesome in trial, and often can not find a solution, even if speed and cross-sectional area are adjusted a lot, fundamental problem of scouring is problem of gate flow distribution, and lack of temperature control, so theoretical basis of flow channel must be thoroughly studied. When there is a problem, we can find a solution. Problem of slag pack exhaust may be relatively simple, but I still put forward my suggestion: Treat slag pack with attitude of treating flow channel. Normally, I will double time to consider arrangement of slag pack exhaust.

 

There is a wonderful heat balance system in human body. When you exercise, you will find that your belly will be cold. Importance of cooling is everywhere. Cooling water is like blood in the human body. Point where water is pressed is controllable. Auto parts are the most common parts of domestic die-casting, and auto parts have strict requirements on internal quality. How to solve problem of shrinkage holes inside die-casting has always been core topic. Die casting is game of temperature. Most of parts shrinkage holes, especially complex position, can not be solved by increasing speed. In many cases, the faster speed, the higher proportion of air shrinkage holes, heat tolerance in some places is limited. When you fill with high speed, temperature rise exceeds tolerance of material itself, and shrinkage cavity is inevitable. At this time, function of cooling system can be well reflected. If you can use cooling system well, internal quality changes of die-cast parts will surprise you. It takes a lot of effort to completely solve internal air shrinkage hole problem when the first trial mold is successful. Design of cooling water requires long-term calculation and subjective certification. Advancement of mold temperature control system and transformation of temperature control ideas of die-casting personnel are the most significant advances in China's die-casting molds.

 

Mold structure is quite similar to a person's skeleton. Strength of skeleton is the most reliable guarantee for stability of die-casting production. First trial is the most direct test of mold structure, because many die casting manufacturer don't care about your mold for the first time. If there is a problem with mold structure, it will be exposed soon: running aluminum, slider retreat, mold misalignment deformation is the most common structural problem. Therefore, in order to achieve a successful test, reliability of mold structure is very important. Small problem of casting system can be optimized, mold structure can't be changed many times, or it takes a lot of energy to make up.

 

Although problem of die-casting machine installation is the simplest part, it is also the most easily overlooked part. How to establish a standard inspection process is an effective means to suppress installation errors. Finally, die casting process, die casting process is the last control point of a successful die casting process. Die casting process decomposes it. You will find that there is no particularly esoteric thing behind it. Starting from the most raw aluminum liquid starting, standard operation of aluminum liquid is a bit of a quality-conscious enterprise. Speed, pressure, travel, time and other factors can be calculated. With basic data and then using scientific method to verify in this range, it is easier to get optimal set of parameters, but the person who is good at summarizing is more time-saving. As for temperature control, heat balance system in early stage has already been prepared. What we need to do is to adjust temperature control instrument. After all pre-conditions are met, you will find that it is most difficult to perform step-by-step implementation of pre-programmed test procedure. Because process setting is not done by you alone, you need to communicate and collaborate with trial mold personnel. Now that we should return to original point, we will find out how important construction team is. It is the most sensible choice to include mold tester and die casting manager in the team.

Some people may ask, is it difficult to test die casting mold once? Let us ask another question. Is it difficult to launch a rocket successfully? Everyone has common sense on this issue. Difficulty of rocket launch is far greater than that of die-casting. Success rate of China Long March rocket is 96%. Aside from cost input behind discussion, we look at success data, indicating that hard things can achieve desired goals through scientific management and decomposition.
At present, competition of die-casting and die casting manufacturer is fierce. Under background of overcapacity and falling gross profit margin, what can managers do for company. I think for die casting manufacturer, success rate of mold is the best answer.