压铸件 铸铝件

常见压铸模具压铸生产问题及分析(中英对照)

摘要:压铸过程中金属液往外溅(跑铝)产生原因,调整方法;影响压射头(压力喷嘴)使用寿命的因素;缺陷:产品表面起皱,症状,解决方案;压铸工艺参数选择,镶件附近的圆柱状部分,表面的皮...

常见压铸模具生产问题及分析
The common production problem and analysis of die-casting moulds


压铸过程中金属液往外溅(跑铝)产生原因 The cause reason of molten metal splash when die casting.

1. 定模间合模不严密,间隙较大 Cover halves close imprecisely, and have big gap.  
2. 锁模力不够 The mould clamming force is not enough.
3. 压铸机动,定模安装板不平行 The die casting machine is  flexible ,and the mounting plate of cover half(fixed die) is not parallel.
4. 支板跨度大,压射力致使套板变形,产生喷料。Support span(跨度) is large, and the injection pressure(force) bring about the cleading(保热套(汽锅的);护罩;护壁板(隧道的))deformation , engendering(使产生;)产生molten metal spouting(喷射) .

调整方法 method of adjustment
1.重新安装模具 reinstall the mould
2.加大锁模力 increase the mould clamming force
3.调整压铸机,使动、定模安装板相互保持平行 adjust the die-casting machine, ensure the mounting plate of fixed die(cover half) and  moving die maintain mutual(共同的;相互的,彼此的) parallel。
4.在动模上增加支板,增加套板的刚度。Add support plate on the movable mould , increase the stiffiness(硬、刚度,rigidity,hardness) of the cleading

影响压射头(压力喷嘴)使用寿命的因素,主要因素有:The factors influencing the working life of the pressure nozzle(喷嘴;管口;鼻) jet ,main factors :   

1.压射头(喷嘴)本身的材料、质量;The material and quality of the nozzle jet
2.压射头与压射料筒之间的配合间隙;The fit clearance of the press charging(炉料;装料) barrel and jet nozzle
3.模具安装时与压射料筒的同心度;The concentricity of the mould and press charging barrel while installing
4.冷却问题;cooling problem
5.选用优质压射头润滑油等。Select and use the superior nozzle jet lube(lubrication) etc.

缺陷名:产品表面起皱  Defect name : surface wrinkling of the product

(一)症状:产品表面形成的不规则褶皱,主要出现在壁较薄的前段部分,如所示。

 (1)Symptom: The irregular folds(皱褶;折痕)  emerging  on the surface of product ,mainly appearing the thinner wall ,as show :

可以看到射出的细小铝颗粒和褶皱。Can see the small aluminium granule

原因:由于吸入了脱模剂和压缩空气,被封闭在前段的气压较高,把产品表面顶起而导致这一现象的发生

Reason: owing to indrawing the release agent or compressed air,air preasure being sealed up in the forepart is high then jack up the surface of the product and result in this phenomenon  

解决方案:排气彻底,清除多余的脱模剂。调整高速高压区的位置以防止溶液降温 

solution :exhaust thoroughgoing,eliminate the extra mold lubricant ,adjust the position of the high speed ,high preasure to prevent the melton metal cooling down  


缺陷名defect name :起皱(二)wrinkle(2)

症状:镶件附近的圆柱状部分,表面的皮膜出现起皱现象起皱的表面部分,根据发生状态有差异。

Symptom: the cylinder part around the insert ,the surface membrana demalis appearing crumpling up ,it is different according to the occuring condition

在靠近镶件的拐角处,出现与镶件平行的褶皱。在离拐角稍远处,表面皮膜起皱部分有细小的铝颗粒聚集,呈粉末状附着在表面起皱的断面可以观察到起皱导致的凹凸,细小的铝颗粒被压碎后嵌入褶皱里。
 Near the corner of the insert ,appearing the parellel wrinkle with the insert .a little far away from the corner .the surface membrana demalis can see the aluminium granule gathered ,appearing in power attached to the surface cut can see the concave-convex , the wee aluminium granule inbedding into the wrinkle after crushed

原因:在模具温度低时进行铸造容易b发生此现象。铝液在流道流淌时前锋冷却,形成 氧化皮膜,在距离浇口较远的突起部分凝固,由于压力增大在表面形成褶皱。

Reason: when die casting with the low temperature of the mould is easy to occur this ,the molten aluminum flowing in the passageway the forepart cooled and form oxide membrana demalis ,then occur solidification at the tuber fruther as due to the high pressure appearing wrinkle on the surface .

解决方案:对模具进行预热,在设定的温度条件下进行生产是很重要的,将模具温度设定在适当的范围。

Solution :preheat of the mould and produce under the setted temperature ,should control the temperature of the mold in aopportune scope .

换导柱以及导套时一定要注意尺寸变化,尤其是长时间使用但是没有回火或者测量的模具,一定要检查模具的尺寸,包括模板平行度、孔直线度、孔内外径是否变化。一般情况下基准尺寸会变化。Exchange the guide pillar or guide sleeve should notice the change in the size ,especially the mould that is used for a long time without tempering or measured including the mould plate parallel, straightness ,change of internal and external diameter.Nomaly the reference dimention will exchange .

锌压铸件毛坯看不到麻点,电镀前抛光就出现麻点,这是怎么回事?这是锌压铸件最易出现的问题之一。

Zink die pressed casting blank is no hard spot ,but when polish before electroplating the hard spot occur. What’s up ?

要注意 notice :

1.原材料的质量(纯净度);the quality of the material (degree of purity)
2.熔化时的精炼除气除渣;rifine to degassing and deslagging when melting .
3.压铸时速度、压力 的调整(特别是皮下气孔等缺陷);adjust the speed and pressure when die-casting
4.抛光时摩擦 的压力和温度不要太高。The pressure and temperature of the friction can not be too high .

中国压铸企业主要集中在长三角、珠三角、京津唐、东北重庆西安等西部、东北等地区。

在生产汽车配件一样壳体时抽芯处老是出现凹槽请问下有些什么原因?

1.浇注系统、排溢系统开设问题;gating system ,ejecting system
2.压铸工艺参数选择问题;die-casting technological parameters choosing problem
3.原材料质量等。The material quality problem

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