Analysis of Influencing Factors of Die-Casting Mould Life
A die casting is a metal mould used in a high pressure moulding process to shape a desired component. Die casting moulds are usually made of either steel or non-ferrous metals, such as aluminium or zinc. The life of a die casting mould is determined by its ability to resist the high heat, pressure, mechanical ability and its wearability. The expected lifespan of a die casting mould can vary between 10,000 to 1,000,000 shots depending on the complexity of the part, particular processes and the material used to make the mould.
Die casting molds are subjected to tremendous stress and fatigue during the production process. Due to this, the key factor that affects the life of a die-casting mould is the design and materials used for the mould. In the design, the selection of materials, the inclinations of surfaces and the shaping of the cooling channels, all of which influence the lifetime and economic efficiency of the mould. In addition, to prevent possible defects caused by dimensional instability, the geometry of the cooling channels should be as consistent as possible, since the thermal load needs to be strongly distributed in order to preserve the dimensional accuracy in the component.
Material selection is also a major factor that influences the die-casting mould life. It is important to select the appropriate grade and type of material (alloy, grade, temper) for the mould that corresponds to the type of casting required. For example, the alloy used should be compatible with both the casting material and the moulds load and thermal conductivity, which should both be taken into account when selecting the appropriate material. In addition, the mould sealing surface should have an appropriate surface texture and hardness to ensure good precision and wear resistance.
One of the most important factors influencing die-casting mould life is the cooling system used. Poor cooling can cause part distortion, mould weakening and component cracking, all of which reduce the life of the mould and the part. Generally, a large number of grooves in the mould form a cooling system that absorbs most of the thermal cycles. In addition, a die casting mold must have effective hot runner systems, which can provide a uniform temperature to the mold surface and keep it in equilibrium.
In addition to the aforementioned factors, the maintenance of a die-casting mould is also an important factor affecting its lifespan. Poor or regular maintenance can lead to wear and tear of the die before its time and render the mould useless. Therefore, it is essential to properly and regularly maintain the die-casting mould, as well as to ensure adequate lubrication and tension in the metal during processing.
In conclusion, the life of a die-casting mould is affected by various factors. In particular, the design and materials chosen for the mould, the cooling systems used, and the maintenance all influence the lifespan of the die. Therefore, when selecting a die for a certain application, these factors should be taken into consideration in order to maximize the mould lifetime and minimize cost.
