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The Deformation of Die-Casting Parts: In-Depth Analysis of the "Metal Twist Man"
2025-10-31
Die-cast parts have become "metal twisters"? This isn't some special effect, but rather a common deformation defect in die-cast parts. Deformation defects are like an invisible killer, causing warping, shrinkage and distortion in die-cast parts. This not only affects appearance but also affects product quality and performance! Today, we'll delve into the causes of deformation defects and learn how to effectively prevent and resolve them!
Common causes of deformation defects
1. Design structure issues
Wall thickness difference: If the wall thickness difference of the casting is too large, the thick-walled parts and the thin-walled parts will shrink at different rates during the cooling process, which will generate internal stress and cause deformation.
Cross-sectional thickness: The cross-sectional thickness of a casting should be as uniform as possible to avoid significant disparity. Uneven thickness can lead to different cooling rates in different parts, generating internal stress and causing deformation. For example, improperly designed bosses and lugs can increase the risk of uneven thickness in a casting and increase the risk of deformation.
2. Improper process parameters
Mold opening time: Opening the mold too early will make the casting less rigid and prone to deformation during the subsequent cooling process.
Ejector pin setting: Improper ejector pin setting will result in uneven force during ejection, causing deformation of the casting.
Gate setting: Improper gate position or too thick gate can easily cause deformation when the gate is cut.
Mold temperature: If the mold temperature is too high, the casting will not be fully solidified, and the force during ejection will be too large, causing product deformation.
3. Alloy material
The properties of the alloy material itself will also affect the die casting. Factors such as large alloy shrinkage, wide quasi-solidus temperature range, and poor high-temperature strength will increase the possibility of deformation.
Deformation defect improvement measures
Improved casting structure
1. Design reasonable wall thickness
Avoid walls that are too thick or too thin. While ensuring that the casting has sufficient strength and rigidity, try to reduce the wall thickness of the casting and keep the thickness of the cross section uniform.
2 Design reinforcement
For die castings with large flat surfaces or thin walls, the use of reinforcing ribs can effectively prevent shrinkage and fracture of the die castings, eliminate deformation and enhance the strength and rigidity of the die casting parts. It should be noted that the thickness of the root of the reinforcing rib should not be greater than the thickness of the wall at this location.
Adjust process parameters
1. Adjust the mold opening time
Reasonably adjust the mold opening time according to the specific conditions of the casting to avoid premature mold opening, which may cause the casting to be insufficiently rigid and deformed.
2.Optimize the ejector pin settings
Reasonably set the ejection position and number of ejector rods. For example, use 4 ejector rods and set them in an open area to ensure uniform force during ejection and reduce deformation caused by uneven force.
3. Control gate parameters
Adjust the gate position and reduce the gate thickness to ensure the casting quality of the product. This will prevent the product from being deformed when the gate is removed.
4. Control mold temperature
Control the local mold temperature to maintain the mold thermal balance. Avoid excessive mold temperature causing incomplete solidification of the casting and excessive force during ejection causing deformation.
Choosing the right material
1. Choose the right alloy material based on product requirements. Selecting alloys with low shrinkage and good high-temperature strength can effectively reduce the risk of deformation.
2. Optimize alloy composition By adjusting the alloy composition, the properties of the alloy can be improved and the occurrence of deformation defects can be reduced.