The production process of zinc alloy die castings mainly includes the following steps:

The production process of zinc alloy die castings mainly includes the following steps:

I. Mold design and manufacturing

Product analysis

Firstly, conduct a detailed analysis of the die casting to be produced, including the shape, size, precision requirements, surface quality requirements of the product. At the same time, factors such as the use environment and mechanical property requirements of the product should also be considered to determine the appropriate zinc alloy material and die casting process parameters.

Mold design

According to the results of product analysis, carry out mold design. Mold design includes the selection of parting surface, the design of gating system, the design of cooling system, the design of ejection mechanism, etc. The quality of mold design directly affects the quality and production efficiency of die castings.

Mold manufacturing

After mold design is completed, carry out mold manufacturing. Mold manufacturing usually adopts advanced processing technologies such as numerical control machining, electric discharge machining, and wire cutting machining to ensure the precision and surface quality of the mold. After mold manufacturing is completed, mold debugging and trial molding are also needed to ensure that the mold can work properly.

II. Raw material preparation

Zinc alloy selection

According to the product requirements, select the appropriate zinc alloy material. There are many kinds of zinc alloy materials. Different zinc alloy materials have different performance characteristics, such as strength, hardness, corrosion resistance, fluidity, etc. When selecting zinc alloy materials, factors such as product use requirements and production costs need to be comprehensively considered.

Raw material inspection

Inspect the purchased zinc alloy raw materials to ensure that the quality of the raw materials meets the requirements. Raw material inspection includes chemical composition analysis, metallographic structure analysis, mechanical property testing, etc.

Raw material melting

Melt the qualified zinc alloy raw materials. Melting is usually carried out in a furnace. Electric heating or gas heating is used to heat the zinc alloy raw materials to a certain temperature to make them melt into a liquid state. During the melting process, certain alloy elements and refining agents need to be added to improve the performance and quality of the zinc alloy.

III. Die casting production

Die casting machine debugging

Before die casting production, the die casting machine needs to be debugged. Debugging includes adjusting parameters such as pressure, speed, and temperature of the die casting machine, as well as installing and debugging the mold. Ensure that the die casting machine and mold can work properly to produce die castings that meet the requirements.

Die casting production

After debugging is completed, carry out die casting production. Inject the molten zinc alloy liquid into the mold. Through the pressure of the die casting machine, the zinc alloy liquid quickly solidifies and forms in the mold to form a die casting. During die casting production, parameters such as the pressure, speed, and temperature of the die casting machine, as well as the working state of the mold's cooling system and ejection mechanism need to be controlled to ensure the quality and production efficiency of die castings.

Casting removal

After die casting is completed, open the mold and take out the die casting. When taking out the die casting, attention should be paid to avoiding damage to the die casting. At the same time, a preliminary inspection of the die casting, such as appearance inspection and dimension measurement, should also be carried out to ensure that the die casting meets the requirements.

IV. Subsequent processing

Deburring

After the die casting is taken out, there are usually some burrs and flashings that need to be deburred. Deburring can be carried out by methods such as manual grinding, mechanical processing, and chemical corrosion to remove burrs and flashings on the surface of the die casting and make the surface of the die casting smooth and flat.

Surface treatment

According to the product requirements, carry out surface treatment on the die casting. There are many methods of surface treatment, such as electroplating, spraying, oxidation, etc. Surface treatment can improve the surface quality and corrosion resistance of die castings, and at the same time give different appearance effects to die castings.

Quality inspection

Conduct quality inspection on the die casting after subsequent processing to ensure that the quality of the die casting meets the requirements. Quality inspection includes appearance inspection, dimension measurement, mechanical property testing, metallographic structure analysis, etc. Die castings that pass quality inspection can be packaged and shipped. Die castings that fail the inspection need to be reworked or scrapped.

In short, the production process of zinc alloy die castings is a complex process. It requires careful design and strict control in multiple links to produce high-quality die castings.