Details

Die Casting Mold Manufacturing Service:
Introduce:
Die casting is a manufacturing process for producing accurately dimensioned, sharply defined, smooth or textured-surface metal parts. It is accomplished by forcing molten metal under high pressure into reusable metal dies. The process is often described as the shortest distance between raw material and finished product. A high-quality die casting mold is an extremely important part of both the zinc and aluminum die casting process.
Why choose us:
R&D Team:
With over many years of experience in the design and manufacture of die casting mold, Lancor mold team has accumulated many experience in alloy die casting mould manufacturing, die casting mould, metal die casting mould, investment casting mould, gravity die casting mould, and Lancor has very strong R& D ability and has successively developed a batch of difficult and advanced level die casting mould, and has successfully presented a wide variety of cold-chamber / hot-chamber die casting mold such as auto mould, LED lamp mould, electric tool mould, sanitary ware mould, moto mould, communication equipment mould, kitchen parts mould, Zinc alloy parts mould and other aluminum casting mould with a well-equipped facility, employing current computer technologies and CAD/CAM techniques. The majority of our manufacturing is accomplished through the use of CNC machining centers.

Unlike competitive supplier, Lancor die casting mold manufacturing feature our dedicated R&D team, who are always not only developing new technologies in die casting, but also ready to respond to customers' questions regarding the correct applications of die casting products and production issues and employ advanced control systems. These extraordinary features allow Lancor molding product to fully exhibit precision performance.

Lancor understands that communication and customer involvement are the keys to quality, Lancor’s strives to provide our customers with the best possible product, in the best possible way, for the best possible price. Consistent perfect mold manufacturing service has made Lancor a recognized professional manufacturer in the aluminum die casting and zinc die casting and injection molding industries by customers worldwide.

Procedure:

Die Casting Mold Manufacturing:

Die casting mold is among the highest volume, mass-produced items manufactured for die casting production, as the high stability of casting quality, the high yield rate, short casting cycle, less labor source input, low production cost or not in mass production, are all greatly depending upon die casting mold. However, the high performance, easy-to-manufacture, long tooling life of die casting mold or not, again depends upon the rationality and creativeness of design scheme, accumulation of lots’ manufacturing experience, rationality of material choice, in-time post maintenance and so on. So the die casting mould is the most technically sophisticated step and with most factors to consider, deserves to arouse enough attention.

Design:

During design, usually limited to part structure, the general sequence of factors to be considered for designing mass production mold are as below:
- Analyze and optimize of part print or casting model
- The determination of optimal parting line and slide surface
- Choice of optimal feed location
- Design of venting and slag discharging and mold flow analysis
- Pairing die casting machine information and production practices of customer
- Analyze and design of ejection mechanism
- Arrangement of temperature control system
- Convenience of disassembly and installation
- The standard of wearing parts and its replacement
- Optimal mold strength design
- Aesthetic appearance
- Ending, less cost on basis of above factor.

Mold Material Inspection

Lancor has very advanced inspection equipment , such as: Al direct reading spectrometer. Tensile tester, X –Ray detector .Hardness testing. To ensure the inspection from Incoming Material to let mold manufacturing to The T1 Sampling.





CNC Milling

CNC, in high-speed milling technology, Computer numerical control machine tools is one of most important processing equipment in modern mold manufacturing, especially in processing die casting mould, as all molding components of die casting mold need quenching treatment, so each component of cavity has to be machined on CNC for twice at least, includes rough machining and fine machining, providing for more accurate parts with superior finishes at a lower cost. Reasonable rough machining or not will greatly affect the uniformity of mold insert in heat treatment, further influence tooling life. The fine machining is the guarantee of precise dimension and good surface finish. So the processing ability of die casting mold greatly depends upon processing ability of CNC.

EDM Electrode

EDM (Electrical Discharge Machining) is especially well-suited for cutting thin ribs and other details that would be difficult to produce with a mill or other cutting tools, works by eroding the material in the path of electrical discharges that form an arc between an electrode tool and the work piece itself. However, we don’t recommend use EDM frequently. Because there will be an electric arc corrosion layer on steel surface after EDM, which needs to be got rid of by hand polishing, or crack will prematurely appear on cavity surface during production, further affect tooling life. However EDM technology, providing faster processing times and superior surface finishes for even the most complex and involved part geometries within parts and assemblies that are too difficult to conventionally machine.

Wire EDM (WEDM)

As a supplement to CNC and EDM, Wire cut Electrical Discharge Machining (WEDM) is the main equipment of processing ejector pin hole, insert pin hole and sub-insert. For the area that is difficult to realize by conventional cutting, or difficult to polish after discharge machining and has difficulty in molding, which can separately machine and precisely cut the mold component, and finally achieved by joining assembly to maintain quality control of our mold components and mold base.

CMM inspection

We carry out fully dimensional inspection for each process of all mold components, referred to incoming inspection, in-process inspection, assembly inspection and tested samples inspection, and covered each process from purchased parts, outsourcing processing parts to completion, as well as mold assembly and tested samples, which are all under strict quality control to ensure all components can meet design requirements. QC department is equipped with all necessary inspection equipments, in the mean time, our inspection engineers have rich experience of mold design and manufacture, which ensure high quality die casting mold made by us.

Mold Polishing

Mold polishing is to eliminate the tool marks and corrosion layer after EDM on working piece, which can make part die mould smoothly, and improve the quality of part surface by increasing the surface finish of mold surface. Fine polishing can improve productivity and cut down the cost of post surface treatment on part.

Before put die casting mold into production, there will be an electric arc corrosion layer on steel surface after EDM, which needs to be got rid of by hand polishing, or crack will prematurely appear on cavity surface during production, further affect tooling life. For some special requirements of part surface or mold structure, we need to make nitriding, titanizing and other coatings on correlative mold components after polishing.

Mold Assembly

Diecasting mold assembly is to inspect the matching precision; the fitting surface of mold has to be uniform and reliable as the ejection force is very large during casting production, or the flashing will be prone to appear during production. Because the working temperature of die casting mold is high and the temperature variation in one casting cycle is very large, too, which make the amplitude of heat expansion and cold contraction fluctuates widely, then there should be rational water line or oil line around cavity to connect to temperature control equipment, which can facilitate precise control and adjustment of temperature. At the meaning time, we need to precisely handle the clearance between moving parts on mold, if the clearance is too small, it will lead to be stuck, if too large, the material slag will come into, so it needs to keep balance to maintain the smoothness and stability of moving parts. Our assembly engineers accumulates rich experience after operating and summarizing for many years, who can ensure good condition of each die casting mold before mass production.

Mold Test

Mold test is put finished mold on corresponding production equipment to proceed with trial production, mainly to inspect molding condition and dimensional accuracy of castings. After inspection and confirmation of mold temperature, material temperature and trial operation of each mold movement, first proceed with low speed trial injection, it can clearly show the metal liquidity through casting surface, which can provide reference for adjustment of die casting parameter, with the mold temperature increases, further inspect the mold assembly clearance and moving condition of each component. After the mold temperature returns to normality, combines with simulant CAE parameter in prophase, then proceed with fast speed trial injection, inspect the molding quality and appearance constantly through optimization of die casting parameter, finally record the corresponding parameter after the optimal condition is achieved. We will record a video of whole mold testing process, and make inspection and judgment of tested samples according to drawing. The testing video, dimensional report will be delivered to customer with samples, to let customer know more about the trial production condition.

After statistics, more than 90% of our produced die casting mold can be directly into mass production after T1 and perform excellently, which help our customers save much time and cost, further gain larger competitive edge. This is primarily because we think highly of prophase design and spend much effort in analysis, discussion and modification to make the design scheme of die casting mold can avoid or prevent potential problem that will happen during mass production.

Die Casting Mold Range:

  - Household Appliance Mold
  - Automotive Mold
  - LED Lamp Mould
  - Electric Tool Mould
  - Sanitary Ware Mould
  - Moto Mold
  - Agricultural Machine Parts Mold
  - Communication Equipment Parts Mold
  - Kitchen Parts Mold
  - Furniture Mold
  - Zinc Alloy Parts Mould

Diesel Engine parts Die Casting