Study of Octagonal Exhaust Plates in Die-Casting Molds

hardware die casting parts 6

 Die casting is a method in which molten metal is filled into the mold cavity under high temperature and pressure and solidified under high pressure. Die casting mold is used to form the casting in pressure casting molding. The die-casting mold includes the mold stator and the mold movable mold. After the mold movable mold and the mold stator are closed, the mold gate, mold cavity, and mold overflow groove are formed between the mold stator and the mold movable mold, and the mold stator also has a pressure chamber. In the process of molten alloy (molten aluminum alloy, magnesium alloy, zinc alloy, etc.) filling the die-casting mold cavity, there are other gases, such as ordinary air and gas, generated by the volatilization of the release agent in the mold cavity. These gases will affect the quality of die-casting product molding if they cannot be discharged from the cavity.

To overcome the above problem, the exhaust plate is often connected to the end of the mold overflow groove, or the exhaust groove is directly opened on the mold-fixed die and mold-moving die. When the high-temperature molten metal enters the exhaust slot with a small thickness, the exhaust plate will absorb the heat of the molten metal for heat exchange. As the depth of the molten metal into the exhaust slot increases, the molten metal will slowly cool down.

Therefore, the exhaust slot is not only used for exhaust but also needs to form a certain obstacle to the flow of molten metal, so the thickness of the exhaust slot needs to meet the manufacturing standards.

Die-casting mold exhaust parts analysis of the current situation

  There are two kinds of traditional exhaust plates, and the shape of the exhaust groove in the cross-section of these two exhaust plates is “one” type and “semi-circle” type. But because the cross-sectional area of the traditional exhaust slot is relatively small, it can not be good to discharge the gas, resulting in the quality of die-casting products is not guaranteed, greatly reducing the product qualification rate.

In response to the defects in the prior art, this paper provides a figure of eight exhaust members for die-casting molds to increase the cross-sectional area of the exhaust slot, which can improve the exhaust volume, die-casting product quality, and yield rate.

The design of the octagonal exhaust plate

 The figure-eight exhaust plate of the die casting mold is equipped with multiple curved grooves on the inner side of the moving die exhaust plate, and the fixed die exhaust plate, and each groove extends from the air inlet end to the exhaust end; the inner side of the other one is equipped with a convex strip that fits the said grooves, and an exhaust slot is formed between the side of each groove and the side of the corresponding strip for exhaust, as shown in Figure 1.

      Both the fixed die exhaust plate and the movable die exhaust plate are rectangular, and three curved grooves are provided on the inner side of the fixed die exhaust plate along the long direction of the fixed die exhaust plate, and the grooves are parallel to each other. The curved grooves improve the path of the exhaust gas tank along the long direction of the exhaust plate and extend the cooling path of the molten metal, which is suitable for most die-casting. Each groove extends from the inlet end of the fixed die exhaust plate to the exhaust end, where each groove extends through an inlet hole to the inlet end of the dynamic fixed die exhaust plate. The inlet holes connect the grooves to the mold overflow grooves, allowing the molten metal to enter the exhaust grooves smoothly.

The inner side of the moving die exhaust plate has tabs that fit into the grooves, and there are three tabs. By inserting the tabs of the moving die exhaust plate into the grooves of the fixed die exhaust plate, the fixed die exhaust plate and the moving die exhaust plate are combined, and an exhaust slot is formed between the side of each groove and the side of the corresponding tabs for exhaust. The “eight” shape here refers to the shape formed by the sides of the cross-section of the tabs. The cross-section of the groove is designed into an “eight” type or improves the area of the exhaust groove within the width of the unit so that the ventilation volume of the exhaust groove can reach a larger value within the allowed range and improve the ventilation rate, which is conducive to the discharge of gas from the mold cavity during the die-casting process, and improve the quality of die-casting products.

Characteristic analysis of octagonal exhaust plate

 1) The distance D between the side of each groove and the side of the corresponding tab is 0.1-2.5mm. The distance between the side of the groove and the side of the corresponding tab is the thickness of the venting groove, and the thickness is controlled between 0.1-2.5mm, which is in line with the manufacturing standard of the venting plate. The resistance to the molten metal at this thickness is moderate so that the cooling speed of the molten metal is not too fast and too slow so that the air in the mold cavity can be discharged from the mold to the maximum extent and the molten alloy is not splashed to the outside of the mold through the exhaust slot, which is conducive to the molding of the die-casting products.

 2) The cross-section of each of the above-mentioned convex bars is “eight,” the angle α between the two sides of each “eight” is 0°-160°, and the maximum distance d between the two sides is 5. The cross-sectional design of the bar is “eight” shaped to increase the area of the exhaust slot per unit cross-sectional area. The bar’s cross-section is designed in the shape of “eight” to increase the area of the venting groove per unit cross-sectional area so that the venting volume of the venting groove can reach a larger value within the allowed range and improve the venting rate.

3) Each groove is extended to the air inlet end of the fixed die exhaust plate or the moving die exhaust plate through an air inlet hole. The air inlet hole connects the grooves to the mold overflow groove so that the molten metal can enter the exhaust groove smoothly.

4) Said grooves are parallel to each other.

5) The top of each said tab is in seamless contact with the bottom of the corresponding groove, and the top of the bulge formed between each adjacent two grooves is in seamless contact with the bottom between the corresponding two tabs. Different mold structures have corresponding requirements on whether adjacent exhaust slots are connected, and such structure is to block the exhaust slots on both sides of the tabs and the exhaust slots on both sides of the grooves to suit the corresponding mold structure requirements.

6) The top of each said projection is provided with a gap with the bottom of the corresponding groove. The top of the projection formed between each adjacent two grooves is provided with a gap with the bottom between the corresponding two projections. This structure connects the exhaust slots on both sides of the tabs and the exhaust slots on both sides of the grooves.

Conclusion

The octagonal mold exhaust plate contains the movable mold air plate and the fixed mold exhaust plate, extending the cooling path of molten metal and making this product suitable for most die casting. In addition, the design of multiple grooves and corresponding tabs optimizes the structure of the exhaust plate. It improves the cross-sectional area of the exhaust grooves, which is conducive to the discharge of gas from the mold cavity outside the mold during the die-casting process and helps to improve the quality of the die-casting product and increase the adjustable range of the die-casting molding process space and improve the yield rate of the die casting product.

The octagonal exhaust plate of the die casting mold is suitable for different kinds of molten metal and adapted to different die-casting mold structures.

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