Dalian precision die-casting: how to achieve one-time molding of complex structural components?

Against the backdrop of increasingly stringent requirements for component complexity and precision in modern manufacturing, precision die-casting technology has become a key process in high-end manufacturing due to its ability to form complex structural components in one go. It breaks through the limitations of traditional multi process and high loss processing, and achieves a leap through three core technologies.

Firstly, mold design is the cornerstone. With the help of CAD/CAM technology and topology optimization algorithms, engineers can decompose complex structures into precision mold cavities, and use electrical discharge machining (EDM) and five axis linkage machining technology to achieve micrometer level precision in molds. For example, the mold for aircraft engine blades ensures even filling of complex surfaces with molten metal through precise layout of cooling channels and exhaust systems, avoiding porosity and shrinkage.

Secondly, precise matching of materials and process parameters is crucial. Die cast alloys need to have both good fluidity and formability, while lightweight alloys such as aluminum alloys and magnesium alloys have become the choice for complex structural components due to their low melting point and fast solidification. Meanwhile, by monitoring the pressure curve, filling speed, and mold temperature in real-time during the die-casting process, the parameters are dynamically adjusted using a closed-loop control system. When die-casting the motor housing of new energy vehicles, a three-stage process of "slow injection pressure building - high-speed filling - pressure boosting and holding" is adopted to ensure that the thin-walled structure and internal flow channel are formed in one go.

 

Intelligent detection and feedback optimization safeguard the quality of molding. After forming, the internal defects of the structural components are analyzed by 3D imaging through CT scanning and industrial CT detection. AI algorithms can quickly locate problems and optimize mold design and process parameters in reverse, forming a closed loop of "design production inspection iteration".

The one-time forming technology of precision die-casting in Dalian not only significantly shortens the manufacturing cycle of complex parts, but also reduces material loss and labor costs, becoming an indispensable manufacturing tool in fields such as aerospace and new energy vehicles.

The above article analyzes the key elements for achieving one-time molding of complex structural components in Dalian precision die-casting. If you wish to add specific cases, data, or adjust the focus of the content, please feel free to let me know at any time.