The wear mechanism of die casting machine template mainly includes mechanical wear, thermal wear and chemical wear. Mechanical wear is caused by the impact and scouring of the template by the molten metal when filling the mold under high pressure and high speed, which leads to the gradual shedding of the template surface material. Thermal wear is caused by the heat exchange between the mold and the molten metal, which causes periodic temperature changes on the mold surface, causing thermal expansion and contraction, thereby generating thermal stress and accelerating the wear of the template. Chemical wear is caused by the chemical reaction between impurities, gases, etc. in the molten metal and the template surface, resulting in corrosion and cracks on the template surface.
Secondly, effective wear monitoring is the key to preventing excessive wear of die casting machine template. In modern industry, commonly used wear monitoring methods include installing sensors and monitoring systems. For example, ultrasonic sensors can monitor the wear of molds by measuring the reflection of sound waves inside or on the surface of the mold, and can detect small changes on the mold surface, such as cracks and depressions. Spectral confocal sensors use the principle that different wavelengths of light have different focal lengths in the lens system to accurately measure the position changes on the mold surface and then evaluate the wear. In addition, temperature sensors and pressure sensors can also be used to monitor the temperature and pressure changes of the mold during operation to warn of possible wear or damage.
In order to prevent the wear of the die casting machine template, it is necessary to start from multiple aspects. First of all, optimizing the die casting process is the key. Through reasonable specific pressure, filling speed and alloy pouring temperature, the impact and scouring of the metal liquid on the template can be reduced, thereby reducing mechanical wear. At the same time, keeping the mold working temperature within a certain range and avoiding sticking and surface damage caused by overheating of the mold temperature are also important measures to prevent thermal wear.
Secondly, the selection of mold materials is also crucial. The die casting machine template should be made of materials with good forgeability, cutting performance, high temperature red hardness, high temperature strength, tempering resistance and impact toughness. These characteristics can ensure that the template maintains stable performance in a high-pressure and high-temperature working environment and reduce the occurrence of wear and cracks.
In addition, regular maintenance and care are also an important part of preventing wear. Including regular cleaning of the mold surface debris to keep the mold surface clean and flat; regular appearance inspection and key dimension measurement of the mold to promptly detect and deal with potential wear problems; and regular heat treatment to eliminate stress inside the template and improve the material's fatigue resistance.
In addition to the above measures, advanced surface treatment technology can also be used to enhance the wear resistance of the template. For example, nitriding and carburizing the template surface can improve the surface hardness and wear resistance; ion implantation, laser cladding and other technologies can form an alloy layer with excellent wear resistance on the template surface.
Finally, establishing a sound mold management system is also an important measure to prevent wear. Including formulating detailed mold use and maintenance procedures, training operators to correctly use and maintain molds; establishing mold files to record mold usage, maintenance records and performance test results, etc., so as to track and evaluate the performance of the mold in real time.
The wear mechanism of die casting machine template involves the interaction of multiple factors, and effective wear monitoring and prevention need to start from optimizing die casting process, selecting suitable mold materials, regular maintenance and care, using advanced surface treatment technology and establishing a sound mold management system.
