Mold Processing

Die Casting Mold Processing Process

(Applies to automotive/3C/aerospace industries)‌

I. Core Manufacturing Process‌

‌Digital Design Validation‌

· Generate 3D models using AI-optimized CAD software (AutoCAD 2025/Autodesk Fusion).

· Validate runner/cooling systems via digital twin simulations.

‌Material Preparation‌

· Use low-carbon mold steel (emissions ≤1.8kgCO₂/kg).

· Pre-processing heat treatment: Vacuum quenching + low-temperature tempering (hardness HRC 48-52).

‌CNC Machining‌

· ‌Rough Machining‌:

· Mold base cavity cutting (tolerance ±0.1mm).

· High-speed milling (spindle speed ≥20,000rpm).

· ‌Precision Machining‌:

· Mold cavity/runner polishing (Ra ≤0.4μm).

· Ejector pin hole accuracy ±0.02mm (AI real-time tool wear compensation).

‌Specialized Processing‌

· EDM for deep grooves/complex surfaces (electrode wear ≤0.05mm).

· Laser-engraved QR code traceability labels (material batch/version).

‌II. Smart Integration & Inspection

‌A[Machining Completion] --> B{IoT Sensor Installation} --> C[Temperature/Pressure/Vibration Ports] --> D[Assembly & Debugging] --> E[3D-Printed Trial Validation] --> F[Blockchain Data Archiving]

‌Key Inspections‌

· ‌Dimensional Checks‌:

· Full CMM scanning (tolerance ±0.02mm).

· Thermal imaging for cooling channel uniformity (ΔT ≤5°C).

· ‌Functional Tests‌:

· Simulate 500 casting cycles to verify ejection stability (no jamming/deformation).

· AI stress distribution analysis (peak stress ≤80% of material yield strength).

‌III. Sustainability Requirements‌

· ‌Waste Management‌: Real-time scrap sorting (metal scrap recycling rate ≥98%).

· ‌Energy Control‌:

· CNC energy consumption ≤0.8kWh/kg (smart meter data required).

· Priority for green energy (wind/solar power ≥40%).

· ‌Mold Lifespan‌:

· Base lifespan ≥200,000 cycles, upgradeable/reparable ≥3 times.

‌IV. Delivery & Traceability‌

Documentation Package‌:

· Drawings/inspection reports/CAE simulation data (STEP format + blockchain hash values).

· eIDAS 2.0-certified digital signatures (designer/machinist/QA).

‌Physical Markings‌:

· IoT sensors embedded in molds (synced to digital twin platform).

· QR code for carbon footprint tracking (raw material to production).