In the field of precision shaft die casting processing, shaft parts of different shapes have their own unique process requirements.
First of all, for slender shaft parts, due to their large length-to-diameter ratio, bending and deformation problems are prone to occur during the die casting process. The process requirements focus on ensuring that the liquid metal evenly fills the mold cavity to avoid deformation caused by lateral pressure due to uneven filling. Countermeasures include optimizing the gate position and size, and adopting a reasonable cooling system to make the shaft cool evenly during solidification and reduce thermal stress. At the same time, support structures can be added to the mold design to assist the slender shaft in maintaining its shape during die casting.
For shafts with complex step shapes, the process difficulty lies in the dimensional accuracy control at different steps and the transition connection between the steps. During die casting, it is necessary to accurately calculate the flow speed and pressure of the molten metal at different parts to ensure that each step can be fully formed and the size meets the requirements. For this, it is necessary to use advanced simulation software to simulate the die casting process and optimize the process parameters. In addition, in mold manufacturing, the processing accuracy is improved to ensure the surface quality and dimensional accuracy of each step part of the mold cavity.
The key to the process of hollow shaft parts is to ensure the molding quality and uniformity of the wall thickness of the hollow part. During the die-casting process, the positioning and strength of the inner core should be controlled to prevent the inner core from shifting or breaking. Use high-strength, high-temperature resistant inner core materials, and use special fixtures to ensure its stability during die-casting. At the same time, adjust the die-casting process parameters so that the molten metal can evenly wrap the inner core and achieve uniform wall thickness.
For special-shaped shafts, such as shafts with special curve profiles or asymmetric shapes, the process requirements focus on the complexity and adaptability of mold design. The mold cavity needs to accurately reflect the special-shaped features of the shaft, which places high demands on mold processing technology. Use advanced equipment such as multi-axis linkage machining centers to manufacture molds, and during die-casting, reasonably design the runner and exhaust system according to the special-shaped shape to ensure that the molten metal can smoothly fill every corner.
For shafts with threaded structures, the clarity and accuracy of the threads must be ensured during precision shaft die casting processing. The threaded part of the mold needs to have good demolding performance, and special demolding agents or thread demolding mechanisms can be used. At the same time, the temperature and fluidity of the molten metal are controlled to avoid defects such as lack of material or flash at the thread.
For spline shaft parts, the dimensional accuracy and tooth integrity of the spline part are the key points of the process. During the die-casting process, it is necessary to ensure that the molten metal can fully fill the spline groove and that no defects such as shrinkage holes appear during the solidification process. This requires optimizing the exhaust design of the mold and accurately controlling the die-casting pressure and speed to ensure the molding quality of the spline part.
Precision shaft die casting processing of different shapes requires a deep understanding of its unique process requirements, and targeted process plans and countermeasures are formulated to produce high-quality shaft products.
