CN101559482A - Method for manufacturing magnesium alloy die casting - Google Patents

Method for manufacturing magnesium alloy die casting Download PDF

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Publication number
CN101559482A
CN101559482A CNA2009100397369A CN200910039736A CN101559482A CN 101559482 A CN101559482 A CN 101559482A CN A2009100397369 A CNA2009100397369 A CN A2009100397369A CN 200910039736 A CN200910039736 A CN 200910039736A CN 101559482 A CN101559482 A CN 101559482A
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parameter
die casting
casting
die
magnesium alloy
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CNA2009100397369A
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林颖
余熳烨
刘斌
胡清明
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South China University of Technology SCUT
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South China University of Technology SCUT
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Abstract

The invention relates to a method for manufacturing a magnesium alloy die casting, comprising the following steps: designing a casting system according to the process characteristics and the quality requirement of the die casting; simultaneously, selecting the parameter and the range thereof of the casting system and a casting condition; then integrating with the parameter to carry out a numerical simulation experiment and analyzing the influence of the each parameter to the quality of the die casting according to the result of the simulation experiment to obtain the optimized parameter of the casting technology; and applying the reasonable technical parameter to actual production by means of combination. The whole design process and simulation process are completed by computers, therefore, the method avoids large numbers of consumption in actual production experiment, reduces defective rate and has more scientific rationality.

Description

A kind of manufacture method of magnesium alloy die casting
Technical field
The present invention relates to a kind of manufacturing process of alloy pressuring casting, be specifically related to a kind of manufacture method of magnesium alloy die casting.
Background technology
Along with The development in society and economy, light weight, the density that magnesium alloy has owing to itself is little, specific stiffness and specific strength height, have good castability, thermal conductivity, shock absorption, magnetic screen, characteristics such as easy to be recycled are widely used in various fields such as automobile, computer, communication and Aero-Space.And also magnesium alloy pressure-casting is had higher requirement simultaneously, in the die casting production process, molten state or semi-molten state metal are at high pressure, high speed lower charging type, and solidify rapidly, be easy to generate defectives such as trace, misrun, cold shut, slag inclusion, pore, cause simultaneously erosion to mould, heat fatigue cracking etc. easily, shorten die life, people press for and understand the reason that defective produces, and make prediction, and cause the wasting of resources to avoid generation of defects.
In the actual production process of die casting, usually need to manufacture experimently new extrusion process, traditional method is that the technical staff is according to technological principle with there has been experience to draft an original scheme, carry out actual production test and correction then, reach the process goal of expection, often will carry out repeatedly actual production test, not only workload is big, and the cost height, this just may cause very big waste, and is difficult to guarantee the quality of technology and the needs of production cycle.Along with the development of computer numerical simulation, the technologist carries out sunykatuib analysis on computers after drafting process program, find out the drawback of scheme, improve at disadvantage then, obtain new scheme, simulate again, up to obtaining satisfied process program.
But a problem that still exists is at present: the numerical simulation of present magnesium alloy pressure-casting substantially all is at the selected several different running gate systems of the current design of part, with the casting quality of method for numerical simulation analysis contrast foundry goods, therefrom determine a kind of prioritization scheme then.Die-casting technological parameter then will obtain by empirical value and die trial, Design of Runner System and die-casting technological parameter are chosen and can not be obtained good combination, and the extrusion process that obtains is not the most satisfied scheme often, the product defect rate height of producing, production efficiency is low, and the performance of enterprises is low.
Summary of the invention
The objective of the invention is to overcome the shortcoming that existing method exists, a kind of manufacture method of magnesium alloy die casting is provided, the inventive method is chosen good combination with Design of Runner System and die-casting technological parameter, can reduction in the numbers of seconds, improve the production efficiency and the economic benefit of enterprise, it is convenient, efficient that parameter is selected, and is applied to can enhance productivity in the actual production.
A kind of manufacture method of magnesium alloy die casting may further comprise the steps:
(1), according to the quality requirement of foundry goods design running gate system, set up the threedimensional model of part again according to part drawing, and the threedimensional model of part is saved as * .stl file format import numerical simulation software.
Utilize Pro/E or other three-dimensional softwares that magnesium alloy die casting is carried out three-dimensional modeling, then add running gate system and overflow system and form complete die casting physical model.
The design of running gate system comprises the design of sprue, cross gate, ingate, exhaust and overflow launder.The design of sprue comprises its structure choice and sprue bush geomery; Its structure is different because of the type of die casting machine, and for horizontal cold-chamber die casting machine, sprue generally is made up of pressure chamber on the die casting machine and the sprue bush on the compression mod;
The design of cross gate comprises the size of the sectional area of its shape and length, thickness; Cross gate position: because magnesium alloy is all faster than alloy grainings such as aluminium, zinc in die cavity, and alloy pressuring casting is a thin-walled parts in general, therefore the selection of cross gate position must be avoided direct impact mold cavity surface as far as possible, guarantee that the flow path of molten metal in die cavity is the shortest, to prevent misrun and cold shut phenomenon.The size of cross gate: in many cases, cross gate removes by machining.The cross gate width should be less than 50% of wall thickness, to avoid in deburring process foundry goods being caused damage.In order to obtain minimum cross gate thickness, guarantee the requirement of Mg alloy castings thin-walled simultaneously, the cross gate width should be got big to guarantee suitable cross gate sectional area as far as possible.
The design of ingate comprises the design of sectional area, thickness, width, length equidimension; The sectional area of ingate adopts the flowmeter algorithm to determine usually, is shown below:
A g=G/ρ/ gt
In the formula, A g---ingate sectional area (mm 2); G---the quality of molten metal (g) by ingate comprises overflow launder quality (g); Density (the g/cm of ρ---liquid metal 3); v g---filling velocity (m/s); The time (s) of t---die cavity filling;
The design of exhaust will be discharged the gas of die cavity the inside, avoids pore to produce, and reduces the air pressure at final filling position, is beneficial to the molten metal filling; The design of overflow launder will be accomplished to discharge foreign material, discharges gas, keeps the temperature balance, improves flow direction.For the thin-wall Mg alloy die casting, best overflow launder inlet area is about the 20-25% of ingate sectional area.
(2), the die-casting technological parameter scope of selecting rational running gate system parameter and adapting according to the quality requirement of die casting.
Select technological parameter: in the parameter of running gate system, the cross gate thickness effect is to what of product waste material, position, direction, flow regime that the design of cast gate and position then enter die cavity with molten metal etc. is closely related, therefore select cross gate thickness, ingate thickness, width, length are as the parametric variable of running gate system.
Extrusion process be with die casting machine, compression mod, diecasting alloys three main points have machine in conjunction with and the process of integrated use in addition.The main technologic parameters of die casting has: pressure, speed, time, temperature.These technological parameters of physicochemical characteristics choose reasonable according to magnesium alloy are the keys that guarantee the die casting processing quality, also directly influence height efficient and die life simultaneously.Extrusion process at first depends on the injection ability that die casting machine provides; Select corresponding technological parameter according to the quality requirement of die casting.The main technological parameter of selecting has: injection speed, pouring temperature, mold temperature.
The range of choice of the level of parameter is to determine according to the scope of selecting for use that the die casting handbook is advised, that adopts perhaps that the die casting handbook advised chooses parameter outside the scope.
(3) with the running gate system parameter selected and die-casting technological parameter all as variable, the numerical simulation of utilizing numerical simulation software to carry out die casting is selected the optimum process parameter combinations; The founder system that the optimum casting process parameters that obtains is made mould uses the coal gas rifle with the even preheating of mould 20~30 minutes then, makes mold temperature reach 160~180 ℃; Again mould is heated, make mould reach 200~220 ℃; Adopt resistance-type double chamber furance melting magnesium liquid, guarantee the degree of purity of magnesium material composition, and to make magnesium liquid pouring temperature be 660~680 ℃, carry out die trial production;
The parameter of selecting combined utilize method for numerical simulation to test, the parametric variable that simulated test is selected comprises that not only the parameter of Design of Runner System also comprises die-casting technological parameter, utilize three-dimensional software that the threedimensional model of foundry goods is made different modifications according to selected running gate system parameter to it again, fill the numerical simulation of type and process of setting then respectively by method for numerical simulation, by observing the type of flow and the solidification law after molten metal among the temperature field simulation result enters die cavity, can draw each technological parameter to the selection of the influence of filling the type quality and each parameter influence, select the optimum process parameter combinations according to the quality requirement of foundry goods and the condition restriction of die casting machine then the casting quality of foundry goods.
The founder system that the optimum casting process parameters that adopts step (3) to obtain is made mould uses the coal gas rifle with the even preheating of mould 20~30 minutes then, makes mold temperature reach 160~180 ℃; Again mould is heated, make mould reach 200~220 ℃; Adopt resistance-type double chamber furance melting magnesium liquid, guarantee the degree of purity of magnesium material composition, and to make magnesium liquid pouring temperature be 660~680 ℃, carry out die trial production.
(4), running gate system and the die-casting technological parameter combination of choosing applied in the actual production.
Because the retrofit work of mould need expend a large amount of time and manpower and materials, obtain the parameter of running gate system and extrusion process in optimization through numerical experiments, the running gate system parameter of You Huaing not only, the product yield rate is improved, determined rational die-casting technological parameter simultaneously, reduce the defect rate of product, improve enterprises production efficiency and benefit.
The present invention has following advantage and beneficial effect with respect to prior art:
1, running gate system and the better parameter of extrusion process are combined, can play good synergy, realize the optimization of extrusion process.
2, easy to operate, be easy to realize.
3, whole process is finished on computers, has avoided the consumption of a large amount of actual production tests, has reduced defect rate, has improved production efficiency and economic benefit.In actual production, adopt the high-performance die casting equipment and instruct production, can obtain die casting quality preferably, thereby improve yield rate, realize the high-quality manufacturing of magnesium alloy die casting, actual production is had important directive function with the technological parameter that obtains.
Description of drawings
Fig. 1 is the vertical view of magnesium alloy engine cylinder head cover part;
Fig. 2 is the right view of magnesium alloy engine cylinder head cover part.
The specific embodiment
Below in conjunction with example the present invention is done further detailed description, but protection scope of the present invention is not limited to following embodiment.
Embodiment (is example with a magnesium alloy engine cylinder head cover)
Quality requirement design running gate system according to foundry goods.
Cylinder head cover belongs to complex thin-wall spare, average wall thickness 2mm, monnolithic case be of a size of (length, mm): 487 * 226 * 146.5.Trying to achieve volume with Pro/E is 1004142mm 3, be 1.81g/cm by the density of AZ91D 3Calculate, as can be known, its quality is 1.82kg.
The design of ingate:
According to the elaboration of ingate design, it is as follows to obtain the required related data of its sectional area calculating:
G=1.82 * (1+30%)=2.366kg=2366g, overflow launder is pressed 30% of die casting and is calculated;
ρ=1.81g/cm 3v g=(40~90) m/s gets v g=54.7m/s; T=0.033s;
So ingate sectional area A g=726mm 2The thickness of ingate is tabled look-up and is got 2.86mm, and then the width of ingate is 726/2.86=254mm; The length of ingate is taken as l=14.4mm.Because the ingate broad keeps even flow for making whole width, the design adopts the pectination ingate.
The design of cross gate:
Select flat trapezoid cross section cross gate, the sectional area of cross gate can calculate by formula (1), (2):
W=(1.25~1.6)A g/D (1)
D≥(1.5~2)H (2)
In the formula, W---cross gate width (mm);
A g---ingate sectional area (mm 2);
D---cross gate thickness (mm);
H---foundry goods average wall thickness (mm);
According to above formula, obtain following data:
Get H=2.5mm by part feature, get D=18.6mm, then: W=1.36 * 726/18.6=53mm
Can finish Design of Runner System according to above data.
Just determine the form of running gate system during the design of die casting is difficult in and attempts for the first time, therefore should design several running gate systems and compare analysis, in the hope of obtaining more excellent running gate system in conjunction with the structure of cylinder head cover part.The design process of other form running gate systems no longer is described in detail in detail here.Be more excellent running gate system form through test T type running gate system.
The design of overflow launder:
According to the design analysis of above cast gate and cross gate, and obtain the following size of overflow launder according to the die casting handbook:
Overflow launder length, width, thickness are respectively:
B=40.2mm;A=35.2mm;H=18.6mm;
Overflow lip length, width, thickness are respectively:
b=20mm;a=11mm;h=1.81mm;
The design of air discharge duct:
Present embodiment adopts the mode that adds overflow launder on die joint, adds the flat type air discharge duct at the overflow launder afterbody, and overflow launder and air discharge duct overflow lip are staggeredly arranged, and according to the requirement of die casting handbook magnesium alloy overflow launder, its size is as follows:
Width 10mm; Length 70mm; Degree of depth 0.15mm.
Utilize Pro/e software to set up the threedimensional model of part, and the threedimensional model of part is saved as * .stl file format import numerical simulation software, utilize grid to divide instrument team entity then and carry out mesh generation according to part drawing.The threedimensional model of part as shown in Figure 1.
The process parameters range of selecting rational running gate system parameter and adapting according to the quality requirement of die casting; The running gate system parameter of present embodiment is selected: ingate thickness, parameter value are 1,1.5,2,2.4 (mm); Ingate width, parameter value are 233,253,273,293 (mm); Ingate length, parameter value are 8.4,10.4,12.4,14.4 (mm); Cross gate thickness, parameter value are 17.1,17.5,18,18.5 (mm); The die casting conditional parameter is selected: injection speed, parameter value are 5.8,6.5,7,7.5 (m/s); Pouring temperature, parameter value be 200,210,220,230 (℃); Mold temperature, parameter value be 660,670,680,690 (℃).
Utilize the orthogonal table of SPSS software development test data in the present embodiment earlier, can effectively reduce the test number (TN) simultaneously integrality and the practicality of guarantee test again.
Carry out the design of orthogonal table in SPSS, design process is: import the Several Factors that you select for use, after several levels, SPSS generates orthogonal table automatically, and is as shown in table 1.Because whole orthogonal table is bigger, only provides part here.
Table 1
Ingate thickness The ingate width Ingate length Cross gate thickness Injection speed Pouring temperature Mold temperature Setting temperature Group
2.4 253 10.4 17.5 7.5 210 690 81.0 1
1.5 273 10.4 18.6 7.5 220 660 80.7 2
2.0 233 10.4 18.0 7.0 230 690 85.3 3
2.0 293 12.4 18.0 7.5 220 680 82.4 4
2.0 253 8.4 17.5 6.5 230 660 82.5 5
1.5 233 14.4 17.1 6.5 230 680 84.5 7
1.0 293 10.4 17.1 7.0 200 660 76.8 8
2.0 253 8.4 17.1 7.5 200 680 78.3 9
1.0 253 14.4 18.0 7.0 220 660 81.1 10
Carry out numerical experiments according to the orthogonal table grouping of being set up, simulation medium casting material is the AZ91D magnesium alloy, and its portion of hot reason parameter is latent heat 373KJ/kg, 650 ℃ of about 1680kg/m of left and right sides density 3, the about 1.3kJ/ of quality thermal capacitance (kgK); Mold materials is the H13 steel, and its portion of hot physical parameter is density 7367kg/m 3, the quality thermal capacitance 0.7262kJ/ (kgK) about 600 ℃, the about 27.76W/ of pyroconductivity (mK).Successively each group parameter is done simulation according to orthogonal table, fill the numerical simulation of type and process of setting respectively, according to filling type and solidification law, draw the happening part of filling time, setting time and shrinkage cavity, gas hole defect, compare flaw size, from filling situation, pore, aluminium shot, the several aspects of defective such as solidification phenomenon compare in advance, every group of overall filling situation estimated.
As: ingate thickness is 2.4mm, width is 253mm, length is 14.4mm, cross gate thickness is 18.6mm, injection speed 5.8m/s, 690 ℃ of pouring temperatures, temperature field simulation result during 210 ℃ of mold temperatures shows: the stowing operation of solution is not too even, the cylinder cap upper wall occurs by the past middle filling in both sides, later ability filling in position in the middle of forming, and this might cause pore even misrun generation of defects.Whole stowing operation 0.045s consuming time, because injection speed is on the low side, since 0.031s (70%), the minimum temperature value in temperature field is respectively 595.95 ℃, 589.47 ℃, 587.02 ℃, be lower than 596 ℃ of the liquidus temperatures of AZ91D, therefore solidification phenomenon has in advance taken place, caused the generation of shrinkage cavity, shrinkage defect, this might cause stress to concentrate and make foundry goods crack, this with actual production in use above parameter production foundry goods occur that crack defect matches.
Final definite optimum die-casting technological parameter is: ingate thickness 2mm, ingate width 293mm, ingate length 12.4mm, the thickness 18.0mm of cross gate, injection speed: 7.5m/s; Pouring temperature: 680 ℃; Mold temperature: in the time of 220 ℃, can obtain die casting quality preferably with this understanding.
Temperature field simulation result shows that parameter is ingate thickness 2mm, ingate width 293mm, ingate length 12.4mm, the thickness 18.0mm of cross gate, injection speed: 7.5m/s; Pouring temperature: 680 ℃; Mold temperature: during 220 ℃ of filling 0.022s, molten metal filing is filled and led up in order steady, evenly scans whole part to arranging the groove that overflows again from cast gate, cross gate, ingate, the right group of cylinder cap portion, cylinder cap upper wall, cylinder cap left side group portion successively, and it is more satisfactory to fill type.The temperature field of filling type is more even, and the running gate system environment temperature is higher, and upside thin-walled place temperature is lower, helps realizing consecutive solidification.
On the basis of optimum extrusion process, carry out the production die trial based on the production of enterprise is actual.
The resistance-type double chamber furance is adopted in the melting of AZ91D, at utmost guarantees the degree of purity of magnesium material composition; Magnesium liquid pouring temperature is 680 ℃; Mould and die preheating with the even preheating of coal gas rifle 30 minutes, makes mold temperature reach 160 ℃ earlier; The mode of producing aluminum alloy die casting with mould makes mould reach 220 ℃ to mold heated again; Adopt the definite optimum die-casting technological parameter of the inventive method, not only reduced the defective of die casting, effectively prevent the appearance of crackle and cold shut defective.
In the process of factory production of reality, the foundry goods that adopts common die-casting technological parameter (injection speed 5.8m/s, 690 ℃ of pouring temperatures, 210 ℃ of mold temperatures) to produce, find through check:
The part trial product has crackle, and crackle mostly occurs at section thickness variation position greatly, and the crackle happening part does not have rule, varies, and a general product has several crackles; May be because casting section thickness is inhomogeneous on the one hand, cause the cooling velocity difference to cause more greatly; May be because injection speed (5.8m/s) is low excessively on the other hand, make setting time long, produce shrinkage cavity, shrinkage defect and finally cause stress to be concentrated causing.Above-mentioned defective also may be owing to injection speed is crossed low the generation.
And adopt optimum die-casting technological parameter of the present invention, and can effectively prevent the appearance of crackle and cold shut defective, reduce the defect rate of product.Owing to optimized running gate system, the product yield rate has improved 7% simultaneously.

Claims (3)

1, a kind of manufacture method of magnesium alloy die casting is characterized in that, may further comprise the steps:
(1), sets up the threedimensional model of part according to part drawing, and the threedimensional model of part is saved as * .stl file format import numerical simulation software according to the quality requirement of foundry goods design running gate system;
(2) select running gate system parameter and process parameters range according to the quality requirement of die casting;
(3) with the running gate system parameter selected and die-casting technological parameter all as variable, the numerical simulation of utilizing numerical simulation software to carry out die casting is selected the optimum process parameter combinations; The founder system that the optimum casting process parameters that obtains is made mould uses the coal gas rifle with the even preheating of mould 20~30 minutes then, makes mold temperature reach 160~180 ℃; Again mould is heated, make mould reach 200~220 ℃; Adopt resistance-type double chamber furance melting magnesium liquid, guarantee the degree of purity of magnesium material composition, and to make magnesium liquid pouring temperature be 660~680 ℃, carry out die trial production;
(4) choosing the optimum process parameter combinations from die trial production applies to the actual production.
2, the manufacture method of a kind of magnesium alloy die casting according to claim 1, it is characterized in that, described selection optimum process parameter combinations is by observing the type of flow and the solidification law after molten metal among the temperature field simulation result enters die cavity, draw each technological parameter to filling the influence of type quality and casting quality, select the optimum process parameter combinations according to the quality requirement of foundry goods and the condition restriction of die casting machine then.
3, the manufacture method of a kind of magnesium alloy die casting according to claim 1 is characterized in that, described parameter area is to determine according to the scope of selecting for use of die casting handbook suggestion, and that adopts perhaps that the die casting handbook advised chooses parameter outside the scope.
CNA2009100397369A 2009-05-26 2009-05-26 Method for manufacturing magnesium alloy die casting Pending CN101559482A (en)

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102211165A (en) * 2011-05-10 2011-10-12 山东省科学院新材料研究所 Method for die casting magnesium alloy guide sleeve
CN104325109A (en) * 2014-10-10 2015-02-04 镁联科技(芜湖)有限公司 Die-cast formation die and die-cast formation method
CN106001489A (en) * 2015-03-25 2016-10-12 加特可株式会社 Crack determination device and method of casting part, crack determination program and storage medium
CN107716871A (en) * 2017-09-22 2018-02-23 共享装备股份有限公司 Negative-pressure los mould casting running gate system
CN109290548A (en) * 2018-10-30 2019-02-01 宁波埃利特模具制造有限公司 A kind of the casting exhaust system and setting method of automobile component compression mod
CN113010972A (en) * 2020-11-11 2021-06-22 哈尔滨工业大学 Accurate design method for casting shrinkage size based on local envelope density
CN113295293A (en) * 2021-04-12 2021-08-24 芜湖泓鹄材料技术有限公司 Method for designing position of inner pouring gate of pouring system by detecting dynamic change of molten iron
CN113333713A (en) * 2021-07-06 2021-09-03 重庆理工大学 Vacuum die-casting die for manufacturing shock absorption tower and vacuum die-casting method of shock absorption tower
WO2021205670A1 (en) * 2020-04-11 2021-10-14 株式会社ダイエンジニアリング Die casting method, die casting device and mold
CN114855041A (en) * 2022-05-06 2022-08-05 上海大学 Die-casting magnesium alloy containing rare earth and forming process thereof
CN117920967A (en) * 2024-01-25 2024-04-26 东莞市德辉玻璃有限公司 Die casting production process of intelligent lock

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102211165A (en) * 2011-05-10 2011-10-12 山东省科学院新材料研究所 Method for die casting magnesium alloy guide sleeve
CN104325109B (en) * 2014-10-10 2018-02-09 深圳市建升科技股份有限公司 Die-casting forming die and method of squeeze forming
CN104325109A (en) * 2014-10-10 2015-02-04 镁联科技(芜湖)有限公司 Die-cast formation die and die-cast formation method
CN106001489B (en) * 2015-03-25 2019-06-07 加特可株式会社 The crackle estimating device and method and storage medium of cast member
CN106001489A (en) * 2015-03-25 2016-10-12 加特可株式会社 Crack determination device and method of casting part, crack determination program and storage medium
CN107716871A (en) * 2017-09-22 2018-02-23 共享装备股份有限公司 Negative-pressure los mould casting running gate system
CN107716871B (en) * 2017-09-22 2020-02-18 共享装备股份有限公司 Pouring method for negative pressure lost foam casting
CN109290548A (en) * 2018-10-30 2019-02-01 宁波埃利特模具制造有限公司 A kind of the casting exhaust system and setting method of automobile component compression mod
WO2021205670A1 (en) * 2020-04-11 2021-10-14 株式会社ダイエンジニアリング Die casting method, die casting device and mold
CN113010972A (en) * 2020-11-11 2021-06-22 哈尔滨工业大学 Accurate design method for casting shrinkage size based on local envelope density
CN113295293A (en) * 2021-04-12 2021-08-24 芜湖泓鹄材料技术有限公司 Method for designing position of inner pouring gate of pouring system by detecting dynamic change of molten iron
CN113295293B (en) * 2021-04-12 2022-06-21 芜湖泓鹄材料技术有限公司 Method for designing position of inner pouring gate of pouring system by detecting dynamic change of molten iron
CN113333713A (en) * 2021-07-06 2021-09-03 重庆理工大学 Vacuum die-casting die for manufacturing shock absorption tower and vacuum die-casting method of shock absorption tower
CN114855041A (en) * 2022-05-06 2022-08-05 上海大学 Die-casting magnesium alloy containing rare earth and forming process thereof
CN117920967A (en) * 2024-01-25 2024-04-26 东莞市德辉玻璃有限公司 Die casting production process of intelligent lock

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Open date: 20091021