2015-07-30

Customer P703

Project No. P703-140134

Part name 171558

Part number 2024086100_R01

Part material ALUMINUM

Shrinkage 6‰

Cavity number 1*1

No. of slide /

Casting machine LK 1250T

Part size 18.37IN*10.25 IN *3.59IN

Mold insert steel (dimension)

DIEVAR (24.3IN*24.8IN*3.6IN/4.75IN) Estimated design dimension

Mold base steel (dimension)

P20 (32IN*36.5 IN*A6.85IN B9 IN C7.2IN) Estimated design dimension

Mold standard DME -IN

Heat treatment hardness

HRC44±1°(For large molds of the heat sink type, the hardness is lower than usual.)

Part picture

Project Information

2015-07-30 1

Mold Flow Simulation

Mold flow simulation on flow pattern.

2015-07-30 2

Tooling Design

Picture on tooling design.

2015-07-30 3

Tooling Manufacturing

Mold Manufacturing. Top right was

implemented on the double head EDM.

2015-07-30 4

Tooling Test

The mold was tested on cold chamber die casting machine of LK 1250T.

2015-07-30 5

Sample Inspection

Sample inspection and reviewing.

2015-07-30 6

Photos of the Mold

2015-07-30 7

Certifications

The files include: Certification of Metal, Heat Treatment, Steel Tempering, Mold Base Material, etc. All these files have been submitted to the customer together with the mold.

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The drawing data include following items: ISIR, general assembly drawing of the die casting die, 2D drawing of mold components and parts, EDM machining drawing and die trial parameter report, etc.

Drawing Data

• 1. Mold manufacturing: The main character of heat sink products is that main part of the product are ribs, and electrode discharging and polishing are the main manufacturing processes on the mold, whose costs are both relatively high.

• 2. Part forming: For ribs (especially for deep and thin ribs), venting is difficult and it tends to trap easily. In the meanwile, the ribs are hard to form, and the venting system is hard to design on the mold. This is why vacuum system should be applied to this type of products sometimes.

• 3. Common problems of mold during production: Die Sticking, Die Cracking:

• A. Die sticking: For this kind of mold, die sticking happens easily because the strength of ribs is usually weak, and the temperature is very high on the mold’s rib feature during mass production. To this issue, we usually suggest to apply surface nitridation on the mold to improve surface hardness and smoothness, so as to decrease the rate of die sticking.

• B. Die cracking: This kind of mold is easy to crack earlier than usual mainly due to following reasons:

– a. EDM machining will produce steel stress on the mold;

– b. Hardness of ribs on mold insert is lower than usual;

– c. Heatness will be concentrated in the ribs on mold insert during mass production.

Geneally, tempering will be applied to the mold after EDM machining; When production reaches 2000-5000 shots (depending on the mold dimension), the mold should be tempered the second time. The mold can be maintained in a common way after these two times of tempering, but the first two times are especially important.

Mold Characters of Heat Sink Products

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Thanks!