How to control deformation and stress during the processing of aluminum die casting automotive parts mold?

In the manufacturing process of aluminum die casting automotive parts mold, since the mold is usually made of high-strength alloy steel, the processing involves multiple processes, including forging, rough machining, heat treatment, and finishing, and each link may generate internal stress and deformation. The initial stage of mold processing usually starts with rough machining, at which time a large amount of material is removed, which is easy to cause stress concentration. In order to reduce the heat generated during the processing and the impact of the tool on the mold material, it is recommended to use reasonable cutting parameters and path planning, control the feed speed and cutting depth during processing, and avoid thermal deformation caused by cutting too much material at one time. After the rough machining is completed, it is often necessary to release the residual stress inside the material through intermediate annealing, so that the subsequent finishing process is more stable.

Heat treatment is an important link in mold manufacturing and has a direct impact on the strength, hardness and toughness of the mold. However, if the heat treatment process is not properly controlled, such as heating or cooling too fast and uneven temperature distribution, it may cause cracking, warping or stress concentration of the mold. During the heat treatment process, slow heating and uniform cooling should be adopted, and multiple tempering treatments should be performed if necessary to further release internal stress and stabilize the organizational structure. At the same time, the reasonable selection of heat treatment process route and temperature parameters is also an important means to ensure the dimensional stability of the mold.

The finishing stage of the mold plays a decisive role in the final dimensional accuracy and surface quality. At this time, the mold material has been heat treated and the stress state tends to be stable, but local stress concentration caused by improper processing parameters must still be avoided. High-precision machine tools and sharp tools should be used in processing, and multiple light cutting methods should be used to gradually approach the target size. In addition, in order to avoid deformation of the mold due to uneven distribution of clamping force during processing, the workpiece clamping method needs to be reasonably designed to ensure that the clamping force is evenly distributed and does not affect the dimensional accuracy of the processing area.

After the mold is processed, it is often necessary to pre-debug or test the mold before it is put into use to check whether its structure and size meet the design requirements. The thermal stress generated during the mold trial may also affect the stability of the mold. Therefore, it should be hot-run by slowly heating up multiple times to gradually adapt the mold to the actual working environment. At the same time, dynamic monitoring and regular inspection of the mold can help to detect minor deformations caused by the release of residual stress and take repair or adjustment measures in time.