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　　Control of Product Dimensional Accuracy in Aluminum Alloy Die - Casting

　　Achieving high - dimensional accuracy in aluminum alloy die - casting products is essential for their proper functioning and assembly in various applications. There are several key factors and techniques involved in controlling dimensional accuracy.

　　The design of the die - casting mold plays a fundamental role. A well - designed mold should take into account the shrinkage characteristics of aluminum alloy during solidification. Aluminum alloy shrinks as it cools from the molten state to the solid state, and the amount of shrinkage varies depending on factors such as the alloy composition, casting temperature, and cooling rate. Mold designers use computer - aided design (CAD) and simulation software to predict the shrinkage behavior accurately. By adjusting the dimensions of the mold cavity accordingly, they can compensate for the shrinkage and ensure that the final cast product has the desired dimensions. For example, if the simulation indicates that a particular area of the casting will shrink by 1%, the mold cavity in that area can be designed to be 1% larger than the target dimension of the final product.

　　The process parameters during die - casting also significantly impact dimensional accuracy. The injection pressure, speed, and holding pressure need to be carefully controlled. A consistent injection pressure ensures that the molten aluminum alloy fills the mold cavity evenly. If the injection pressure is too low, the cavity may not be fully filled, resulting in incomplete castings and incorrect dimensions. On the other hand, if the pressure is too high, it can cause excessive flash (thin, unwanted layers of metal around the casting) and dimensional distortion. The injection speed affects the filling pattern of the molten metal. A proper injection speed helps to avoid turbulence in the mold cavity, which can lead to air entrapment and dimensional defects. The holding pressure, applied after the mold is filled, helps to compensate for the shrinkage during solidification by forcing additional molten metal into the cavity.

　　Quality control during the production process is crucial. Regular inspections of the die - casting products using precision measuring instruments such as coordinate measuring machines (CMMs) are carried out. CMMs can accurately measure the dimensions of the castings, and any deviations from the specified tolerances can be detected. If a trend of dimensional errors is observed, adjustments can be made to the mold or the process parameters. Additionally, maintaining the integrity of the die - casting mold is important. Regular maintenance, including cleaning, polishing, and repair of the mold surface, helps to ensure consistent dimensional accuracy over a large number of casting cycles.

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