Customized production of die-cast aluminum accessories: deep integration of precision, performance and application
Publish Time: 2025-05-06
Under the trend of lightweight automobiles, precision electronics and intelligent industrial equipment, die-cast aluminum accessories have become the core basic parts in the field of high-end manufacturing due to their high hardness, high precision and customizable characteristics. Through the high-pressure casting process, liquid aluminum alloy is injected into the precision mold, combined with subsequent polishing treatment, this type of accessories can achieve a mirror effect with a surface roughness of Ra0.8-3.2μm, a hardness of HB60-150, a tensile strength of 440-560MPa, and maintain structural stability under complex working conditions. The service life is more than 3 times higher than that of traditional processes.The processing customization link is the core carrier of the value of die-cast aluminum accessories. Taking a new energy vehicle battery shell as an example, the customer requires that the IP67 waterproof level and 0.1mm dimensional tolerance be met at the same time. The manufacturer uses a cold chamber die-casting machine with vacuum die-casting technology to inject ADC12 aluminum alloy at a pressure of 90MPa, and eliminates pores through local extrusion pins, so that the density of the casting reaches 99.5%. During the surface treatment stage, a three-axis CNC polishing machine is used to grind the inner cavity and threaded holes at 0.01mm level, and the glossiness is increased to more than 85GU with chemical polishing liquid, which completely replaces the traditional machining solution and reduces the cost of each piece by 40%.Material upgrade and structural optimization are the key to extending the service life. In view of the pain point that the housing of outdoor lamps is exposed to acid rain environment for a long time, the company has developed thickened die-cast aluminum accessories, which increases the wall thickness from 2.5mm to 4mm and embeds 304 stainless steel reinforcement ribs. Through topological optimization design, the weight of the shell is reduced by 15% while ensuring that the heat dissipation area is not reduced, and the impact strength is increased to 120J/cm². The actual measurement of a municipal street lamp project shows that after 5 years of continuous use, the thickness of the surface oxide layer of the accessory is only 0.02mm, which is far lower than the national standard corrosion limit of 0.1mm.The mold opening accuracy directly affects the interchangeability and assembly efficiency of accessories. Industry-leading companies use five-axis linkage machining centers to manufacture molds, with a cavity surface roughness of Ra0.4μm. With the laser scanning detection system, the parting surface error is controlled within ±0.02mm. A precision valve body customized by a medical equipment customer requires a position accuracy of 0.05mm for its 16 threaded holes. By pre-embedding ceramic inserts in the mold, a one-time molding pass rate of 98% is achieved, which reduces 6 processes and shortens the delivery cycle by 40% compared with the traditional split processing solution.In terms of application scenario expansion, die-cast aluminum accessories are breaking through traditional boundaries. In the 5G base station heat dissipation module, by integrating a microchannel structure on the surface of the accessory and combining it with a 0.3mm fin spacing design, the thermal resistance is reduced to 0.05℃/W, meeting the 200W/cm² high power density heat dissipation requirements. In the joint components of industrial robots, the harmonic reducer housing is die-cast with 7075 high-strength aluminum alloy. By setting a conformal cooling water channel in the mold, the cycle is shortened from 12 seconds to 8 seconds, and the positioning accuracy is improved to ±0.01mm.With the penetration of digital technology, the production of die-cast aluminum accessories has entered the intelligent era. The mold design software developed by a certain company can automatically adjust the gate position and runner size based on CAE simulation results, so that the filling time error is controlled within ±0.05 seconds. In the quality inspection process, an AI visual inspection system is introduced to perform 360° scanning of castings, with a defect recognition accuracy of 99.9%, which is 20 times more efficient than manual inspection. In the future, with the integration of semi-solid die casting and additive manufacturing technology, die-cast aluminum accessories will develop towards more complex structures and higher performance, providing stronger support for high-end equipment manufacturing.
