The upper mold cavity design of automotive die-casting molds is a complex and precise process, which directly affects the shape, size and quality of the final parts.

Part geometry considerations:

The cavity design of the upper mold first needs to consider the geometry of the final part. This includes the part's contours, internal and external surfaces, special structures such as grooves and protrusions. Using CAD (computer-aided design) software, designers can accurately draw the shape of the mold cavity and ensure it is consistent with the part design.

Material flow analysis:

When designing the mold cavity of the upper mold, it is necessary to analyze the material fluidity to ensure that the molten metal can evenly fill the entire mold cavity and avoid the occurrence of defects such as bubbles and cold insulation. This may involve locating gates and nozzles and optimizing metal flow paths to improve filling efficiency.

Mold cavity structure design:

The design of the mold cavity structure includes the finish, surface treatment and geometry of the inner wall. In order to ensure the surface quality of the parts, the mold cavity of the upper mold usually undergoes surface treatment such as polishing or electrolytic polishing to reduce surface defects and improve the finish. In addition, the geometry of the inner wall of the mold cavity needs to take into account the requirements of the component while avoiding problems such as uneven wall thickness or eddy currents.

Cooling system design:

Cooling channels need to be designed in the mold cavity to control the temperature of the upper mold. The layout and design of the cooling channel need to consider the metal filling and solidification process to ensure the uniformity of temperature in the mold cavity during the entire process and prevent the occurrence of thermal cracks and other problems.

Integration of ejection system:

For the special structures that some parts may require, an ejection system may need to be integrated into the cavity design of the upper mold. The ejection system is driven by mechanical or hydraulic force, allowing the mold to form protrusions or other special structures within the part.

Exhaust system considerations:

In mold cavity design, an exhaust system needs to be considered to eliminate bubbles or gases that may be generated when metal fills the mold cavity. Proper exhaust system design helps prevent pores on the surface of parts and ensures the quality of the final product.

Mold cavity surface coating:

To further improve the wear resistance of the mold cavity and reduce metal adhesion, coatings are sometimes applied to the surface of the mold cavity. These coatings are usually carbide or ceramic materials that can improve the wear resistance of the mold cavity and extend the service life of the mold.