Reason:

1. Structural design: Uneven wall thickness of die-casting parts and inconsistent cooling shrinkage result in internal stress.
2. Mold temperature: During mold testing, the local temperature of the mold may be too high or too low, resulting in significant differences in cooling rates.
3. Process parameters: The injection speed is too fast, the holding pressure is insufficient, or the holding time is too short, resulting in loose tissue.
4. Mold structure: inaccurate positioning of the core/cavity, unbalanced ejection mechanism, and uneven force during ejection. 5. Cooling method: After the casting is taken out, it is not effectively shaped and undergoes free cooling deformation.

Improvement measures:

1. Structural design: Optimize wall thickness to ensure uniformity, add reinforcing ribs or process rounded corners.
2. Mold temperature: The mold temperature is controlled by a mold temperature machine to ensure that the temperature difference in each area is within a reasonable range.
3. Process parameters: Reduce injection speed, increase holding pressure, and extend holding time.
4. Mold structure: recalibrate the core/cavity positioning, adjust the ejection mechanism to balance the ejection force.
5. Cooling method: Design a specialized shaping fixture to immediately clamp and cool the casting after removal.
 

Permanent improvement direction: Conduct CAE analysis during new product development to proactively avoid predicted deformation risks and optimize solutions; Real time monitoring of mold temperature and process parameters during the trial molding process to ensure stability