The difference between forged wheel hub molds and casting molds

The difference between forged wheel hub molds and casting molds
The forging die is subjected to high-pressure solid-state forming, while the mold is subjected to high-temperature liquid erosion. The materials, structures, and failure modes of the two are completely different.
Different ways of force application
The forging die is subjected to high pressure from the press, with a unit pressure often reaching 50-120MPa. The mold should have extremely high compressive strength and rigidity.
The mold is subjected to the erosion and thermal cycling of aluminum liquid, and the temperature gradient is the main load. Thermal cracking resistance is more important than compressive strength.
This difference determines the material selection: forging dies often use high toughness mold steel, while molds often use hot work mold steel.
structural difference
The forging die consists of a pre forging die, a final forging die, and a trimming die, which are used in combination with three sets of molds.
The mold consists of a fixed mold, a moving mold, and a sand core (or insert), with the core being the pouring system and cooling system.
The design of the flash groove in the forging die is crucial, as improper dimensions can result in insufficient filling or folding.
Materials and Heat Treatment
Forging dies commonly use 5CrNiMo, H13, etc., with lower hardness requirements than molds, usually 42-48HRC, with priority given to toughness.
The H13 hardness of the mold is often set at 45-52HRC, balancing wear resistance and heat cracking resistance.
The heat treatment of forging dies emphasizes uniformity and toughness, while molds emphasize surface hardness and resistance to thermal fatigue.
Lifespan and Failure Modes
The failure of forging dies is mostly due to wear and fatigue cracks, and their lifespan is usually between 50000 and 200000 blows.
The failure of molds is mostly caused by hot cracks and fractures, and the service life is usually 30000 to 50000 mold cycles.
The two cannot be directly compared for lifespan, as their units of measurement are different.
cost structure
A single set of forging dies often costs between 300000 and 800000 yuan, with higher equipment investment. Suitable for mass production of over 100000 pieces per year.
The cost of a single set of molds is often between 150000 and 450000 yuan, and the equipment investment is relatively low. Suitable for small to medium batches and complex shapes.
Xinfeng Mold also has the ability to design casting molds, and will provide input-output calculations for two options in the forging and casting route comparison project.
development cycle
The development cycle of forging dies is usually 60-90 days, including the debugging of two sets of cavities for pre forging and final forging.
The development cycle of molds is usually 45-70 days, including T0 and T1.
The debugging of forging dies relies more on the press, and the cost of mold testing is higher.
Key maintenance points for forging dies
The maintenance focus of forging dies is on the flying edge groove and the rounded corners of the mold cavity. After the wear of the flash groove, the flash thickens, the cutting force increases, and the mold life decreases.
Check the depth of the flash groove every 5000 strikes, and if the wear exceeds 0.3mm, it should be ground or replaced with inserts.
Practical tips
Preheat the forging die to 150-250 ℃ before use. Direct impact of the cold die will cause thermal cracks on the surface of the mold cavity.
The cooling and lubrication of the forging die should be uniform, as excessive local cooling can cause thermal stress cracks in the mold.
The surface roughness of the forging die cavity should be lower than Ra1.6. If it is too rough, it will increase friction and accelerate wear.
Frequently Asked Questions
Q: Can forging dies and molds be used interchangeably?
Answer: No, the way of force is completely different from the structure.
Q: What material is used for forging dies?
Answer: Commonly used 5CrNiMo, H13, hardness 42-48HRC.
Question: What is the lifespan of the forging die?
Answer: According to the number of strikes, it usually ranges from 50000 to 200000 times.
Question: How much is the forging die?
Answer: A single set usually costs 300000 to 800000 yuan.
Q: How long has the forging die been developed?
Answer: Usually 60-90 days, including pre forging debugging.
Q: Which one is more suitable for complex shapes?
Answer: Casting and forging have lower degrees of freedom in forming.
Recommended search keywords
Forging wheel hub molds, forging molds and casting molds, forging die materials, wheel hub forging processes, wheel hub mold manufacturers, aluminum alloy forging, forging die life, forging die costs, forging wheel hubs, mold manufacturers