08,03,2026 1 views
In the wave of lightweight new energy vehicles, integrated shock absorbers are gradually replacing traditional multiple assembly components with their advantages of "weight reduction, integration, and efficiency". However, its complex geometric shape and alternating thin and thick structure pose extremely high requirements for die-casting equipment.
How to achieve high yield mass production of one out of two shock absorber towers? The Izumi NEXT ² two plate die-casting machine provides a powerful answer. Mr. Han Tao, Product Manager of the Product and Market Management Center of the Yizhimi Die Casting Machine Division, explained the technical bottlenecks and application achievements of NEXT ² in this typical structural component.
01.
'High end Breakthrough'
The threshold for mass production of two shock absorber towers
The overall contour of the shock absorber tower is arc-shaped, with significant differences in wall thickness, and a large number of longitudinal and transverse reinforcement ribs, ribs, and local machining areas are distributed. These structures hinder the sequential filling and densification of the metal liquid, and are prone to gas and oxide slag entrapment. Take the shock absorber tower produced by NEXT ² 4400T as an example: the size of the workpiece is 500+mm × 400+mm × 400+mm, the minimum and maximum basic wall thickness are 2.5 mm and 14 mm, the weight of the workpiece is 13 kg (the first mock examination and two cavities), and the pouring weight is 31 kg.
Among them, the wall thickness of the SPR (self piercing riveting connection) area is only 2.5mm, requiring high-speed and stable filling; The thickest part of the tower surface is 14mm, which is extremely sensitive to pressure control. Mr. Han Tao introduced that there is an extreme wall thickness difference of 2.5mm to 14mm on the same part, and the injection system must switch precisely between speed and pressure. ”
The traditional classic shock absorber tower adopts high vacuum and T7 heat treatment process, with aluminum alloy material AlSi10MnMg. Basic requirements for mechanical properties: tensile strength ≥ 180MPa, yield strength ≥ 120MPa, elongation ≥ 10%,moldThe lifespan target is 60000+. These stringent conditions determine that the equipment must have high precision, high stability, and high response speed.
It is precisely based on such industry pain points and process thresholds that NEXT ² has the opportunity to verify its own strength. Mr. Han Tao pointed out: "Currently, there are very few projects in the market that can stably achieve mass production of one and two shock absorber towers that meet the above requirements, and NEXT ² is one of the few successful cases. ”
02.
Yi Cast Injection System
Balancing 'fast' and 'accurate'
The Yi Cast high-speed injection system equipped on NEXT ² is the core to solving the problem of alternating filling between thin and thick layers. Mr. Han Tao introduced that the NEXT ² 4400T is equipped with a 190mm punch diameter, which improves the injection performance by up to 49%. Under the same dynamic injection force, larger or heavier parts can be produced; More dynamic injection force can also be provided for the same component. ”
For the process pain points of the shock absorber tower: the SPR area (2.5mm) needs to be "fast" - quickly and stably filled to avoid cold insulation and porosity, especially at the rear end of high speed, the speed cannot decrease, which ensures the porosity requirements of the SPR area; The tower surface area (14mm) needs to be "accurate" - when switching from filling to pressurization, pressure control must be stable, fast, and accurate.
Yi Cast adopts real-time closed-loop control and customized high-performanceservo valveBy combining algorithm learning with ORCA control system, the pressure building time is extremely short and the pressure overshoot is controllable. Mr. Han Tao emphasized that the shock absorber tower is highly sensitive to the VP conversion point, and inaccurate conversion can directly lead to porosity or shrinkage. NEXT ² performs outstandingly in this regard. ”
In addition, NEXT ² adopts servo+compensation hydraulic drive technology, which reduces comprehensive energy consumption by 40% while ensuring repeated accuracy under long-term high-pressure injection, avoiding air entrapment caused by hydraulic fluctuations. Combined with a quantitative furnace, a mold temperature machine, and a high-pressure point cooler, it is possible to focus on cooling local hot spots such as threaded holes, effectively reducing shrinkage and porosity, laying the foundation for a high elongation rate of ≥ 10% after T7 heat treatment.
03.
Stable as a rock
Collaborative guarantee of raptor locking system and high vacuum process
The requirements for the locking system of the first and second shock absorber towers are also strict. NEXT ² adopts the patented RAPTOR Raptor multi cylinder locking system, with a combination design of plunger cylinder and piston cylinder, which can quickly establish locking force, control accurately, and overcome mold opening vibration problems.
On key components, the progressive thread design of the brake nut can evenly distribute the stress on all teeth, extending the life of the nut and the large rod. Actual testing shows that the NEXT ² 4400 has a mold locking and pressure building time of about 2.5 seconds, significantly reducing the dry cycle period and improving production efficiency.
In order to meet the requirements of OEM modular production, the classic one out two mold of shock absorber tower often uses a three plate mold structure. Manager Han explained the adaptation advantages of NEXT ²: "The two board design of NEXT ² eliminates the need for mold adjustment steps and provides greater ejection space, making it very suitable for complex core pulling and multi-point ejection molds. Meanwhile, thanks to the two plate structure design, NEXT ² reduces its footprint by 10% and increases mold changing speed by 20%. ”
In terms of process matching, NEXT ² can be equipped with integrated mold temperature control system and vacuum system, making process adjustment and monitoring more accurate and fast.
04.
More than just devices
The full chain value from die-casting to post-processing
NEXT ² can handle a wide range of production needs from small to large structural components with ease. Its clamping force covers 1800T to 9200T, and can produce various new energy structural components such as shock absorbers, longitudinal beams, battery trays, and rear baseplates. Among them, 3500T~4500T is the mainstream range of the first and second shock absorber towers.
NEXT ² does not simply provide locking force and injection force, but truly solves the contradiction between thickness alternation, high porosity requirements, high mold life, and high production efficiency through three core technologies: Dolphin intelligent control system, Yi Cast high-speed injection system, and RAPTOR Raptor multi cylinder locking system.
It is worth mentioning that the birth of high-quality castings is not limited to the die-casting process. In the later stage, the customer also needs to use a trimming mold to remove the water outlet, and develop a correction plan (before/after heat treatment) and a heat treatment support frame. Yizhimi can provide complete process advice to help customers form a full chain solution from die-casting to finished products.
Mr. Han Tao emphasized in the end: "The high production requirements for complex structural components should not be at the expense of yield and mold life. The significance of NEXT ² is to 'simplify complexity' and turn 'more difficult' into 'more stable'. ”
*The data is obtained under specific testing conditions and may vary in reality. It is for reference only and not a commitment.
