1. Introduction
1.1 Background
In recent years, the consumer electronics industry has witnessed rapid growth and continuous innovation. The demand for consumer electronic products with high performance, light weight, and excellent appearance has been increasing. Squeeze casting, as an advanced metal forming technology, has the potential to meet these requirements and has been widely used in the manufacturing of consumer electronic products. However, to further improve the quality and performance of products and reduce production costs, it is necessary to optimize the squeeze casting process.
1.2 Purpose and Significance
The main purpose of this study is to optimize the squeeze casting process for consumer electronic products and analyze its performance. By optimizing the process parameters, we can improve the mechanical properties and surface quality of products, reduce the occurrence of defects, and enhance the production efficiency and economic benefits. This research is of great significance for promoting the development of lightweight and high-performance consumer electronic products and improving the competitiveness of enterprises in the market.
1.3 Research Methods and Contents
In this study, we will adopt a combination of experimental research and numerical simulation methods. Firstly, through orthogonal experiments, the influence of key process parameters such as casting pressure, mold temperature, and alloy composition on the quality of castings will be systematically studied, and the optimal parameter combination will be determined. Secondly, a finite element model of the squeeze casting process will be established to simulate and analyze the temperature field, flow field, and stress field during the casting process, predict the formation of defects and mechanical properties of castings, and provide a theoretical basis for process optimization. Finally, the optimized process will be applied to the production of specific consumer electronic products, and the performance and quality of the products will be tested and verified.
2. Current Situation of Squeeze Casting Process in Consumer Electronic Products
2.1 Application Scope and Advantages
Squeeze casting is widely used in the manufacturing of various consumer electronic products, especially for aluminum and magnesium alloy parts with complex shapes, thin walls, and high strength requirements. The advantages of squeeze casting include high production efficiency, high dimensional accuracy, good mechanical properties of castings, and low production costs. It can meet the development needs of consumer electronic products for lightweight, miniaturization, and high performance.
2.2 Existing Problems and Challenges
Despite the wide application of squeeze casting in the consumer electronics industry, there are still some problems that need to be addressed. For example, internal defects such as shrinkage cavities and cracks are prone to occur in castings, which affect the mechanical properties and reliability of products. The surface quality is difficult to control, and phenomena such as roughness and peeling often appear, affecting the appearance and feel of products. In addition, the wear of molds is severe, and the service life is short, which increases the production cost.
3. Key Factors Affecting the Optimization of Squeeze Casting Process
3.1 Influence of Casting Pressure on Product Performance
| Casting Pressure Level | Filling Capacity | Compactness | Internal Defects | Mechanical Properties | Surface Quality |
|---|---|---|---|---|---|
| Low | Poor | Low | Prone to form insufficient filling and cold shut defects | Reduced strength and reliability | May cause surface defects such as flashes and burrs |
| High | Good | High | May lead to mold deformation and size deviation | Affected by mold deformation, size accuracy decreases | Affected by mold deformation, surface quality deteriorates |
Casting pressure is a crucial process parameter that directly affects the filling speed and compaction degree of the metal melt in the mold cavity, thereby influencing the internal microstructure and defect distribution of the casting. When the casting pressure is too low, the filling ability of the metal melt is insufficient, resulting in internal defects such as insufficient filling and cold shut, which severely weaken the mechanical properties and reliability of the product. Conversely, when the casting pressure is too high, it may cause mold deformation, leading to product size deviation and even surface defects such as flashes and burrs, affecting the precision and appearance quality of the product.
3.2 Influence of Mold Temperature on Surface Quality
| Mold Temperature Level | Metal Melt Fluidity | Filling Behavior | Solidification Process | Surface Defects |
|---|---|---|---|---|
| Low | Reduced | Prone to insufficient filling defects such as cold shut and wrinkles | Shortened solidification time | Rough surface and poor appearance |
| High | Increased | Improved filling integrity | Prolonged solidification time | Oxidation and sticking to the mold, affecting surface quality and subsequent processing performance |
The mold temperature significantly impacts the surface quality of squeeze-cast products. The temperature level and distribution of the mold directly affect the filling behavior and solidification process of the metal melt in the mold cavity, thereby influencing the surface quality and defect situation of the casting. When the mold temperature is too low, the fluidity of the metal melt in the mold cavity decreases, leading to insufficient filling defects such as cold shut and wrinkles, resulting in a rough surface and poor appearance of the product. On the other hand, when the mold temperature is too high, the solidification time of the metal melt is prolonged, causing metallurgical defects such as oxidation and sticking to the mold on the casting surface, which affects the surface quality and subsequent processing performance of the product.
3.3 Influence of Alloy Composition on Mechanical Properties
| Alloy Element | Effect on Strength | Effect on Hardness | Effect on Toughness | Effect on Wear Resistance | Effect on Corrosion Resistance |
|---|---|---|---|---|---|
| Silicon (Si) | Increases with appropriate addition | Increases | Decreases with excessive addition | Improves | – |
| Magnesium (Mg) | – | – | Improves with appropriate addition | – | Improves |
| Copper (Cu) | Significantly enhances | Increases | Decreases with excessive addition | – | – |
The alloy composition is a material factor that determines the mechanical properties of squeeze-cast products. Different alloy elements have varying effects on the strength, hardness, toughness, wear resistance, and other mechanical properties of the casting. For example, adding silicon to aluminum alloy can precipitate hard primary silicon phases, enhancing the wear resistance and high-temperature strength of the casting. However, excessive silicon content reduces the plasticity and toughness of the casting. Adding magnesium can form precipitation strengthening phases, improving the plasticity and corrosion resistance of the casting, but excessive magnesium content 容易引发热裂纹. Adding copper can significantly enhance the strength and hardness of the casting through solid solution strengthening and precipitation strengthening, but excessive copper content leads to a decrease in the toughness and processing performance of the casting.
4. Optimization of Squeeze Casting Process Based on Orthogonal Experiments
4.1 Orthogonal Experimental Design
Orthogonal experimental design is an efficient multi-factor experimental design method widely used in the optimization of the squeeze casting process. By conducting orthogonal experiments, the influence of various process parameters on the casting quality can be comprehensively investigated with the minimum number of experiments, and the optimal parameter combination can be selected. During the orthogonal experimental design, based on the preliminary single-factor experiments and production experience, the process parameters that significantly affect the casting quality, such as casting pressure, filling speed, mold temperature, and alloy composition, are determined, and an appropriate range of levels is chosen. According to the number of parameters and levels, a suitable orthogonal table is selected to design a complete orthogonal experimental scheme.
4.2 Experimental Result Analysis and Process Parameter Optimization
The large amount of experimental data obtained from the orthogonal experiments requires systematic result analysis and process parameter optimization. Firstly, statistical analysis is performed on various quality evaluation indicators, such as dimensional accuracy, surface roughness, and mechanical properties. The mean, variance, signal-to-noise ratio, and other statistical quantities of each indicator are calculated to evaluate the discreteness and robustness of the experimental results. Secondly, the main effect plots and interaction plots of each process parameter are drawn to visually analyze the influence trend and significance of each parameter on the casting quality. Through main effect analysis, the optimal level of each parameter, that is, the parameter value that enables the casting quality to reach the optimum, can be determined. Through interaction analysis, the coupling effect between parameters can be revealed, and the parameter combination scheme can be optimized. On this basis, combined with methods such as variance analysis and grey relational analysis, the contribution rate and optimal parameter combination of each parameter are quantitatively calculated, and significance tests and verification experiments are carried out to ensure the reliability and effectiveness of the optimization results.
5. Finite Element Simulation and Verification of the Optimized Process
5.1 Establishment of the Finite Element Model
Finite element simulation is an important means to optimize the squeeze casting process. By establishing an accurate finite element model, the evolution laws of the temperature field, flow field, stress field, and other fields during the casting process can be revealed, the forming defects and mechanical properties of the casting can be predicted, and the optimization design of the process parameters can be guided. When establishing the finite element model of squeeze casting, according to the three-dimensional geometric model of the product, a suitable mesh generation method is used to spatially discretize the casting, mold, cooling pipes, and other components to generate a high-quality mesh model. The thermal physical parameters of the casting alloy and mold material, as well as the initial conditions and boundary conditions, are defined. A suitable finite element solution method is selected to establish the mathematical model of the casting process. To improve the simulation accuracy and computational efficiency, optimization strategies such as adaptive mesh technology and parallel computing technology are also adopted. Finally, a dedicated squeeze casting simulation software is developed through computer programming to provide an efficient numerical simulation tool for process optimization.
5.2 Simulation Result Analysis and Discussion
The rich data obtained from the finite element simulation requires in-depth result analysis and discussion to reveal the evolution laws and influence mechanisms of the temperature field, flow field, stress field, and other fields during the squeeze casting process. Visual analysis of the casting filling process is performed, and the distribution maps of the flow trajectory, filling time, and velocity field of the metal melt in the mold cavity are drawn to evaluate the rationality of the filling process. The temperature field evolution during the casting solidification process is analyzed, and the distribution maps of the cooling curve, solidification time, and liquid fraction are drawn to predict the microstructure evolution and shrinkage porosity and shrinkage cavity defects of the casting. In the stress field analysis, the residual stress level and cracking tendency of the casting are evaluated by analyzing the stress distribution and deformation situation of the casting during the cooling and contraction process, and the heat treatment process of the casting is optimized. The numerical prediction of the mechanical properties of the casting is carried out, and the stress distribution, deformation behavior, and failure mode of the casting during use are simulated using the thermo-mechanical coupling analysis method to evaluate the strength, stiffness, and reliability of the casting. Through the comparative analysis of the simulation results, the influence laws of different process parameters on the casting quality are revealed, the optimal parameter combination is selected, and the sensitivity analysis and robustness design are carried out. In addition, comparison and verification with the experimental results are required to evaluate the accuracy and applicability of the simulation results and provide a reliable theoretical basis and data support for process optimization.
5.3 Experimental Verification
To verify the effectiveness and reliability of the optimized process, a systematic experimental study is required. The process parameters optimized by simulation are applied to actual production, and the improvement of the casting quality and performance is evaluated. During the experiment, a reasonable experimental scheme is designed, representative samples are selected, and detailed experimental procedures and quality inspection standards are formulated. All process parameters are strictly controlled to ensure the stability and consistency of the experimental process. Online monitoring and intelligent control technologies are used to collect casting process data in real time and realize the dynamic feedback control of process parameters. In the casting quality inspection, nondestructive testing equipment is used to evaluate the dimensional accuracy, surface quality, and internal defects of the casting, and a comparative analysis is conducted with the quality of the casting before optimization to quantitatively evaluate the process improvement effect. For the verification of mechanical properties, mechanical property testing methods are used to systematically evaluate the strength, plasticity, toughness, and other indicators of the casting, and failure mode and fracture morphology analysis is carried out. Through the statistical analysis of the experimental data, a quantitative correlation model between the process parameters and the casting quality and performance is established, and an experimental database for process optimization is established to provide a reliable basis for subsequent process design and quality control.
6. Application of the Optimized Process in Consumer Electronic Products
6.1 Application Case 1: Notebook Computer Shell
The notebook computer shell is a typical component in consumer electronic products that requires high lightweight, high strength, and excellent appearance quality. Traditional notebook computer shells are mostly made of plastic or metal stamping parts, which have problems such as low strength, large thickness, and poor appearance. By using the optimized squeeze casting process, an integrated aluminum alloy shell with high strength, thin wall, and exquisite appearance can be produced, improving the performance and quality of the notebook computer. When applying the optimized process to produce the notebook computer shell, a high-strength and tough aluminum alloy material, such as ADC12 or A380, is preferably selected according to the structure and mechanical property requirements of the shell, and the alloy composition is appropriately adjusted to improve the impact resistance and wear resistance of the shell. Mold flow analysis and casting process simulation technologies are used to optimize the gating system and filling scheme to ensure the smooth filling and sequential solidification of the aluminum liquid in the mold cavity, minimizing casting defects such as shrinkage cavities and inclusions. In the mold design, advanced demolding structures such as multi-point ejection, inclined ejection, and core-pulling are adopted, combined with high-strength and high-thermal conductivity mold materials and surface treatment technologies, to improve the dimensional accuracy and surface quality of the shell and realize environmentally friendly processes such as spray-free and polish-free. At the same time, online monitoring and intelligent control technologies are used to collect temperature, pressure, speed, and other parameters of the casting process in real time and dynamically adjust the process parameters to ensure the stability and consistency of product quality. Through the systematic evaluation of the mechanical properties, surface roughness, dimensional accuracy, and other indicators of the notebook computer shell, the effectiveness and reliability of the optimized process are verified. The application results show that the strength of the notebook computer shell produced by the optimized squeeze casting process is increased by more than 30%, the wall thickness is reduced by more than 20%, and the surface roughness is reduced by more than 50%. The comprehensive performance and quality are significantly improved, realizing the integrated manufacturing of lightweight, high strength, and high quality.
6.2 Application Case 2: Smartphone Middle Frame
The smartphone middle frame is a key structural component that connects various parts of the smartphone and has extremely high requirements for strength, toughness, and precision. Traditional smartphone middle frames are mostly produced by CNC machining or MIM processes, which have problems such as low production efficiency, low material utilization rate, and high manufacturing cost. By using the optimized squeeze casting process, the rapid, low-cost, and high-quality production of the smartphone middle frame can be realized, promoting the lightweight and high-performance development of the smartphone. When applying the optimized process to produce the smartphone middle frame, a high-strength and tough magnesium alloy material, such as AZ91D or AM60B, is selected according to the structural characteristics and usage requirements of the middle frame, and the alloy composition is optimized and microalloyed to further improve the comprehensive mechanical properties of the middle frame. A combined forming process of hot runner injection molding and squeeze casting is adopted, and high-strength metal inserts are pre-placed in the mold cavity to realize the integrated forming of the middle frame and the inserts, effectively reducing the number of connectors and improving the overall strength and manufacturing precision of the middle frame. In the mold design, complex demolding structures such as multi-slide and core-pulling are used, combined with high-wear-resistant and high-thermal conductivity mold materials and nano-coating technologies, to realize the precision forming and production of the middle frame. Online visual inspection and defect recognition technologies are used to monitor the size, position, and defect quality characteristics of the middle frame in real time, and a quality feedback control system is established to ensure the stability and consistency of product quality. Through the systematic testing of the dimensional accuracy, position accuracy, mechanical properties, and other indicators of the smartphone middle frame, the advanced nature and reliability of the optimized process are verified. The application results show that the dimensional tolerance of the smartphone middle frame produced by the optimized squeeze casting process reaches ±0.05mm, the position error is less than 0.1mm, and the strength is increased by more than 50%. The comprehensive performance and precision level are significantly improved, realizing the flexible, precise, and integrated manufacturing of the smartphone middle frame.
7. Conclusion and Prospect
7.1 Research Results Summary
In this study, through the optimization of the squeeze casting process for consumer electronic products, the following results are obtained:
- The influence of key process parameters such as casting pressure, mold temperature, and alloy composition on the product performance and quality is systematically analyzed, and the optimal parameter combination is determined.
- The finite element model of the squeeze casting process is established, and the simulation and analysis of the casting process are carried out, which provides a theoretical basis for process optimization.
- The optimized process is applied to the production of notebook computer shells and smartphone middle frames, and the performance and quality of the products are significantly improved, verifying the effectiveness and reliability of the optimized process.
7.2 Future Research Directions
In the future, the following aspects can be further explored in the research of the squeeze casting process for consumer electronic products:
- Explore the application of new materials and new processes in squeeze casting to meet the increasing performance requirements and environmental protection requirements.
- Strengthen the cooperation and innovation among industry, academia, and research institutes to promote the sustainable development of the squeeze casting technology.
- Further improve the accuracy and efficiency of the finite element simulation method to provide more accurate guidance for process optimization.
- Study the recycling and reuse of waste materials in the squeeze casting process to reduce the environmental impact and production costs.
In conclusion, the optimization of the squeeze casting process for consumer electronic products has important practical significance and application value. With the continuous development of technology and the increasing demand for high-quality products, the squeeze casting technology will continue to play an important role in the manufacturing of consumer electronic products.
