CN111159873A - Method for calculating working flow of each cavity of thermal forming die - Google Patents
Method for calculating working flow of each cavity of thermal forming die Download PDFInfo
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Abstract
The invention relates to the technical field of mould manufacturing, in particular to a method for calculating the working flow of each cavity of a thermal forming mould, which comprises the steps of utilizing a water channel simulation model, taking an initial value of the working pressure of a water inlet of a module cooling water channel and recording the corresponding flow; fitting the recorded numerical values into a unitary quadratic curve, calculating a fitting constant according to an equation formula, and obtaining a calculation formula of the working pressure of the module and the corresponding cooling water flow; recording the pressure of the outlet and the inlet of the heat exchanger and the flow of the inlet of the heat exchanger, and performing the same fitting calculation on the recorded related numerical values to obtain a calculation formula of the corresponding cooling water flow under the working pressure of the heat exchanger; the working flow and the working pressure of the heat exchanger, the working pressure of the module cooling water channel and the flow of the cooling water channel in each cooling module are calculated, a large amount of analysis time is saved, the pressure and the flow of each cavity are quickly calculated, a water valve needing to be adjusted can be quickly found, and the size of the quantity needing to be adjusted is clearly and intuitively understood.
Description
Technical Field
The invention relates to the technical field of mold manufacturing, in particular to a method for calculating the working flow of each cavity of a thermal forming mold.
Background
Automobile hot forming parts are more and more widely applied, and when a hot forming die is developed, in order to avoid uneven temperature on the die and reduce the time of pressure maintaining and quenching, a water pipe is generally arranged in the die to carry heat on the die. The flow rate of a cooling system of a single set of die is generally analyzed by means of finite element and fluid analysis software to judge the rationality of water channel design; and (4) carrying out mold temperature analysis on the single set of mold, and analyzing the cooling uniformity and the pressure maintaining time.
Thermoforming consumes relatively high energy, and in order to reduce the production and manufacturing costs, a multi-cavity mold is generally adopted, and as shown in fig. 2, the multi-cavity mold can be combined into 2 cavities, 3 cavities, 4 cavities or more. The analysis and calculation of a single set of moulds may be without problems, but sets of moulds are combined, and the pump has a limited flow rate, which involves flow distribution problems in the mould cavities. Improper distribution can result in a large portion of the mold cavity flow and a small portion of the mold cavity flow, which can result in failure of a cavity to thermally form a part, or a long dwell quench time. The flow distribution is reasonable, generally means that all cavity molds meet the cooling rate requirement, and the whole cooling time is minimum.
The multiple sets of dies are combined together, the flow of each water inlet can only be displayed on the press, and the flow of the upper die and the lower die of each set of die is unknown after the water inlets are redistributed by water valves. Even if the problem of the overheating of the mold is found, the debugging personnel can not know which water valve to adjust and what the adjustment amount is. The flow distribution of the multi-cavity mold is related to the operating characteristics of the pump, the resistance characteristics of each set of molds, and the like. The same pump needs to supply water to the upper die and the lower die of a plurality of sets of dies, the simulation calculation is adopted, the calculation amount is large, the consumed calculation resources are large, and even the model is too large, the simulation result cannot be obtained, so that a new flow distribution theoretical calculation method for the multi-cavity die is needed to be provided.
Disclosure of Invention
The invention breaks through the difficult problems in the prior art and designs a calculation method for calculating the working flow of each cavity of the thermal forming die by using a simulation model.
In order to achieve the purpose, the invention designs a method for calculating the working flow of each cavity of a thermal forming die, which is characterized by comprising the following steps: the calculation is carried out according to the following steps:
step 1: by utilizing a water channel simulation model, taking i values between 0 and 0.5 as an initial working pressure p of a module cooling water channel water inletiAnd recording the flow Q (p) of the module cooling water channel under the corresponding pressure initial valuei）；
Step 2: fitting the initial value of the working pressure of the water inlet of the module cooling water channel and the corresponding cooling water flow into a unitary quadratic curve;
and step 3: fitting the pressure and flow relation of the upper die and the lower die of each die cavity according to the step 2, and then obtaining a unitary quadratic equation formula
Calculating a fitting constant k0、k1、k2So as to obtain a calculation formula of the working pressure of the water inlet of the module cooling water channel and the corresponding cooling water flow:
wherein Q (p)i) For module cooling channel inlet flow, piIs an initial value of the working pressure k of the water inlet of the module cooling water channel0、k1、k2Are all formula fitting constants, Qi(p) is the water inlet flow of the ith module under the working pressure of the cooling water channel, and p is the working pressure of the cooling water channel of the module;
and 4, step 4: measuring heat exchanger inlet pressure pJiAnd pressure p of the outletJi', and inlet flow rate QJAnd recording;
and 5: fitting the pressure at the inlet and outlet of the heat exchanger and the working flow of the heat exchanger into a unitary secondary curve, and then matching the working pressure at the inlet of the heat exchanger with the working pressure at the outlet of the heat exchangerThe corresponding cooling water flow is fitted into a unitary quadratic curve according to a unitary quadratic equation formula
Calculating a fitting constant k0’、k1’、k2', to obtain the calculation formula for the corresponding cooling water flow rate at the working pressure of the heat exchanger:
wherein Q isJ（pJi) For heat exchangers at a pressure of pJiWorking flow of time, pJiOperating pressure at the inlet of the heat exchanger, k0’、k1’、k2' is a fitting constant, QJIs the working flow of the heat exchanger, pJThe working pressure for heat exchange;
step 6: according to the principle of conservation of fluid mass, the flow of the heat exchanger is equal to the sum of the water inflow of all the modules, and the working flow Q of the heat exchanger is calculatedJ（pJ）；
And 7: calculating the working pressure p of the heat exchangerJ；
And 8: performing combined calculation on the formulas in the steps to obtain the working pressure p of the module cooling water channel;
and step 9: according to the formula
Making a calculation judgment, wherein QPIs the flow rate of the water pump, Qi(p) the water inlet flow of the ith module under the working pressure of the cooling water channel, n is the total number of the cooling modules, when the formula is established, the next step is carried out, and when the formula is not established, delta p is added to the obtained p value, wherein delta p is a pressure adjustment amount until the formula is met;
step 10: when the working pressure p of the die is obtained by calculation, the formula can be used
Each is calculated to obtainThe flow rate Q (p) of the cooling water channel in the cooling module.
The specific calculation method of the step 6 is as follows: according to the principle of conservation of fluid mass, the flow rate of the heat exchanger is equal to the sum of the water flows of the modules, i.e.
Wherein Q isJ（pJ) The flow rate of cooling water entering and exiting the heat exchanger, i.e. the working flow rate of the heat exchanger, n is the total number of modules, i is the module number, i =1, 2, 3 … … n, QiAnd (p) is the water inlet flow of the ith module under the working pressure of the cooling water channel.
The specific calculation method of the step 7 is as follows: p is a radical ofJ=PJ（QJ) Wherein p isJIs the working pressure of the heat exchanger, PJ（QJ) At a flow rate QJThe operating pressure of the heat exchanger.
The specific calculation mode of the step 8 is as follows: the working pressure of the pump is equal to the sum of the pressure of the water flow on the die and the pressure loss of the water flow on the heat exchanger, namely P = PJ+ P, where P is the operating pressure of the pump, PJThe pressure loss caused by the heat exchanger is referred to as p as the module cooling water channel working pressure.
When the mold contains a water valve, the step 11 is added: according to the formula
Performing a calculation of which αiThe opening degree of a water valve is 0-1, Q (P) is the flow of a cooling water channel in each cooling module obtained through calculation, and QiThe flow of the cooling water channel in each cooling module is controlled by a water valve.
Compared with the prior art, the method saves a large amount of analysis time, rapidly calculates the pressure and flow of each cavity, can rapidly find the water valve to be adjusted, and clearly and intuitively understands the amount to be adjusted.
Drawings
FIG. 1 is a simplified schematic diagram of a multichamber model system.
FIG. 2 is a graph of the pressure in the present invention.
Detailed Description
The invention is further described with reference to the accompanying drawings.
The invention designs a method for calculating the working flow of each cavity of a thermal forming die, which comprises the steps of firstly utilizing a water channel simulation model, wherein the die consists of an upper die and a lower die, a plurality of die cavities are distributed in the upper die and the lower die, each die cavity consists of a plurality of modules, a cooling water channel is required to be arranged in each module, and firstly, randomly taking i values between 0 and 0.5 as an initial value p of the working pressure of a water inlet of a cooling water channel of each module1~piAnd recording the flow of the cooling water channel of the module under the corresponding pressure, as shown in the following table:
TABLE 1 relationship of Water inlet pressure and flow obtained by simulation
| Initial value of working pressure of water inlet of module cooling water channel | p1 | p2 | …… | pi |
| Module water inlet flow Q (p)i） | -- | -- | -- | -- |
By the above table, the initial value of the working pressure of the water inlet of the module cooling water channel and the corresponding cooling water flow are fit to be aA unary quadratic curve, then according to the formula
The flow rate of each cavity mold at any pressure can be calculated, wherein Q (p)i) For module cooling channel inlet flow, piIs an initial value of the working pressure k of the water inlet of the module cooling water channel0、k1、k2All are formula fitting constants, and the pressure and flow relation of the upper die and the lower die of each cavity is fitted, so that the fitting constant k of the formula is obtained0、k1、k2。
Referring to fig. 2, since the cooling water first passes through the heat exchanger before reaching the mold. The heat exchanger is composed of a plurality of bent pipes, and the pressure loss is generated when flowing water passes through the heat exchanger, so that the working flow Q of the heat exchanger needs to be calculatedJAnd the operating pressure loss p of the heat exchangerJ. Because the structure of the heat exchanger is complex, the relationship between the pressure and the flow of the heat exchanger needs to be obtained by test, and the specific test mode is as follows: the pressures at the inlet and outlet of the heat exchanger, and the operating flow of the heat exchanger were measured and the values were recorded in the following table:
TABLE 2 relationship between pressure and flow at water inlet and outlet of heat exchanger
| Working pressure at water inlet of heat exchanger | pJ1 | pJ2 | …… | pJi |
| Working pressure at water outlet of heat exchanger | pJ1’ | pJ2’ | …… | pJi’ |
| Working flow rate Q of heat exchangerJ（pJ） | -- | -- | -- | -- |
By the above table, the pressure of the inlet and the outlet of the heat exchanger and the working flow of the heat exchanger are fitted into a primary secondary curve, then the working pressure of the inlet of the heat exchanger and the corresponding cooling water flow are fitted into a primary secondary curve, and the primary secondary curve is obtained according to a primary quadratic equation formula
Calculating a fitting constant k0’、k1’、k2' so as to obtain a calculation formula of the cooling water flow corresponding to the water inlet pressure of the heat exchanger, and calculating the working flow of the heat exchanger at any water inlet working pressure according to the formula.
The water in the water tank has higher temperature, enters the heat exchanger through the pump to reduce the temperature, then enters the die, and the temperature of the water from the die is increased. The heat of the thermoforming cooling system is continuously transferred into the refrigerating system through the heat exchanger.
The latter flows into the mold cooling circuit due to the flow through the heat exchanger. According to the principle of conservation of fluid mass, neglecting the leakage part of the pipeline, the flow of the heat exchanger is equal to the sum of the water inflow of each module, and the formula is as follows:
wherein Q isJ（pJ) The flow rate of cooling water entering and exiting the heat exchanger, i.e. the working flow rate of the heat exchanger, n is the total number of modules, i is the module number, i =1, 2, 3 … … n, QiAnd (p) is the water inlet flow of the ith module under the working pressure of the cooling water channel.
Similarly, the working pressure of the cooling water pump is changed into single atmospheric pressure through the heat exchanger and the die. That is, the working pressure of the pump is equal to the sum of the pressure on the die and the pressure on the heat exchanger, which results in the formula P = PJ+ P, where P is the operating pressure of the pump, PJThe pressure loss caused by the cooling water passing through the heat exchanger, namely the working pressure of the heat exchanger, and p is the working pressure of the module cooling water channel.
The pressure value of the outlet of the cooling water channel of the mold is zero without considering the action of the atmospheric pressure, so that the working pressure p value of the mold can be calculated.
Because the pressure characteristic curve of the pump and the pressure flow curve of the heat exchanger are obtained through experiments, the pressure flow curve of the mold cooling system can also be subjected to mapping solution, and the pressure flow curve is shown in fig. 2.
Then according to the formula
Making a calculation judgment, wherein QPIs the flow rate of the water pump, QiAnd (p) is the water inlet flow of the ith module under the working pressure of the cooling water channel, n is the total number of the cooling modules, when the formula is established, the next step is carried out, and when the formula is not established, the value of p is increased by delta p, wherein the delta p is a pressure adjustment amount, such as 0.01MPa, until the formula is satisfied.
When the working pressure p of the die is obtained by calculation, the formula can be used
And calculating the flow Q (p) of the cooling water channel in each cooling module.
Referring to fig. 1, if the mold contains a water valve, the water valve needs to be aligned with the moldThe flow Q (p) of the cooling water channel in each cooling module is obtained through calculation and is simply processed, and the specific formula is as follows:
wherein αiThe opening degree of a water valve is 0-1, Q (P) is the flow of a cooling water channel in each cooling module obtained through calculation, and QiThe flow of the cooling water channel in each cooling module is controlled by a water valve.
Since the present invention is implemented without involving complex calculations, it is only described how to quickly obtain the flow rate of each module on the die at a specific working pressure.
In the specific implementation, firstly, a simulation model is established, a mold with 3 mold cavities is adopted, the inlet pressure of a cooling system of each module of the mold is any 5 values between 0.1 and 0.5MPa, the flow of each module is calculated according to the invention, and the result is shown in table 3.
TABLE 3 flow of modules at inlet pressure
| Pressure of | 0.1MPa | 0.2MPa | 0.3MPa | 0.4MPa | 0.5MPa |
| Flow rate of mold on mold cavity 1 | 13.25 | 19.97 | 24.55 | 28.41 | 31.78 |
| Mold cavity 1 lower mold flow | 10.66 | 14.99 | 18.41 | 21.64 | 24.19 |
| Flow rate of mold on |
20.42 | 28.56 | 34.78 | 40.31 | 45.14 |
| Die |
14.01 | 20.31 | 24.96 | 28.91 | 32.45 |
| Flow rate of mold on |
13.25 | 19.97 | 24.55 | 28.41 | 31.78 |
| |
10.66 | 14.99 | 18.41 | 21.64 | 24.19 |
From the data in table 3, 6 mathematical polynomials can be built to obtain the parameters of the polynomial. Then, according to the method proposed by the present invention, the working pressure was calculated to be 0.04 MPa.
The flow rate of the entire mold cavity can be rapidly calculated by fitting 6 polynomials as shown in table 4.
TABLE 4 flow rate (m) at operating pressure for the entire die cavities3/s）
| Cavity 1 upper die | Cavity 1 | Cavity | 2 | Cavity | 2 | Cavity | 3 | Cavity | 3 lower die | Calculating time | |
| The method of the invention | 9.23 | 7.93 | 15.59 | 10.18 | 9.23 | 7.93 | 1s | ||||
| Finite element simulation method | 9.16 | 7.85 | 15.23 | 10.39 | 9.16 | 7.85 | 12 hours |
Computer configuration adopted by finite element simulation method, 8 cores and 16G
As can be seen from table 4: the integral cooling water channel comprises an upper die cooling water channel, a lower die cooling water channel, a connecting water pipe and a water inlet. If a finite element simulation method is adopted, working pressure is set, and the whole working flow and the upper and lower mold flows of each cavity are calculated, the calculation time is very long due to the large number of model units. By adopting the method, the flow of the upper die and the lower die of each cavity can be calculated only by substituting each fitting parameter. The difference of the calculation results of the two methods is not large, but the method is far faster than a finite element simulation method in the aspect of calculation time. The method can be used for debugging the actual die, and cannot be applied to on-site die adjustment if only a finite element simulation method is adopted.
Claims (5)
1. A method for calculating the working flow of each cavity of a thermal forming die is characterized by comprising the following steps: the calculation is carried out according to the following steps:
step 1: by utilizing a water channel simulation model, taking i values between 0 and 0.5 as an initial working pressure p of a module cooling water channel water inletiAnd recording the flow Q (p) of the module cooling water channel under the corresponding pressure initial valuei）；
Step 2: fitting the initial value of the working pressure of the water inlet of the module cooling water channel and the corresponding cooling water flow into a unitary quadratic curve;
and step 3: fitting the pressure and flow relation of the upper die and the lower die of each die cavity according to the step 2, and then obtaining a unitary quadratic equation formula
Calculating a fitting constant k0、k1、k2So as to obtain a calculation formula of the working pressure of the water inlet of the module cooling water channel and the corresponding cooling water flow:
wherein Q (p)i) For module cooling channel inlet flow, piIs an initial value of the working pressure k of the water inlet of the module cooling water channel0、k1、k2Are all formula fitting constants, Qi(p) is the water inlet flow of the ith module under the working pressure of the cooling water channel, and p is the working pressure of the cooling water channel of the module;
and 4, step 4: measuring heat exchanger inlet pressure pJiAnd pressure p of the outletJi', and inlet flow rate QJAnd recording;
and 5: the pressure of the inlet and the outlet of the heat exchanger and the working flow of the heat exchanger are fitted into a unitary secondary curve, then the working pressure of the water inlet of the heat exchanger and the corresponding cooling water flow are fitted into a unitary secondary curve, and the unitary secondary curve is obtained according to a unitary quadratic equation formula
Calculating a fitting constant k0’、k1’、k2', to obtain the calculation formula for the corresponding cooling water flow rate at the working pressure of the heat exchanger:
wherein Q isJ（pJi) For heat exchangers at a pressure of pJiWorking flow of time, pJiIs a heat exchangerWorking pressure of nozzle, k0’、k1’、k2' is a fitting constant, QJIs the working flow of the heat exchanger, pJThe working pressure for heat exchange;
step 6: according to the principle of conservation of fluid mass, the flow of the heat exchanger is equal to the sum of the water inflow of all the modules, and the working flow Q of the heat exchanger is calculatedJ（pJ）；
And 7: calculating the working pressure p of the heat exchangerJ；
And 8: performing combined calculation on the formulas in the steps to obtain the working pressure p of the module cooling water channel;
and step 9: according to the formula
Making a calculation judgment, wherein QPIs the flow rate of the water pump, Qi(p) the water inlet flow of the ith module under the working pressure of the cooling water channel, n is the total number of the cooling modules, when the formula is established, the next step is carried out, and when the formula is not established, delta p is added to the obtained p value, wherein delta p is a pressure adjustment amount until the formula is met;
step 10: when the working pressure p of the die is obtained by calculation, the formula can be used
And calculating the flow Q (p) of the cooling water channel in each cooling module.
2. The method for calculating the working flow of each cavity of the hot forming die as claimed in claim 1, wherein: the specific calculation method of the step 6 is as follows: according to the principle of conservation of fluid mass, the flow rate of the heat exchanger is equal to the sum of the water flows of the modules, i.e.
Wherein Q isJ（pJ) The flow rate of cooling water entering and exiting the heat exchanger, i.e. the working flow rate of the heat exchanger, n is the total number of modules, i is the module markNumber, i =1, 2, 3 … … n, QiAnd (p) is the water inlet flow of the ith module under the working pressure of the cooling water channel.
3. The method for calculating the working flow of each cavity of the hot forming die as claimed in claim 1, wherein: the specific calculation method of the step 7 is as follows: p is a radical ofJ=PJ（QJ) Wherein p isJIs the working pressure of the heat exchanger, PJ（QJ) At a flow rate QJThe operating pressure of the heat exchanger.
4. The method for calculating the working flow of each cavity of the hot forming die as claimed in claim 1, wherein: the specific calculation mode of the step 8 is as follows: the working pressure of the pump is equal to the sum of the pressure of the water flow on the die and the pressure loss of the water flow on the heat exchanger, namely P = PJ+ P, where P is the operating pressure of the pump, PJThe pressure loss caused by the heat exchanger is referred to as p as the module cooling water channel working pressure.
5. The method for calculating the working flow of each cavity of the hot forming die as claimed in claim 1, wherein: when the mold contains a water valve, the step 11 is added: according to the formula
Performing a calculation of which αiThe opening degree of a water valve is 0-1, Q (P) is the flow of a cooling water channel in each cooling module obtained through calculation, and QiThe flow of the cooling water channel in each cooling module is controlled by a water valve.
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