CN112453345A - Die-casting system and die-casting process for preparing aluminum alloy die-casting - Google Patents
Die-casting system and die-casting process for preparing aluminum alloy die-casting Download PDFInfo
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- CN112453345A CN112453345A CN202011221946.2A CN202011221946A CN112453345A CN 112453345 A CN112453345 A CN 112453345A CN 202011221946 A CN202011221946 A CN 202011221946A CN 112453345 A CN112453345 A CN 112453345A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/14—Machines with evacuated die cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/2272—Sprue channels
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
Abstract
The invention belongs to the technical field of aluminum alloy part forming and processing, and particularly relates to a die-casting system for preparing an aluminum alloy die casting, which comprises a sprue, a cross runner, an ingate and a die cavity which are sequentially communicated, wherein the die cavity is connected with an exhaust channel, the exhaust channel is communicated with a vacuumizing device, the end part of the ingate is provided with an ingate connected with the die cavity of a die set, the lower end surface of the ingate is inclined upwards, molten metal forms a jet angle with the plane of the ingate through the direction of the ingate, and the jet angle is 30-60 degrees. In addition, the invention also relates to a die-casting process. Compared with the prior art, the invention can effectively reduce the eddy and the air entrainment generated by mixing the molten metal with air in the mold filling process, thereby ensuring complete mold filling of the product, less surface bubbles and flow marks, high surface smoothness and high product percent of pass.
Description
Technical Field
The invention belongs to the technical field of aluminum alloy part forming and processing, and particularly relates to a die-casting system and a die-casting process for preparing an aluminum alloy die-casting piece.
Background
With the development of communication band in the communication industry, especially the rapid popularization of 5G communication at present, the communication interface grows rapidly, and the problem of heating of communication components caused by the increase of the communication speed inevitably exists, so that heat exchange must be carried out through a radiator. In order to reduce the cost, most aluminum alloy radiators are adopted, and the die casting is the lowest cost in the processing technology of the aluminum alloy radiators, so that the aluminum alloy die casting with high heat conductivity becomes necessary.
The die-casting molding of the aluminum alloy part is a method of pouring molten liquid aluminum alloy into a pressure chamber of a die-casting machine, filling the molten liquid aluminum alloy into a die-casting mold cavity at a high speed under the action of high pressure through the movement of an injection punch, and solidifying and molding the aluminum alloy under pressure to form the aluminum alloy die-casting part. The prepared die casting has high dimensional accuracy, smooth surface and clear outline. The general shape of this kind of large-scale die-casting part is all more complicated, and is casing class die casting for the most part, and the structure of watering of mould needs to synthesize the overall arrangement according to the structural feature of product, needs to guarantee the smoothness nature that flows of aluminium liquid in the die cavity, avoids the inside gas pocket defect of product, need reduce the washing away of aluminium water to the mould core simultaneously, alleviates the strain defect of product and improves the mould life-span, and consequently reasonable die-casting system is extremely important to aluminum alloy die-casting. In the prior art, the most common defects of the aluminum alloy die casting are surface bubbling and loose structure, so that the strength is reduced, the conductivity is reduced, the quality standard cannot be met, the product reject ratio is high, and the normal production of the product is seriously influenced. More seriously, some defects are difficult to detect in the die-cast semifinished product and are revealed only in the subsequent working processes, such as plating, which undoubtedly result in more serious losses in production.
Disclosure of Invention
One of the objects of the present invention is: aiming at the defects of the prior art, the die-casting system for preparing the aluminum alloy die-casting piece is provided, has a simple structure, can effectively reduce the eddy and the air entrainment generated by mixing the molten metal with air in the mold filling process, further ensures that the product has complete mold filling, less surface bubbles and flow lines, high surface smoothness and high product qualification rate.
In order to achieve the purpose, the invention adopts the following technical scheme:
the die-casting system for preparing the aluminum alloy die castings comprises a sprue, a cross gate, an ingate and a die cavity which are sequentially communicated, wherein the die cavity is connected with an exhaust channel, the exhaust channel is communicated with a vacuumizing device, the end part of the ingate is provided with an ingate connected with the die cavity of a module, the lower end surface of the ingate is inclined upwards, molten metal forms a jet angle with the plane where the ingate is located through the direction of the ingate, and the jet angle is 30-60 degrees.
As an improvement of the die casting system for producing an aluminum alloy die casting according to the present invention, the cross-sectional areas of the sprue, the runner and the ingate are gradually reduced in the molten metal flow direction.
As an improvement of the die casting system for producing an aluminum alloy die cast part according to the present invention, the width of the ingate gradually increases in the flow direction of the molten metal.
As an improvement of the die-casting system for preparing the aluminum alloy die-casting piece, the width of the ingate is 83-130 mm, and the thickness of the ingate is 2-4 mm.
As an improvement of the die-casting system for preparing the aluminum alloy die-casting piece, the cross section of the ingate is in an isosceles trapezoid shape.
As an improvement of the die-casting system for preparing the aluminum alloy die-casting piece, the exhaust passage is provided with a plurality of exhaust passages, the exhaust passages are respectively connected to the side end of the die cavity and the rear end of the die cavity far away from the sprue, and the exhaust passages are mutually communicated.
As an improvement of the die casting system for preparing the aluminum alloy die casting, the vacuumizing device comprises a vacuum pump and a vacuum pipeline connected with the vacuum pump, and the vacuum pipeline is connected with the exhaust pipe.
The second purpose of the invention is: there is provided a die casting process using the die casting system described hereinbefore in the specification, comprising the steps of:
1) preparing an alloy solution;
2) starting a die-casting system, preheating the die-casting system to a set temperature, and then preserving heat for 10-15 min to make the temperature of each part of the die-casting system consistent;
3) raising the temperature of the preheated die-casting system to the working temperature again, injecting the alloy solution into the die-casting system, and injecting the alloy solution into a die cavity through a sprue, a cross runner, an ingate and an ingate in sequence to form in the die cavity finally; in the die-casting process, the vacuumizing device is communicated with the exhaust pipeline, so that the die cavity is in a vacuumizing state;
4) and after the die casting is finished, opening a die cavity to take out the die casting, placing the die casting in air for natural cooling, polishing the surface of the die casting, and removing burrs.
As an improvement of the die casting process, in the step 3), the injection specific pressure is 950-1000 bar, and the injection speed is 3.8-4.8 m/s.
As an improvement of the die casting process, the preheating temperature is 150-200 ℃, and the working temperature is 180-210 ℃.
Compared with the prior art, the beneficial effects of the invention include but are not limited to:
1) the die-casting system has a simple structure and reasonable design, the molten metal enters the die cavity through the ingate and is injected at a certain jet angle instead of a right angle, the jet angle of the molten metal entering the die cavity is 30-60 degrees, so that the direction of the molten metal entering the die cavity is controlled, the flow process of the molten metal entering the die cavity through each runner is further effectively controlled, the degree of mixing with air is reduced, the molten metal is well filled in the die integrally, the proportion of foaming on the surface of a product, flow lines on the surface, loose structure, low strength and reduced conductivity is reduced, and the qualification rate of the product is improved.
2) The die-casting system adopts a vacuumizing mode, and the compactness of a die-casting product is better than that of a conventional die-casting product, and the porosity is low.
Drawings
Fig. 1 is one of the schematic structural views of the die casting system in the present invention.
Fig. 2 is a second schematic diagram of the die casting system according to the present invention.
Fig. 3 is a third schematic structural diagram of the die casting system of the present invention.
FIG. 4 is an SEM photograph of a die casting made in example 1 of the present invention.
Wherein: 1-sprue, 2-runner, 3-ingate, 4-mould cavity, 5-exhaust channel and 31-ingate.
Detailed Description
The present invention will be described in further detail with reference to the following detailed description and the accompanying drawings, but the embodiments of the invention are not limited thereto.
1. Die casting system
The first aspect of the invention provides a die-casting system for preparing an aluminum alloy die casting, as shown in fig. 1-3, the die-casting system comprises a sprue 1, a runner 2, an ingate 3 and a die cavity 4 which are sequentially communicated, the die cavity 4 is connected with an exhaust channel 5, the exhaust channel 5 is communicated with a vacuumizing device (not shown), an ingate 31 connected with the die cavity 4 is arranged at the end part of the ingate 3, the lower end surface of the ingate 3 is inclined upwards, molten metal forms a jet angle with the plane of the ingate 31 through the direction of the ingate 3, and the jet angle is 30-60 degrees. Preferably 30 ° to 45 °, such as 30 °, 33 °, 35 °, 40 °, and 45 °. The direction of seting up of ingate 31 is towards the X direction, and the lower terminal surface of ingate 3 is the slope up simultaneously for molten metal is through being the contained angle setting between the efflux direction W of ingate 3 and the X direction, consequently, behind molten metal inflow ingate 31, it has the minute speed along the Y direction, thereby can fill the type more completely. The angle of the jet of molten metal entering the mold cavity 4 through the ingate 3 is a large factor affecting the quality of the product. The jet angle is determined by two component speeds, and the X direction is the horizontal component speed of the metal liquid advancing along the direction of the cross gate 2; the Y direction is the vertical component velocity generated by the action of the metal hydraulic pressure, and W is the jet angle.
Further, the cross-sectional areas of the sprue 1, the runner 2 and the ingate 3 are gradually reduced in the molten metal flow direction. Thereby, the flow rate of the molten metal is increased so that the flow rate of the molten metal near the in-gate 31 reaches the flow rate required for good mold filling.
Further, the width of the ingate 3 is gradually increased in the flow direction of the molten metal.
Further, the width of the ingate 3 is 83mm to 130mm, and the thickness is 2mm to 4 mm.
Further, the cross section of the ingate 3 is in an isosceles trapezoid shape. The cross-sectional area of the ingate 3 can be various shapes, such as square, oval or trapezoid, and the isosceles trapezoid is preferred in the invention.
Further, a plurality of exhaust passages 5 are provided, the plurality of exhaust passages 5 are connected to a side end of the mold cavity 4 and a rear end of the mold cavity 4 away from the sprue 1, respectively, and the plurality of exhaust passages 51 communicate with each other.
Further, the vacuum pumping device comprises a vacuum pump and a vacuum pipeline connected with the vacuum pump, and the vacuum pipeline is connected with the exhaust pipe.
In the invention, according to the calculation formula of the total sectional area of the air passage: fq＝(2.24*10-3Vq)/(tqK), wherein: fqTotal cross-sectional area of the exhaust passage, mm2；VqVolume of the whole system, cm, not yet filled with molten metal in the mould cavity, die-casting system and pressure chamber3；tq-the time of expulsion of the gas, s; k-percentage of the exhaust channel still open during filling. Thus, as seen from the formula, FqAnd tqInversely proportional, the total area of the vent passages is increased to reduce the pump down time, which in turn is less than the shot time. In the invention, a plurality of exhaust channels are arranged, and the exhaust channels are communicated to two sides of the die cavity and one end of the die cavity far away from the sprue through the flow channels, so that the total area design of the exhaust channels is increased, and the purposes of vacuum starting during die assembly and vacuum time less than injection time are achieved.
2. Die-casting process
A second aspect of the present invention provides a die casting process using the die casting system of the present invention, including the steps of:
1) preparing an alloy solution;
2) starting a die-casting system, preheating the die-casting system to a set temperature, and then preserving heat for 10-15 min to make the temperature of each part of the die-casting system consistent;
3) raising the temperature of the preheated die-casting system to the working temperature again, injecting the alloy solution into the die-casting system, and injecting the alloy solution into a die cavity through a sprue, a cross runner, an ingate and an ingate in sequence to form in the die cavity finally; in the die-casting process, the vacuumizing device is communicated with the exhaust pipeline, so that the die cavity is in a vacuumizing state;
4) and after the die casting is finished, opening a die cavity to take out the die casting, placing the die casting in air for natural cooling, polishing the surface of the die casting, and removing burrs.
Further, in the step 3), the injection specific pressure is 950-1000 bar, and the injection speed is 3.8-4.8 m/s.
Furthermore, the preheating temperature is 150-200 ℃, and the working temperature is 180-210 ℃.
Embodiments of the present invention are illustrated below with reference to examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the claimed invention.
Example 1
The die casting system (the jet angle is 30 degrees) is adopted to prepare the aluminum alloy die casting, and the specific die casting process comprises the following steps:
1) firstly melting alloy raw materials (by mass fraction, 10% of silicon, 13.5% of iron, less than 1% of copper, less than 0.55% of manganese, less than 0.15% of zinc and 80% -88% of aluminum), then refining the alloy raw materials by adopting a refining agent, adding a refiner, then applying ultrasound to disperse the refiner in the melt, simultaneously removing alloy solution gas, standing and preserving heat for later use;
2) starting a die-casting system, preheating the die-casting system to a set temperature (150-200 ℃) and then preserving heat for 10-15 min to enable the temperature of each part of the die-casting system to be consistent;
3) raising the temperature of the preheated die-casting system to the working temperature (180-210 ℃) again, injecting an alloy solution into the die-casting system, injecting the alloy solution into a die cavity through a sprue, a cross runner, an ingate and an ingate in sequence, wherein the injection specific pressure is 950-1000 bar, the injection speed is 3.8-4.8 m/s, and finally forming in the die cavity; in the die-casting process, the vacuumizing device is communicated with the exhaust pipeline, so that the die cavity is in a vacuumizing state;
4) and after the die casting is finished, opening a die cavity to take out the die casting, placing the die casting in air for natural cooling, polishing the surface of the die casting, and removing burrs.
Example 2
The difference from example 1 is:
the jet angle was 33 °.
The rest is the same as embodiment 1, and the description is omitted here.
Example 3
The difference from example 1 is:
the jet angle was 35 °.
The rest is the same as embodiment 1, and the description is omitted here.
Example 4
The difference from example 1 is:
the jet angle was 40 °.
The rest is the same as embodiment 1, and the description is omitted here.
Example 5
The difference from example 1 is:
the jet angle was 45 °.
The rest is the same as embodiment 1, and the description is omitted here.
Testing
1) The die casting molding process of examples 1 to 5 was analyzed by digital simulation, and the filling process of the die casting was digitally simulated by flow simulation software, to obtain simulation results shown in table 1. In addition, the quality of the obtained die casting sample was observed, and the results are shown in table 2.
2) The die cast part obtained in example 1 was subjected to morphology characterization to obtain an SEM image as shown in FIG. 4.
Table 1 filling simulation results
TABLE 2 die casting quality
As can be seen from the simulation results of table 1: when the jet angle is 45 degrees, the temperature field change of the die casting is small, the molten metal converging area is small, the entrainment gas is small, the eddy is few, the integral filling state is good, and the quality is good. When the jet angle is 40 degrees, the temperature field change of the die casting is small, the metal liquid convergence area on the die casting is small, the entrainment is very little, the vortex is very little, and the whole filling state of the die casting is good. When the jet angle is 35 degrees, the temperature field change is small, the metal liquid confluence area on the die casting is very small, the entrainment is very little, no vortex is generated, and the whole filling state of the die casting is good. When the jet angle is 33 degrees, the temperature field change is extremely small, the converging area of molten metal on the die casting is small, no entrainment and vortex exist, and the whole filling state is good. When the jet angle is 30 degrees, the temperature field change is extremely small, the molten metal is finally converged in an extremely small range area, the whole filling state is good, and the phenomena of gas entrainment and vortex are avoided. Therefore, from a digital simulation point of view, the filling effect is clearly optimal when the jet angle is 30 °.
From the results of table 2 it can be seen that: the sample prepared by the jet flow angle of 45 degrees has fewer surface bubbles, smaller bubble volume, less flow marks on the surface and better surface smoothness of the die casting; the sample prepared by the jet flow angle of 40 degrees has fewer surface bubbles, smaller bubble volume, less flow marks on the surface and better surface smoothness of the die casting; the sample prepared by the jet flow angle of 35 degrees has few surface bubbles, small bubble volume, a small amount of flow marks on the surface and good surface smoothness of a die casting; the sample prepared by the jet flow angle of 33 degrees has few surface bubbles, small bubble volume, no flow line phenomenon on the surface and better surface smoothness of the die casting; the sample prepared by the jet flow angle of 30 degrees has few surface bubbles, small bubble volume, no flow line phenomenon on the surface and better surface smoothness of the die casting.
In conclusion, through the above-mentioned numerical analysis of the mould filling process of die casting, the result of filling is contrasted, and the sample is combined again, it can be seen that: for the miniature aluminum alloy thin-wall casting, when the metal is filled in the die cavity, the angle is non-vertical, and when the jet angle is between 30 and 45 degrees, the metal liquid is well filled in the die, the obtained aluminum alloy thin-wall casting product has few surface bubbles, small bubble volume, high strength and normal conductivity, and the qualification rate of the product is improved. When the jet angle is 30 degrees, the die casting filling effect is optimal, and the obtained product yield is highest.
In addition, as can be seen from the SEM image, the die cast article obtained in example 1 was substantially free of voids. Therefore, the die casting product prepared by the die casting system and the die casting process has good quality.
Variations and modifications to the above-described embodiments may also occur to those skilled in the art, which fall within the scope of the invention as disclosed and taught herein. Therefore, the present invention is not limited to the above-mentioned embodiments, and any obvious improvement, replacement or modification made by those skilled in the art based on the present invention is within the protection scope of the present invention. Furthermore, although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims (10)
1. The die-casting system for preparing the aluminum alloy die castings is characterized by comprising a sprue, a cross gate, an ingate and a die cavity which are sequentially communicated, wherein the die cavity is connected with an exhaust channel, the exhaust channel is communicated with a vacuumizing device, the end part of the ingate is provided with an ingate connected with the die cavity of a module, the lower end surface of the ingate is inclined upwards, molten metal forms a jet angle with the plane where the ingate is located through the direction of the ingate, and the jet angle is 30-60 degrees.
2. The die casting system for producing aluminum alloy die castings according to claim 1, wherein the cross-sectional areas of the sprue, the runner and the ingate are gradually reduced in a molten metal flow direction.
3. The die casting system for producing an aluminum alloy die cast piece according to claim 1, wherein a width of the ingate gradually increases in a flow direction of the molten metal.
4. The die casting system for preparing an aluminum alloy die casting according to claim 3, wherein the ingate has a width of 83mm to 130mm and a thickness of 2mm to 4 mm.
5. The die casting system for preparing aluminum alloy die castings according to claim 3, wherein the cross section of the ingate is arranged in an isosceles trapezoid shape.
6. The die casting system for producing an aluminum alloy die casting according to claim 1, wherein a plurality of the exhaust passages are provided, the plurality of the exhaust passages are connected to a side end of the mold cavity and a rear end of the mold cavity away from the sprue, respectively, and the plurality of the exhaust passages are communicated with each other.
7. The die casting system for producing an aluminum alloy die casting according to claim 1, wherein the vacuum evacuation device includes a vacuum pump and a vacuum pipe connected to the vacuum pump, the vacuum pipe being connected to the exhaust pipe.
8. A die casting process using the die casting system according to any one of claims 1 to 7, comprising the steps of:
1) preparing an alloy solution;
2) starting a die-casting system, preheating the die-casting system to a set temperature, and then preserving heat for 10-15 min to make the temperature of each part of the die-casting system consistent;
3) raising the temperature of the preheated die-casting system to the working temperature again, injecting the alloy solution into the die-casting system, and injecting the alloy solution into a die cavity through a sprue, a cross runner, an ingate and an ingate in sequence to form in the die cavity finally; in the die-casting process, the vacuumizing device is communicated with the exhaust pipeline, so that the die cavity is in a vacuumizing state;
4) and after the die casting is finished, opening a die cavity to take out the die casting, placing the die casting in air for natural cooling, polishing the surface of the die casting, and removing burrs.
9. The die casting process according to claim 8, wherein in the step 3), the injection specific pressure is 950 to 1000bar, and the injection speed is 3.8 to 4.8 m/s.
10. The die casting process according to claim 8, wherein the preheating temperature is 150 to 200 ℃ and the working temperature is 180 to 210 ℃.
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Cited By (5)
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| CN113351848A (en) * | 2021-05-19 | 2021-09-07 | 东风(十堰)有色铸件有限公司 | Deep cavity exhaust technology in high-pressure casting mold |
| CN113787178A (en) * | 2021-08-02 | 2021-12-14 | 金榀精密工业(苏州)有限公司 | Three-dimensional vacuum extraction die-casting forming structure |
| CN114309541A (en) * | 2022-03-04 | 2022-04-12 | 浙江华朔科技股份有限公司 | Die-casting die for producing shell and production method of shell |
| CN114603109A (en) * | 2022-03-16 | 2022-06-10 | 南京工业大学 | Mixed lap joint type ingate system of aluminum alloy die-casting gearbox shell |
| US11648609B1 (en) * | 2022-01-20 | 2023-05-16 | ShengHua Wang | Die-casting die, die-casting device and ultra-high speed die-casting method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113787178A (en) * | 2021-08-02 | 2021-12-14 | 金榀精密工业(苏州)有限公司 | Three-dimensional vacuum extraction die-casting forming structure |
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| CN114603109B (en) * | 2022-03-16 | 2023-09-08 | 南京工业大学 | Mixed lap joint type ingate system of aluminum alloy die-casting gearbox shell |
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Application publication date: 20210309 |