CN117620125B - Production process of bulb die casting - Google Patents
Production process of bulb die casting Download PDFInfo
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- CN117620125B CN117620125B CN202410104505.6A CN202410104505A CN117620125B CN 117620125 B CN117620125 B CN 117620125B CN 202410104505 A CN202410104505 A CN 202410104505A CN 117620125 B CN117620125 B CN 117620125B
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- 238000004512 die casting Methods 0.000 title claims abstract description 70
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 28
- 238000000465 moulding Methods 0.000 claims abstract description 244
- 239000007788 liquid Substances 0.000 claims abstract description 238
- 238000000034 method Methods 0.000 claims abstract description 37
- 230000008569 process Effects 0.000 claims abstract description 34
- 238000005266 casting Methods 0.000 claims description 13
- 238000007493 shaping process Methods 0.000 claims description 6
- 230000008859 change Effects 0.000 claims description 4
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Classifications
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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
- B22D17/2015—Means for forcing the molten metal into the die
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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
- B22D17/2015—Means for forcing the molten metal into the die
- B22D17/2069—Exerting after-pressure on the moulding material
-
- 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
- B22D17/32—Controlling equipment
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- Engineering & Computer Science (AREA)
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Abstract
The invention relates to a production process of a bulb die casting, belongs to the technical field of die casting, and solves the technical problem of lower molding quality of the bulb die casting in the prior art. At least comprises the following steps; a first plug-flow stage, wherein the first plug-flow stage pushes the molding liquid in the flow passage at a speed V1 and has a duration of T1; a second plug-flow stage, which pushes the molding liquid in the flow passage at a speed V2 and has a duration of T2; the speed V2 of the second plug-flow stage is higher than the speed V1 of the first plug-flow stage; a pressurizing stage, namely pressurizing the molding liquid which completes the second plug flow stage to a set pressure P2 at least; the set pressure P2 is larger than the plug pressure P1 of the first plug stage and the second plug stage; and (5) forming and demolding. The multi-pass bulb die casting can realize integrated molding, thereby optimizing the process flow, avoiding secondary processing, shortening the process cycle and reducing the production and manufacturing cost.
Description
Technical Field
The invention belongs to the technical field of die casting, relates to a technology for improving the molding quality of a bulb die casting, and in particular relates to a production process of the bulb die casting.
Background
A multi-way bulb is generally referred to as a ball valve fitting for use in a piping system that allows multiple pipes to be connected to a ball valve and the flow of the pipes can be controlled by the ball valve.
Multi-pass ball and socket fittings are common in some industrial applications where multiple shaped fluid passages need to be managed, such as chemical plants, petroleum industries, water treatment facilities, etc. They provide flexibility and convenience, allowing a user to control and manage the flow of multiple pipes through a single valve, simplifying the design and operation of the piping system. In particular in the automotive field, multi-way bulb members are commonly used in power systems, hydraulic systems, and the like.
However, due to the product specificity of the multi-way bulb, the manufacturing of the multi-way bulb has some problems, and the product characteristics are as follows:
1. the structure is complex, multi-parameter constraint/limitation exists, such as the angle, axis relation, end face angle, flatness, surface parameters, internal mechanics of materials, air tightness and other parameters of the pipe orifice of each channel, the machining forming is too complex, the efficiency is low and the precision is difficult to meet the high-precision requirements of the automobile industry and the like through sand casting and the like;
2. the pipeline main body and the connecting part are generally involved, the thickness difference of the pipeline main body and the connecting part is extremely large, and is usually a gap of several times to more than ten times, and core requirements such as speed, flow passage, control of a die casting process and the like are difficult to be considered when a high-pressure die casting forming process is adopted, and the quality defects such as cold insulation, flow lines and the like of a thin wall or the defects such as bubbles, pinholes and shrinkage holes and the like of a thick wall are shown on the forming quality of a product;
3. If a complex control process or a highly dynamic mold system is designed, on the one hand, the mold production cost and the use and maintenance cost are high, the failure rate is high, and on the other hand, the complex control process leads to the reduction of the production efficiency and the high production cost of products.
Therefore, the multi-way ball pipe fitting has certain forming defects after being processed and formed due to the structural specificity of the multi-way ball pipe fitting.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides a production process of a bulb die casting.
In order to achieve the above purpose, the technical scheme adopted by the invention is as follows:
providing a production process of a bulb die casting, which at least comprises the following steps of;
a first plug-flow stage, wherein the first plug-flow stage pushes the molding liquid in the flow passage at a speed V1 and has a duration of T1;
a second plug-flow stage, which pushes the molding liquid in the flow passage at a speed V2 and has a duration of T2;
wherein the speed V2 of the second plug-flow stage is higher than the speed V1 of the first plug-flow stage;
wherein the duration T2 of the second plug-flow phase is smaller than the duration T1 of the first plug-flow phase;
the switching nodes of the first plug flow stage and the second plug flow stage are as follows: the molding liquid contacts an inner gate of the mold;
A pressurizing stage, namely pressurizing the forming liquid which completes the second plug-flow stage at least to a set pressure P2;
the set pressure P2 is larger than the pushing pressure P1 of the first pushing stage and the second pushing stage;
and (5) forming and demolding.
Preferably, the shaping liquid has a plug flow path one by the first plug flow stage;
the forming liquid is provided with a second plug flow path by the second plug flow stage;
the first plug flow path flows towards the direction of the inner pouring gate;
the second plug flow path flows in the direction of entering the forming cavity;
the end point of the first plug flow path and the start point of the second plug flow path are both inner gates of the mold, and the front end of the molding liquid reaches the inner gates to serve as switching nodes of the first plug flow stage and the second plug flow stage.
Preferably, the distance from the start point O of the pushing structure for pushing the molding liquid to the inner gate in the second pushing stage is H;
and, H satisfies at least:；
wherein M is the mass of the molding liquid entering the flow channel at present, S is the cross-sectional area of the driving end of the plug flow structure, ρ is the density of the molding liquid, and K1 is the compensation coefficient;
And, the value range of the compensation coefficient K1 is as follows: 0.90 to 0.97.
Preferably, the speed V1 of the first plug-flow stage and the speed V2 of the second plug-flow stage at least satisfy:
V2=V1×K2；
and, the value range of K2 is: 1.2 to 1.5;
the speed V1 of the first plug-flow stage and the speed V2 of the second plug-flow stage are both the moving speed of the driving end of the plug-flow structure.
Preferably, the thrust pressure P1 and the set pressure P2 at least satisfy:
P2=P1＋K3；
and, the value range of K3 is: 15 to 30bar;
and, the value range of the push flow pressure P1 is as follows: 50bar to 70bar;
and, the value range of the set pressure P2 is as follows: 65bar to 100bar.
Preferably, the duration T2 of the second plug-flow stage has a value ranging from: 0.05s to 0.1s.
Preferably, the molding and demolding stage comprises at least:
and a pressure maintaining stage, wherein the value range of the pressure maintaining time T3 in the pressure maintaining stage is as follows: 5s to 8s;
and a die-retaining stage, wherein the value range of the die-retaining time T4 in the die-retaining stage is as follows: 8s to 12s;
and (5) demolding.
Preferably, the casting temperature t of the molding liquid is in the range of: 630 ℃ to 720 ℃;
wherein, in the second plug-flow stage, a stagnation area is formed at least in the flow passage;
And, the time node of the forming liquid in the stagnation area entering the forming chamber is later than the time node of the forming liquid in the rest areas entering the forming chamber;
wherein the temperature of the molding liquid in the stagnation area is t1 when the molding liquid is injected into the molding cavity, and the temperature of the molding liquid in the rest areas enters the molding cavity is t2;
and, t1< t2.
Preferably, the forming liquid in the stagnation area is used for filling at least a class A area of the bulb die casting, and the forming liquid in the rest area is used for filling at least a class B area of the bulb die casting;
and, the wall thickness H1 of the A-type region > the wall thickness H2 of the B-type region.
Preferably, the surface temperature of the mold is q;
and, the value range of q is:wherein t is the casting temperature of the molding liquid.
The invention provides a production process of a bulb die casting, which has the beneficial effects that:
firstly, the die casting of the multi-way bulb tube can be integrally formed, so that the process flow is optimized, the secondary processing is avoided, the process period is shortened, and the production and manufacturing cost is reduced;
secondly, the quality of the molding surface of the pipeline structure of the multi-way bulb die casting can be ensured, the occurrence of defects on the molding surface is reduced, and the molding quality of a molded part is improved. The structural strength of the connecting structure of the multi-way bulb die casting is ensured, so that the service life of the multi-way bulb die casting is prolonged.
Drawings
FIG. 1 is a perspective view of a die of the bulb die casting production process of the present invention;
FIG. 2 is a perspective view of the structure shown in FIG. 1;
FIG. 3 is an enlarged view of a portion of the structure shown in FIG. 2;
FIG. 4 is a block diagram of a bulb die casting in accordance with the present invention;
FIG. 5 is one of the structural diagrams of the flow channel body of the present invention;
FIG. 6 is a second block diagram of the flow channel body of the present invention;
FIG. 7 is a schematic diagram of a first flow path and a second flow path;
FIG. 8 is a schematic diagram of flow paths three and four;
FIG. 9 is a schematic diagram showing the relationship between the plug flow structure and the molding liquid in the process for producing the bulb die casting according to the present invention;
FIG. 10 is a diagram showing a second relationship between a plug flow structure and a molding liquid in the process for producing a bulb die casting according to the present invention;
FIG. 11 is a third schematic illustration of the relationship between the plug flow structure and the molding liquid in the process for producing the bulb die casting according to the present invention.
Reference numerals illustrate:
1. a flow channel body; 2. a flow outlet; 201. a guide surface; 202. a reflecting surface; 3. a first flow path; 4. an outflow path; 5. a second flow path; 6. an inflow path; 701. region one; 702. a second region; 8. a third flow path; 9. a flow path IV; 10. a plug flow structure; 11. a runner; 12. forming liquid; 13. ball tube die castings; 1301. a pipeline structure; 1302. a connection structure.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1 to 11, the following embodiments of the present invention are provided:
as shown in fig. 9 to 11, a first embodiment of the present invention proposes a production process of a bulb die casting 13, which includes at least the following steps;
a first pushing stage, wherein the first pushing stage pushes the molding liquid 12 in the runner at a speed V1 and the duration time is T1;
a second pushing stage, which pushes the molding liquid 12 in the runner at a speed V2 and has a duration of T2;
wherein the speed V2 of the second plug-flow stage is higher than the speed V1 of the first plug-flow stage;
wherein the duration T2 of the second plug-flow phase is smaller than the duration T1 of the first plug-flow phase;
The switching nodes of the first plug flow stage and the second plug flow stage are as follows: the molding liquid 12 contacts the in-gate 11 of the mold;
a pressurizing stage for pressurizing at least the molding liquid 12 having completed the second plug-flow stage to a set pressure P2;
the set pressure P2 is larger than the pushing pressure P1 of the first pushing stage and the second pushing stage;
and (5) forming and demolding.
In this example, the following analysis was performed on the problems occurring in the prior art:
the structure of the multi-way bulb die casting 13 has certain specificity. In particular, since the multipass bulb die casting 13 has a pipe structure 1301 in a tubular shape and a connection structure 1302 in a flange shape, the pipe structure 1301 is generally thin in wall thickness, and thus it is generally necessary for the filling process of this portion to pay attention to the gas content at the time of filling, the larger the gas content is, the more defects are at the molding surface of the pipe structure 1301, and the smaller the gas content is, the better the defects are at the molding surface of the pipe structure 1301. While the wall thickness is typically thicker for the connection structure 1302, it is often necessary to pay attention to the structural density for this portion of the filling process to ensure the overall strength of the connection structure 1302. Thus, the molding surface defect, the structural density, the contour definition and the like of the multi-way bulb die casting 13 are considered, so that the multi-way bulb die casting 13 is difficult to be molded by one-step die casting in the prior art.
Based on this, we have optimized the processing of the multipass bulb die cast 13. The emphasis is on the process of forming liquid 12 entering the runner from the gate and entering the forming chamber from the in-gate 11 through the runner.
The above procedure is now divided into a first plug flow stage and a second plug flow stage.
The action time period of the first plug flow stage is as follows: molding liquid 12 is injected into the runner and not before entering the molding chamber from the in-gate 11. During this time, since the molding liquid 12 is in exposed contact with air, if the molding liquid 12 is forcibly pushed into the molding chamber, the air is mixed with the molding liquid 12 in the form of bubbles and simultaneously enters the molding chamber to cause major defects such as pinholes, shrinkage cavities, surface foaming, etc. on the molding surface of the pipe structure 1301. Therefore, at this stage, the pushing is performed at a speed V1, where the pushing speed of V1 is less than the speed V2, so as to ensure that the air has a certain discharge time, and avoid mixing the air with the molding liquid 12, thereby improving the molding quality of the pipe structure 1301 and reducing the occurrence of molding surface defects.
The action time period of the second plug flow stage is as follows: the molding liquid 12 reaches the in-gate 11 and begins to need to be filled into the molding cavity by the in-gate 11. During this time, the saturation of the molding liquid 12 in the molding cavity affects the molding quality, the structural density, and the definition of the contours of the molded part. Therefore, if the pushing velocity of the first pushing stage is continuously adopted, the molding liquid 12 enters the molding chamber in a relatively smooth state, so that the compactness of the molding liquid 12 relative to the molding chamber is reduced to a certain extent. Thus, when the second plug-flow stage pushes the forming liquid 12 into the forming chamber at a plug-flow velocity V2 (greater than the plug-flow velocity V1 of the first stage):
In one aspect, gas and bubbles can be reduced: the molding liquid 12, when fed at a high speed, helps to quickly fill the molding chamber to reduce the mixing of gas or bubbles, thereby reducing the rate of occurrence of air holes and bubbles in the multipass bulb die cast 13.
In yet another aspect, the material density can be increased: the rapid filling allows the molding liquid 12 to more densely fill the fine structures and cavities of the molding cavity during the mold filling process, improving the density and uniformity of the multipass bulb die casting 13.
In yet another aspect, the mechanical properties can be improved: the velocity and shear action of the forming liquid 12 to some extent helps to form finer grains in the forming liquid 12 and the fine grains help to improve the mechanical properties, such as the overall strength and wear resistance, of the multipass bulb die cast 13, and in particular the connection structure 1302 thereof.
In yet another aspect, shrinkage and deformation can be reduced: rapid filling and rapid solidification can reduce shrinkage and deformation of the material during cooling, and the dimensional stability of the final product is higher.
On the basis of the above, the duration of the first and second plug-flow phases, in particular the second plug-flow phase, also needs to be taken into account. The reason is that this plug flow stage pushes the forming liquid 12 into the forming chamber, and for the tube configuration 1301 of the multipass die casting 13 we find that the quality of the forming surface and the definition of the profile have a certain correlation with the filling time. To some extent, the shorter the filling time, i.e. the duration T2 of the second plug flow stage, the quality of the molding surface of the pipe arrangement 1301 and the definition of the contour are significantly improved. While for the first plug-flow phase it is necessary to provide sufficient time for the evacuation of air, thus allowing its duration T1 to be of a certain duration. Based on this, the present embodiment further defines that the duration T2 is much smaller than the duration T1, on the one hand, for improving the quality of the in-line shaping of the pipe configuration 1301 of the multipass bulb die casting 13, and reducing the occurrence of surface defects. On the other hand, the clearance rate of the molding liquid 12 is increased so as to reduce the defective rate of the multi-pass bulb die casting 13.
On the basis of the above, with the end of the second plug-flow stage, we have further found that it is difficult to further increase the structural strength of the multipass bulb die cast 13 after the molding liquid 12 has entered the molding chamber, if only against the pressure of the second plug-flow stage.
Based on this, a pressurizing stage is added, and this stage is used to apply a significantly increased pressure to the molding liquid 12 in the molding cavity, so as to further compress the molding liquid 12, so as to increase the adhesion therebetween, and further ensure that both the pipe structure 1301 and the connection structure 1302 of the molded bulb die casting 13 have a certain structural strength.
After the above process is completed, the molding and demolding process is performed, and the process can adopt a mature technology in the prior art, and will not be repeated here.
As can be seen, the production process of the bulb die casting 13 provided in this embodiment at least includes:
firstly, the multi-way bulb die casting 13 can be integrally formed, so that the process flow is optimized, the secondary processing is avoided, the process period is shortened, and the production and manufacturing cost is reduced;
secondly, the quality of the molding surface of the pipe structure 1301 of the multipass bulb die casting 13 can be ensured, the occurrence of molding surface defects can be reduced, and the molding quality of the molded part can be improved. The structural strength of the connection structure 1302 of the multipass bulb die casting 13 is ensured to improve the service life of the multipass bulb die casting 13.
The second embodiment of the invention provides a production process of a bulb die casting 13, and on the basis of the first embodiment, the first plug flow stage enables the forming liquid 12 to have a plug flow path I;
the shaping liquid 12 is provided with a plug flow path II by the second plug flow stage;
the first plug flow path flows in a direction toward the in-gate 11;
the second plug flow path flows in the direction of entering the forming cavity;
the end point of the first plug flow path and the start point of the second plug flow path are both the in-gate 11 of the mold, and the front end of the molding liquid 12 reaches the in-gate 11 to serve as a switching node of the first plug flow stage and the second plug flow stage.
In this embodiment, the switching node of the first push stage and the second push stage needs to be located.
In the first plug-flow stage, we have found that the plug-flow path of the molding liquid 12 is moved toward the in-gate 11, and at this stage we have a tendency to slow down the flow of the molding liquid 12, increase the air discharge amount, and reduce the gas content of the molding liquid 12, in preparation for filling the molding chamber.
In the second plug flow stage, it was found that the second plug flow path of the molding liquid 12 was introduced into the molding cavity from the in-gate 11. At this stage, we tend to increase the flow profile of the shaping liquid 12 so that it fills the shaping chamber quickly.
It can thus be found that an important switching node of the first plug flow stage and the second plug flow stage is whether the molding liquid 12 reaches the position of the in-gate 11. Therefore, by taking the position as the switching node, the smooth switching between the first plug flow stage and the second plug flow stage can be ensured, so that the expected different action effects on the molding liquid 12 are realized to achieve different beneficial effects.
As shown in fig. 9 to 11, a third embodiment of the present invention proposes a production process of a bulb die casting 13, and on the basis of the above embodiment, a distance H from a start point O of a plug structure 10 for pushing molding liquid 12 to an in-gate 11 in the second plug stage is indicated;
and, H satisfies at least:；
wherein M is the mass of the molding liquid 12 currently entering the runner, S is the cross-sectional area of the driving end of the plug-flow structure 10, ρ is the density of the molding liquid 12, and K1 is the compensation coefficient;
And, the value range of the compensation coefficient K1 is as follows: 0.90 to 0.97.
In the present embodiment, we found that although the switching nodes of the first plug flow stage and the second plug flow stage are provided, it is difficult for an outside person to observe whether the molding liquid 12 has reached the switching nodes because the in-gate 11 is located inside the mold. It is therefore desirable to provide a method that enables relatively accurate predictions of handover nodes. Moreover, the different specifications of the die-cast piece 13 with the multipass bulb will result in different amounts of molding liquid 12 being required, thereby resulting in a change in the pressing node, i.e. the switching node, of the plug-flow structure 10.
Based on the above, the estimation mode of the switching node is embodied. Since both the first and second plug-flow stages are plug-flow by the plug-flow structure 10, when the molding liquid 12 reaches the in-gate 11, the end of the plug-flow structure 10 must also reach a point, i.e., the start point O, which represents the need for the plug-flow structure 10 to switch from the first plug-flow stage to the second plug-flow stage. The position estimate for this starting point O should satisfy:
；
the formula can obtain the distance H from the start point O of the front end of the in-gate 11 to the in-gate 11 by the push structure 10 by knowing the mass of the molding liquid 12 entering the runner, the cross-sectional area of the driving end of the push structure 10 and the density of the molding liquid 12, so as to obtain the position of the start point O, which means that the push structure 10 needs to switch between the first push stage and the second push stage when reaching the position.
However, in the practical application process, it is found that, when the plug-flow structure 10 performs the first plug-flow stage, a small amount of molding liquid 12 actually enters the molding cavity from the in-gate 11, so that there is a certain deviation in the position of the start point O calculated according to the above method, and further, a deviation in the switching node between the first plug-flow stage and the second plug-flow stage is caused.
Thereby, the compensation coefficient K1 is increased on the basis of the above, i.e. according to the following formula:
；
the compensation coefficient K1 is used for compensating the reduced distance of the initial point O caused by the first plug flow stage entering the molding liquid 12 entering the molding cavity from the in-gate 11. By being able to obtain a specific position of the starting point O in a specific way, the pressure or the advancing speed of the plug-flow structure 10 is increased at this position, so that the process is switched from the first plug-flow stage to the second plug-flow stage, thus meeting the aforementioned requirements.
Furthermore, the above formula can also be used to calculate the mass of the molding liquid 12 currently entering the molding chamber, thereby ensuring that the mass of the molding liquid 12 meets the molding requirements of the multi-pass bulb die cast 13.
For the range of values of the compensation coefficient K1 we need to take further consideration. Due to the difference in the dimensions of the in-gates 11 of the different molds, there is a slight difference in the volume of the molding liquid 12 flowing into the cavity, thereby defining a fluctuation in the compensation coefficient between 0.90 and 0.97.
The fourth embodiment of the present invention provides a process for producing a bulb die casting 13, and on the basis of the previous embodiment, the speed V1 of the first plug-flow stage and the speed V2 of the second plug-flow stage at least satisfy:
V2=V1×K2；
and, the value range of K2 is: 1.2 to 1.5;
the speed V1 of the first pushing stage and the speed V2 of the second pushing stage are both the moving speed of the driving end of the pushing structure 10.
In the present embodiment, the speeds of the first plug-flow stage and the second plug-flow stage are defined.
As described above, in the above definition, only the speed V1 of the first plug-flow stage is defined to be smaller than the speed V2 of the second plug-flow stage, but no clear definition is given for the association relationship between the two.
We have further found that the velocity V1 of the first plug flow stage is relatively slow to increase the clearance of the forming liquid 12, but that there is a temperature reduction of the forming liquid 12 at this stage, which results in a temperature after filling into the forming chamber below the desired temperature, which in turn results in forming defects of the formed part.
Based on this, it is necessary to remedy the aforementioned problems in the second plug-flow stage so that the temperature of the molding liquid 12 can approach the desired temperature to some extent. Thus, it has further been found that in the prior art a relatively good speed correlation can be achieved: v2=v1×k2;
And, the value range of K2 is: 1.2 to 1.5. Under this association, the second plug-flow stage can be made to compensate the temperature of the molding liquid 12 consumed in the first plug-flow stage to a certain extent so that there is no large deviation between the temperature decrease value and the desired value thereof, thereby ensuring the molding quality of the bulb die casting 13.
The fifth embodiment of the present invention proposes a production process of a bulb die casting 13, and on the basis of the previous embodiment, the thrust pressure P1 and the set pressure P2 at least satisfy:
P2=P1＋K3；
and, the value range of K3 is: 15 to 30bar;
and, the value range of the push flow pressure P1 is as follows: 50bar to 70bar;
and, the value range of the set pressure P2 is as follows: 65bar to 100bar.
In the present embodiment, the correlation between the pushing pressure and the set pressure is defined.
The pushing pressure is the pressure applied by the pushing structure 10 in the first pushing stage and the second pushing stage, and the set pressure is the pressure applied by the pressurizing stage to the molding liquid 12.
When the pushing pressure P1 is 50bar to 70bar, the molding liquid 12 can be ensured to smoothly enter the molding cavity, and the desired filling degree can be ensured for the fine or complex structure inside the molding cavity, so that the outline shape of the multi-way bulb die casting 13 is ensured to be sufficiently clear and complete.
When the set pressure is 65bar to 100bar, the connection strength inside the molding liquid 12 can be improved, and further the physical quality of the molded bulb die casting 13 is improved, such as the connection strength and the bearing capacity, so that the service life of the bulb die casting 13 is prolonged.
As shown in fig. 4, a sixth embodiment of the present invention proposes a production process of a bulb die casting 13, and based on the previous embodiment, the duration T2 of the second plug-flow stage has a value range of: 0.05s to 0.1s.
In this embodiment, we have further found that the requirements for the forming surface are relatively high for the pipe configuration 1301 of the multipass bulb die casting 13, and the thinner the wall thickness, the higher the requirements for the filling time.
Based on this, the shorter the fill time, the higher the fill saturation of the forming liquid 12 in the forming chamber, and the clearer and complete the profile of the thin-walled structure. Thus, when the filling time is controlled within the time period of 0.05s to 0.1s, the molding liquid 12 can be made to rapidly enter the molding chamber, so that the molding liquid has relatively large kinetic energy, and the filling degree in the molding chamber is ensured.
A seventh embodiment of the present invention provides a process for producing a bulb die casting 13, and on the basis of the previous embodiment, the forming and demolding stages at least include:
And a pressure maintaining stage, wherein the value range of the pressure maintaining time T3 in the pressure maintaining stage is as follows: 5s to 8s;
and a die-retaining stage, wherein the value range of the die-retaining time T4 in the die-retaining stage is as follows: 8s to 12s;
and (5) demolding.
In this embodiment, the molding and demolding stages are defined.
The pressure maintaining stage is to maintain the pressure in the pressurizing stage, so that the molding liquid 12 can be fully filled and permeated in the molding cavity to ensure the filling quality. More preferably, the dwell time T3 of the dwell stage is in the range of 5s to 8s, which ensures a sufficient degree of filling of the forming liquid 12 and a sufficient mixing time of the forming liquid 12 during this period, and the forming liquid 12 solidifies under the effect of the boost pressure, so that the shrinkage generated during solidification is compensated for obtaining a substantially dense structure, the dwell time being related to the casting wall thickness and the alloy crystallization temperature, and we choose dwell time of 6 seconds, ensuring that the quality of the bulb meets the requirements.
The mold-retaining stage refers to the period from the end of the pressure maintaining time to the mold opening, the mold-retaining time is too long, and the packing force formed by solidification and shrinkage of the molding liquid 12 is increased, so that the core pulling and ejection are difficult, the mold is easy to adhere, cracks are determined, the ejector rod is broken, and the like. The mold retention time is too short, and since the molding liquid 12 is not yet completely solidified and the strength is insufficient, the value range of the mold retention time T4 is: 8s to 12s, preferably, the mold retention time is 10s, to ensure that the bulb die casting 13 has strong physical properties.
An eighth embodiment of the present invention provides a process for producing a bulb die casting 13, and on the basis of the previous embodiment, the range of the pouring temperature t of the molding liquid 12 is as follows: 630 ℃ to 720 ℃;
wherein, in the second plug-flow stage, a stagnation area is formed at least in the flow passage;
and, the time node of the forming liquid 12 in the stagnation area entering the forming chamber is later than the time node of the forming liquid 12 in the rest area entering the forming chamber;
wherein the molding liquid 12 in the stagnation area has a temperature t1 at the injection molding chamber and the molding liquid 12 in the rest area has a temperature t2 at the entry molding chamber;
and, t1< t2.
In this embodiment, the casting temperature of the forming liquid 12 (which is the temperature at which the forming liquid 12 enters the forming chamber) is optimized. The reason is that, for the pipe structure 1301 of the multi-pass ball die casting 13, a relatively high casting temperature is required, and for the connection structure 1302 of the multi-pass ball die casting 13, a relatively low casting temperature is required, and if the casting temperature is too high, the air intake of the aluminum alloy liquid increases, pinholes, shrinkage cavities, surface foaming and the like are liable to occur at the thick wall, and the die is liable to age and crack, the temperature is too low, the fluidity is poor, cold insulation, flow lines, insufficient casting, increased hard spots and knife striking during processing are liable to occur. Thereby, a range of values for the casting temperature is provided: 630 ℃ to 720 ℃.
On the basis of the above, as the thin-walled member and the thick-walled member require the casting temperature of the molding liquid 12, it is desirable to control the temperature of the molding liquid 12 to be lower than the temperature of the molding liquid 12 filled into the thick-walled member, i.e. t1, to ensure that the requirement of different wall thicknesses is satisfied.
And how to achieve the temperature regulation of the molding liquid 12 is given as follows. The specific structure of the runner is optimized, a stagnation area is added, and the time node of the forming liquid 12 in the stagnation area entering the forming cavity is delayed, so that the forming liquid is subjected to a temperature dissipation process in the area, and the temperature of the forming liquid meets the forming requirement of the thick-wall part, thereby improving the forming quality of the thick-wall part and reducing the defect formation of the thick-wall part.
As shown in fig. 1 to 8, more specifically, the flow channel includes at least:
a flow channel body 1;
wherein, the outflow port 2 of the runner body 1 is provided with a plurality of outflow ports;
and, each of the outflow ports 2 has at least:
a guide surface 201 and a reflection surface 202;
wherein the flow channel structure is optimized such that the aforementioned push flow path one and push flow path two of the molding liquid 12 are divided into a plurality of flow paths (push flow path is understood to be a path in which the push flow structure applies a push force to the molding liquid 12 to cause the molding liquid 12 to form, and flow path is understood to be a path in which interference occurs between the molding liquid 12 and the flow channel structure due to the optimization of the flow channel structure, i.e., a plurality of flow paths constitute the push flow path).
Wherein the first flow path 3 formed by guiding the molding liquid 12 by the guiding surface 201 has a set angle a with the outflow path 4 of the molding liquid 12 from the outflow port 2;
and, the molding liquid 12 is reflected by the reflecting surface 202 according to the first flow path 3 to form a second flow path 5;
and, the said second flow path 5 forms the route conflict with its inflow route 6 at least;
the path collisions include, but are not limited to:
the second flow path 5 and the inlet flow path 6 form a combination of various included angles which are not 90 degrees;
the second flow path 5 and the inlet flow path 6 form an included angle of 90 degrees;
the second flow path 5 is parallel to the inlet flow path 6.
Specifically, the runner body 1 has a plurality of outflow openings 2 to meet the die casting requirement of the multi-pass bulb. The outflow opening 2 is understood to mean the passage of the molding liquid 12 from the runner into the mold cavity.
The outflow opening 2 has a guide surface 201 and a reflecting surface 202. When the molding liquid 12 enters the runner from the pouring port, the pushing structure 10 gradually applies pressure to the molding liquid 12, and the pushing structure 10 refers to a driving member that applies pressure to the molding liquid 12 in the runner, so that the molding liquid 12 enters the runner rapidly, and at this time, the molding liquid 12 enters each of the outflow ports 2 along the path formed by the runner body 1.
The molding liquid 12 first contacts the guiding surface 201, and the guiding surface 201 guides the flow path of the molding liquid 12, i.e. forms a flow path one 3, and at this time, the flow path one 3 and the outflow path 4 of the molding liquid 12 out of the outflow port 2 have a set angle a, i.e. the flow path one 3 is at least not consistent with the direction of the outflow path 4. The reason is that if the direction of the first flow path 3 is consistent with that of the outflow path 4, the molding liquid 12 directly enters the cavity from the outflow port 2, and at this time, the molding liquid 12 with a higher jet velocity will convect or randomly diffuse in the cavity in a splashing turbulence state, so that a large amount of gas is mixed or the cavity is unevenly filled. Thus, when the first flow path 3 and the outflow path 4 form a set angle a, it can be ensured that the molding liquid 12 being guided or having finished being guided does not enter the cavity from the outflow port 2 according to the outflow path 4, so that its turbulent state is slowed down. In addition, at this time, the forming liquid 12 and the inflow direction of the forming liquid 12 into the runner body 1 also have an included angle, and the two forming liquids 12 interfere with each other to further slow down the kinetic energy of the forming liquid 12. Of course, there may be a portion of the molding liquid 12 that will flow out of the outflow port 2 during the directing process along the outflow path 4, but with a relatively small volume that is negligible.
Further, the reflective surface 202 is added. Wherein the molding liquid 12 is guided to the reflecting surface 202 by the guiding surface 201, and is reflected by the reflecting surface 202 to form the flow path two 5. The second flow path 5 collides with the inflow path 6 of the molding liquid 12. The reason is that if the kinetic energy of the molding liquid 12 consumed by the guiding action against the guiding surface 201 alone is relatively weak, it is desirable to add the reflecting surface 202 so that the reflecting molding liquid 12 and the entering molding liquid 12 further interfere, thereby stabilizing the situation of the molding liquid 12.
Among them, path collisions include, but are not limited to, the following three cases:
first, the second flow path 5 and the inlet flow path 6 form a combination of various included angles which are not 90 degrees. In this case, the reflection angle of the reflection molding liquid 12 may be an acute angle or an obtuse angle. The reflective molding liquid 12 and the entering molding liquid 12 form mixed flow and convection conditions from different directions, so that the full mixing of the reflective molding liquid 12 and the entering molding liquid 12 is facilitated, the splitting property between the molding liquids 12 is reduced, the saturation of the molding liquid 12 in a runner before entering a cavity is improved, and the defect of the molded multi-way bulb is further reduced or avoided.
And the second flow path 5 and the inlet flow path 6 form an included angle of 90 degrees. In this case, the reflection direction of the reflection molding liquid 12 is perpendicular to the inflow path 6, so that interference and collision between the reflection molding liquid 12 and the entering molding liquid 12 are formed to a large extent, and the turbulent flow state of the molding liquid 12 is slowed down, so that the molding liquid is made to approach a steady state;
third, the second flow path 5 is parallel to the inlet flow path 6. In this case, the partially reflective molding liquid 12 is guided or reflected to form a flow path parallel to and opposite to the inflow path 6, and the partially reflective molding liquid 12 collides with the inflow molding liquid 12 in a convection manner to considerably alleviate the turbulent state of itself.
The above-described flow paths are of course simultaneously possessed by the molding liquid 12, so that the reflection molding liquid 12 can be subjected to a process of situation alleviation to a large extent, and a process of mixing the molding liquid 12.
It can be seen that the outlet opening 2 of the flow body 1 is optimized and adjusted such that it is provided with at least:
firstly, the collision of paths between the molding liquid 12 is caused by the action of the reflecting surface 202 and the guiding surface 201, so that the turbulent flow state of the molding liquid 12 is smoothed, the molding liquid 12 is prevented from entering the cavity in a relatively violent state, the convection impact of a plurality of strands of molding liquid 12 is formed in the cavity, the diffusion is not needed, the molding quality of the multi-pass bulb is finally improved, and the molding defective rate is reduced;
Secondly, the forming liquid 12 is fully and uniformly mixed, so that the saturation of the forming liquid 12 in the runner before entering the cavity is improved, and the multi-port discharging synchronism and uniformity of the plurality of outflow ports 2 are improved.
More specifically, at least:
region one 701, the remaining regions described above, the region one 701 accommodating the occurrence of the path collision;
a second zone 702, a stagnation zone, the second zone 702 accommodating the guidance of the first flow path 3;
the first region 701 and the second region 702 are formed by dividing a region defined by the guide surface 201 and the reflection surface 202;
wherein the first region 701 is a partial region near the reflecting surface 202;
the second region 702 is a partial region near the guide surface 201;
and, the first region 701 (i.e., the remaining region) and the second region 702 (i.e., the stagnant region) do not have a defined split line.
In this embodiment, it has further been found that either the guiding surface 201 guides the molding liquid 12 or the reflecting surface 202 reflects the molding liquid 12, so that sufficient space is required for the molding liquid 12 to avoid being limited in the guiding process or the reflecting process due to the large restriction of the molding liquid 12.
Based on this, the guiding surface 201 and the reflecting surface 202 need to enclose a region.
This region is divided into a first region 701 and a second region 702. The first region 701 is used for providing a space for forming a path conflict with the rest of the molding liquid 12 according to the second flow path 5 after the molding liquid 12 is reflected, so as to increase the interaction time and the path conflict, further ensure that the path conflict of the molding liquid 12 occurs sufficiently and thoroughly, thereby slowing down the situation of the molding liquid 12 to a greater extent, and improving the saturation of the molding liquid 12.
The second zone 702 is used to provide a guiding space for the inflow molding liquid 12 according to the first flow path 3, so as to increase the guiding stroke and guiding space, and guide the molding liquid 12 in a step-by-step manner to change the flow path.
It should be noted that the first region 701 and the second region 702 do not have a relatively definite dividing line, and the volume ratio thereof also has a relatively complicated convection and mixing according to the molding liquid 12 and does not have a definite value.
The first region 701 and the second region 702 have a first property and a second property due to a change in the filling state of the molding liquid 12;
wherein the first property is configured to allow the first region 701 to accommodate the occurrence of the path conflict when the molding liquid 12 is not filled, and the second region 702 to accommodate the guiding of the flow path one 3;
The second property is configured to allow the molding liquid 12 flowing through the first region 701 to have a flow path three 8 and the molding liquid 12 flowing through the second region 702 to have a flow path four 9 when the molding liquid 12 fills;
and, the flow path III 8 coincides with the outflow path 4;
the flow path four 9 is a turning path.
In this embodiment, the various states of the molding liquid 12 in the aforementioned region, namely the filled state and the unfilled state, are present. The filled state should be understood as the aforementioned region being completely filled with the molding liquid 12, and the unfilled state should be understood as the aforementioned region being partially filled with the molding liquid 12.
Based on this, the molding liquid 12 in the first region 701 and the second region 702 also have different properties.
When the molding liquid 12 is in an unfilled state, the first region 701 and the second region 702 also have more white spaces, and these spaces can bear occurrence of path collision and occurrence of guiding of the molding liquid 12, so that the molding liquid 12 is guided and reflected in the first region 701 and the second region 702 according to the desired flow path. Namely, property one of region one 701 and region two 702.
When the pushing structure 10 pushes the molding liquid 12 in the first region 701 on the outflow path or close to the outflow path, the molding liquid 12 in the first region is pushed out to the outflow port 2 and enters the cavity, because the first region 701 and the second region 702 no longer have a blank space when the molding liquid 12 is in the full state. It is envisioned that the more the molding liquid 12 is pushed out, the less heat it consumes, and this portion of the molding liquid 12 enters the mold cavity to form the thin wall structure of the multipass bulb, i.e., the molding liquid 12 of the conduit passageway. As described above, the thin-walled structure requires a higher temperature, so that the occurrence of defects in the molded article can be reduced.
During the process of pushing the molding liquid 12 in the first region 701, the molding liquid 12 in the second region 702 forms a rotating path due to the collision between the molding liquids 12, and the rotating path cannot enter the outflow path and is pushed into the cavity. Thus, the molding liquid 12 of the second region 702 is pushed in with a delay, and the temperature of the molding liquid 12 is gradually consumed during the delay, so that the temperature after the molding liquid enters the cavity is relatively low to form the thick-wall structure of the multi-pass bulb, namely, the molding liquid 12 connected with the passage. As described above, when the wall thickness structure is molded by the molding liquid 12 having a relatively high temperature, defects in the wall thickness portion are generated.
The ninth embodiment of the present invention proposes a production process of a bulb die casting 13, and on the basis of the previous embodiment, the molding liquid 12 located in the stagnation area is at least used for filling the a-type area of the bulb die casting 13, and the molding liquid 12 located in the remaining area is at least used for filling the B-type area of the bulb die casting 13;
and, the wall thickness H1 of the A-type region > the wall thickness H2 of the B-type region.
In this embodiment, as described above, temperature control is required for the structures with different wall thicknesses, and the technical effects thereof are not described herein.
The tenth embodiment of the present invention proposes a production process of a bulb die casting 13, and on the basis of the previous embodiment, the surface temperature of the mold is q;
and, the value range of qThe enclosure is:wherein t is the casting temperature of the molding liquid.
In this embodiment, die temperature greatly affects die casting mechanical properties, dimensional accuracy, and die life. Therefore, the surface temperature of the mold must be defined to meet the above requirements to ensure satisfaction of the aforementioned requirements.
In describing embodiments of the present invention, it is to be understood that terms "upper", "lower", "front", "rear", "left", "right", "horizontal", "center", "top", "bottom", "inner", "outer", and the like indicate an azimuth or positional relationship.
In describing embodiments of the present invention, it should be noted that the terms "mounted," "connected," and "assembled" are to be construed broadly, as well as being either fixedly connected, detachably connected, or integrally connected, unless otherwise specifically indicated and defined; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention will be understood in specific cases by those of ordinary skill in the art.
In the description of embodiments of the invention, a particular feature, structure, material, or characteristic may be combined in any suitable manner in one or more embodiments or examples.
In describing embodiments of the present invention, it will be understood that the terms "-" and "-" are intended to be inclusive of the two numerical ranges, and that the ranges include the endpoints. For example: "A-B" means a range greater than or equal to A and less than or equal to B. "A-B" means a range of greater than or equal to A and less than or equal to B.
In the description of embodiments of the present invention, the term "and/or" is merely an association relationship describing an association object, meaning that three relationships may exist, e.g., a and/or B, may represent: a exists alone, A and B exist together, and B exists alone. In addition, the character "/" herein generally indicates that the front and rear associated objects are an "or" relationship.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (5)
1. The production process of the bulb die casting is characterized by at least comprising the following steps of;
a first plug-flow stage, wherein the first plug-flow stage pushes the molding liquid in the flow passage at a speed V1 and has a duration of T1;
a second plug-flow stage, which pushes the molding liquid in the flow passage at a speed V2 and has a duration of T2;
wherein the speed V2 of the second plug-flow stage is higher than the speed V1 of the first plug-flow stage;
wherein the duration T2 of the second plug-flow phase is smaller than the duration T1 of the first plug-flow phase;
the switching nodes of the first plug flow stage and the second plug flow stage are as follows: the molding liquid contacts an inner gate of the mold;
a pressurizing stage, namely pressurizing the forming liquid which completes the second plug-flow stage at least to a set pressure P2;
the set pressure P2 is larger than the pushing pressure P1 of the first pushing stage and the second pushing stage;
molding and demolding;
the distance between the initial point O of the pushing structure for marking pushing forming liquid and the inner gate in the second pushing stage is H;
and, H satisfies at least:；
wherein M is the mass of the molding liquid entering the flow channel at present, S is the cross-sectional area of the driving end of the plug flow structure, ρ is the density of the molding liquid, and K1 is the compensation coefficient;
And, the value range of the compensation coefficient K1 is as follows: 0.90 to 0.97;
the speed V1 of the first plug-flow stage and the speed V2 of the second plug-flow stage at least satisfy:
V2=V1×K2；
and, the value range of K2 is: 1.2 to 1.5;
the speed V1 of the first plug-flow stage and the speed V2 of the second plug-flow stage are both the moving speed of the driving end of the plug-flow structure;
the pushing pressure P1 and the set pressure P2 at least satisfy:
P2=P1＋K3；
and, the value range of K3 is: 15 to 30bar;
and, the value range of the push flow pressure P1 is as follows: 50bar to 70bar;
and, the value range of the set pressure P2 is as follows: 65bar to 100bar;
the casting temperature t of the molding liquid has the following range: 630 ℃ to 720 ℃;
wherein, in the second plug-flow stage, a stagnation area is formed at least in the flow passage;
and, the time node of the forming liquid in the stagnation area entering the forming chamber is later than the time node of the forming liquid in the rest areas entering the forming chamber;
wherein the temperature of the molding liquid in the stagnation area is t1 when the molding liquid is injected into the molding cavity, and the temperature of the molding liquid in the rest areas enters the molding cavity is t2;
And, t1< t2;
the flow channel comprises at least:
a flow channel body;
wherein, the outflow port of the runner body is provided with a plurality of outflow ports;
and, each of the outflow ports has at least:
a guide surface and a reflecting surface;
the structure of the runner is optimized, so that the first pushing flow path and the second pushing flow path of the molding liquid are divided into a plurality of flow paths;
the flow path I formed by guiding the molding liquid by the guiding surface and the outflow path of the molding liquid outflow port have a set included angle a;
the molding liquid is reflected by the reflecting surface according to the first flow path to form a second flow path;
and, the said second flow path forms the route conflict with its inflow path at least;
the path conflict includes:
the second flow path and the inlet flow path form a combination of various included angles which are not 90 degrees;
the second flow path and the inlet flow path form an included angle of 90 degrees;
the second flow path is parallel to the inlet flow path;
at least has:
a first zone accommodating the occurrence of the path conflict;
a second region accommodating the guidance of the first flow path;
the first area and the second area are formed by dividing an area formed by enclosing the guide surface and the reflecting surface;
Wherein the first area is a partial area close to the reflecting surface;
the second area is a partial area close to the guide surface;
and, said first and second regions do not have a defined parting line;
the first and second regions having a first and second property as a result of a change in the filling state of the forming liquid;
wherein the first property is configured to allow the first region to accommodate the occurrence of the path conflict when the molding liquid is not filled, and the second region to accommodate the guiding of the first flow path;
the second property is configured to allow the molding liquid flowing through the first region to have a third flow path and the molding liquid flowing through the second region to have a fourth flow path when the molding liquid fills;
and, the flow path three coincides with the outflow path;
the flow path IV is a rotary path;
when the molding liquid is in a filling state, the first area and the second area do not have a blank space, and when the pushing structure pushes, the molding liquid in the first area is positioned on the outflow path, so that the molding liquid in the first area is pushed out to the outflow port and enters the cavity; the more the molding liquid is pushed out, the less heat is consumed, and the part of molding liquid enters the cavity to form a thin-wall structure of the multi-way bulb tube;
In the process that the molding liquid in the first area is pushed and flowed, the molding liquid in the second area forms a rotary path due to collision among the molding liquids, and the rotary path can not enter the outflow path and is pushed into the cavity; therefore, the molding liquid in the second area is pushed in a lagging way, and the temperature of the molding liquid is gradually consumed in the lagging process, so that the temperature of the molding liquid after entering the cavity is relatively low to form a thick-wall structure of the multi-way bulb tube;
the forming liquid in the stagnation area is at least used for filling an A-type area of the bulb die casting, and the forming liquid in the rest areas is at least used for filling a B-type area of the bulb die casting;
and, the wall thickness H1 of the A-type region > the wall thickness H2 of the B-type region.
2. The bulb die casting production process of claim 1, wherein the shaping liquid has a plug flow path one by the first plug flow stage;
the forming liquid is provided with a second plug flow path by the second plug flow stage;
the first plug flow path flows towards the direction of the inner pouring gate;
the second plug flow path flows in the direction of entering the forming cavity;
the end point of the first plug flow path and the start point of the second plug flow path are both inner gates of the mold, and the front end of the molding liquid reaches the inner gates to serve as switching nodes of the first plug flow stage and the second plug flow stage.
3. The process for producing a bulb die casting according to claim 1, wherein the duration T2 of the second plug flow stage has a value ranging from: 0.05s to 0.1s.
4. The process for producing a bulb die casting according to claim 1, wherein the forming and demolding phases comprise at least:
and a pressure maintaining stage, wherein the value range of the pressure maintaining time T3 in the pressure maintaining stage is as follows: 5s to 8s;
and a die-retaining stage, wherein the value range of the die-retaining time T4 in the die-retaining stage is as follows: 8s to 12s;
and (5) demolding.
5. The process for producing a bulb die casting according to claim 1, wherein the surface temperature of the die is q;
and, the value range of q is:；
wherein t is the casting temperature of the molding liquid.
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