EP1105237A1 - Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux - Google Patents

Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux

Info

Publication number
EP1105237A1
EP1105237A1 EP99944412A EP99944412A EP1105237A1 EP 1105237 A1 EP1105237 A1 EP 1105237A1 EP 99944412 A EP99944412 A EP 99944412A EP 99944412 A EP99944412 A EP 99944412A EP 1105237 A1 EP1105237 A1 EP 1105237A1
Authority
EP
European Patent Office
Prior art keywords
calculated
mold
temperature
time
solidification
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP99944412A
Other languages
German (de)
English (en)
Other versions
EP1105237B1 (fr
Inventor
Christophe Bagnoud
Miroslaw Plata
Jürgen Wüst
Klaus Währisch
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3A Composites International AG
Original Assignee
Alusuisse Technology and Management Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alusuisse Technology and Management Ltd filed Critical Alusuisse Technology and Management Ltd
Priority to EP99944412A priority Critical patent/EP1105237B1/fr
Publication of EP1105237A1 publication Critical patent/EP1105237A1/fr
Application granted granted Critical
Publication of EP1105237B1 publication Critical patent/EP1105237B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • 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
    • B22D17/007—Semi-solid pressure die casting
    • 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

Definitions

  • the invention relates to a method for process monitoring in die casting or thixoforming of metals in a vacuum in a mold.
  • the invention has for its object to provide a method of the type mentioned with which the production of die cast and thixo molded parts can be continuously and reliably monitored under production conditions.
  • the solution to the object according to the invention is that the time profile of the temperature at at least one point in the system is measured continuously and the temperature profile of the system is calculated in real time using a program, and that the time profile of the heat flow and the heat flow are calculated from the temperature profile of the system the time course of the energy of the system and the amount of heat of solidification of the solidified metal is calculated, values calculated at a fixed point in time being used as characteristic values for the monitoring.
  • the amount of heat that is exchanged per unit of time between the metal to be cast and the mold halves determines the rate of solidification of the part produced by die casting or thixoforming. Since the characteristics of this exchange directly determine the mechanical properties of the die-cast or thixiform part, monitoring the solidification of the metal in the mold is essential to maintain a high quality standard.
  • the detection of the amount of solidification heat dissipated via the mold makes it possible, among other things. determine whether the solidification takes place completely within the mold, whether pre-solidification occurs or what liquid-solid ratio is present in a thixomaterial.
  • a major part of the heat that is exchanged during solidification comes from the latent heat released during solidification.
  • the amount of latent heat in turn depends heavily on the liquid metal content when filling the mold cavity.
  • the amount of latent heat given off via the mold halves in turn depends on the metal to be cast or on the alloy used and can be further influenced by the temperature of the mold or mold halves, by the pressure exerted, by the piston speed and by the thickness of the lubricant layer become.
  • the heat exchange that takes place during the various phases of solidification is calculated using a program.
  • the calculations are based on temperature measurements on the mold, the temperature in the mold wall preferably being measured and the time profile of the temperature on the shaping surface of the mold being calculated.
  • sensors are used which are attached in the mold wall of the mold halves at a distance of, for example, 1 mm from the surface.
  • the program takes inverse heat conduction into account and calculates the temperature in real time the shaping surface of the mold halves and the heat exchange between the solidifying metal and the mold. With the temperature sensors arranged in this way, the uniformity of the cooling process and the thermal equilibrium on the mold surface can be monitored in real time in the various successive phases of casting and cooling.
  • the sensors are therefore preferably arranged at locations where the thermal equilibrium and solidification can be easily detected.
  • a characteristic value for the amount of solidification heat dissipated at a specified time is preferably between approximately 20% and 100%, in particular between approximately 50% and 100% of the maximum amount of solidification heat.
  • the temperature calculated immediately before each shot for the mold surface can be used as a further characteristic value.
  • the time course of the heat exchange coefficient can be calculated from the time course of the temperature.
  • the value for the heat exchange coefficient e.g. the maximum values in the solidification phase or in the cooling phase, or also the entire curve profile, can be used as further additional characteristic values.
  • the time course of the solidification length can be calculated from the time course of the temperature. Solidification length is understood to mean the thickness of the solidified metal measured from the mold surface. The solidification length calculated at a specified time can be used as a further additional characteristic value.
  • characteristic values are the minimum pressure, which is determined from the measurement of the time course of the pressure in the mold cavity, and the minimal relative humidity measured immediately before a shot in the mold cavity.
  • the calculated or measured characteristic values can be compared as actual values with corresponding target values, it being possible for an alarm to be triggered within a tolerance range if the actual values deviate from the target values in an impermissibly strong manner and the die casting or thixoforming process is interrupted when the tolerance range is exceeded becomes.
  • the setpoint for the amount of solidification heat removed is given, for example, as an average value with a standard deviation.
  • the standard deviation can, for example, be set as the first tolerance limit, the exceeding of which triggers an alarm due to the actual value.
  • a particularly interesting area of application of the process is die casting and thixoforming, in particular of aluminum and magnesia. alloys, for example for the production of safety components for the automotive industry.
  • 2 shows the temperature profile over time during a die casting cycle
  • 3 shows the time course of the energy during a die casting cycle
  • 5 shows the course of the temperature over time as the mold cools in area B of FIG. 2
  • 6 shows the course over time of the heat exchange coefficient during the cooling of the mold in region B of FIG. 2;
  • Aluminum alloys with increasing number of shots 9 shows a die casting system with process monitoring.
  • FIG. 8 shows the result of a series of tests with three different aluminum alloys. 128 identical parts were cast on the same die casting machine, namely 79 parts made of alloy 1, 35 parts made of alloy 2 and 14 parts made of alloy 3.
  • the standard deviation defines a first limit value, which includes a tolerance range R with a second limit value.
  • the second limit delimits the tolerance range R from the error range S. If two successive actual values U E n for the amount of solidification heat fall within the tolerance range R, as is the case with sections 76 to 79 (area X), an alarm is triggered and the corresponding correction is initiated.
  • Deviations are immediately displayed online.
  • the calculated values can be forwarded, for example, via an RS232 interface to a programmable machine that controls the die casting machine.
  • the data is checked, if necessary displayed and finally archived. If the calculated values for the amount of solidification heat fall within the tolerance range R, an alarm can be triggered directly by the machine. An automatic production stop can be triggered, for example, in the case of more deviating values which fall in the area S.
  • temperature sensors can be arranged at various points in the mold halves.
  • the calculations are preferably carried out individually for the individual temperature sensors and also recorded individually as monitoring results. In this way it is possible to localize specific production problems on the mold.
  • the recorded monitoring results are expediently archived and can later be used, for example, to demonstrate the production quality of a specific die-cast or thixiform part.
  • the process monitoring can be understood from the following description of FIG. 9.
  • a die casting system 10 has a filling chamber 12 with a filling chamber cavity 14.
  • the liquid metal filled into the filling chamber cavity 14 from a furnace 18 via a feed line 20 for each shot is injected with a piston 16 from a filling channel 22 out of the filling chamber cavity 14 into a mold cavity 28 formed from a fixed mold half 24 and a movable mold half 26.
  • the mold cavity 28 has one or more ventilation channels 30, which may be combined to form a collecting channel.
  • a control insert 32 with a control pin 34 is arranged in the fixed mold half 24.
  • the control pin 34 has a closure head 36 for opening or closing the ventilation duct 30.
  • the control bolt 34 is displaced by means of an actuating cylinder 38. When the mold has been filled, the venting channel 30 at the end of the mold cavity 28 is closed via the closure head 36 of the control bolt 34.
  • a vacuum line 40 connects to the control insert 32 and is connected via valves 42 to a vacuum container, not shown in the drawing. Before the metal is shot into the mold cavity 28, the latter is evacuated and the time profile of the pressure in the mold cavity 28 is measured via a pressure sensor 44 connected into the vacuum line 40.
  • Temperature sensors 46 are arranged at different points in the two mold halves 24, 26. Not shown in the drawing is a probe connected to the mold cavity for measuring the relative humidity.
  • the temperature sensors 46, the pressure sensor 44 and the probe (not shown) for measuring the relative humidity are connected to a program-controlled computer 48.
  • This computer transfers the measured and calculated parameters to a data acquisition device 50 for monitoring and archiving. An alarm or a production stop when tolerance values for individual or all characteristic values are exceeded is triggered directly by the computer.

Abstract

L'invention concerne un procédé de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de métaux sous vide, dans un moule, selon lequel la courbe temporelle de la température (T) est mesurée en continu en au moins un point du système et la courbe de température du système est calculée en temps réel à l'aide d'un programme. La courbe temporelle du flux thermique (W) est dérivée de la courbe temporelle du système et la courbe temporelle de l'énergie (U) du système, ainsi que le volume de chaleur de solidification (UE) du métal solidifié dans le moule sont calculés à partir du flux thermique. Des valeurs calculés à un moment déterminé sont utilisées comme paramètres pour la surveillance.
EP99944412A 1998-08-27 1999-08-16 Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux Expired - Lifetime EP1105237B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP99944412A EP1105237B1 (fr) 1998-08-27 1999-08-16 Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP98810846A EP0982089A1 (fr) 1998-08-27 1998-08-27 Procédé de contrôle le processus de couler à pression ou formage thixotropique
EP98810846 1998-08-27
PCT/EP1999/006002 WO2000012246A1 (fr) 1998-08-27 1999-08-16 Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux
EP99944412A EP1105237B1 (fr) 1998-08-27 1999-08-16 Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux

Publications (2)

Publication Number Publication Date
EP1105237A1 true EP1105237A1 (fr) 2001-06-13
EP1105237B1 EP1105237B1 (fr) 2002-05-29

Family

ID=8236284

Family Applications (2)

Application Number Title Priority Date Filing Date
EP98810846A Withdrawn EP0982089A1 (fr) 1998-08-27 1998-08-27 Procédé de contrôle le processus de couler à pression ou formage thixotropique
EP99944412A Expired - Lifetime EP1105237B1 (fr) 1998-08-27 1999-08-16 Procede de surveillance de processus s'utilisant lors du moulage sous pression ou du thixoformage de metaux

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP98810846A Withdrawn EP0982089A1 (fr) 1998-08-27 1998-08-27 Procédé de contrôle le processus de couler à pression ou formage thixotropique

Country Status (9)

Country Link
US (1) US6557617B1 (fr)
EP (2) EP0982089A1 (fr)
AT (1) ATE218081T1 (fr)
CA (1) CA2341264A1 (fr)
DE (1) DE59901565D1 (fr)
DK (1) DK1105237T3 (fr)
ES (1) ES2176025T3 (fr)
PT (1) PT1105237E (fr)
WO (1) WO2000012246A1 (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7886807B2 (en) * 2007-06-15 2011-02-15 Die Therm Engineering L.L.C. Die casting control method
JP4889783B2 (ja) * 2009-11-17 2012-03-07 日信工業株式会社 重力鋳造方法
DE102010053125A1 (de) * 2010-12-01 2012-06-06 Volkswagen Ag Verfahren zum Herstellen einer Serie von Gussbauteilen und Vorrichtung zum Herstellen eines Gussbauteils
DE102012220513B4 (de) * 2012-11-12 2023-02-16 Bayerische Motoren Werke Aktiengesellschaft Verfahren und Vorrichtung zur Herstellung eines Druckgussteils

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS57187154A (en) * 1981-05-15 1982-11-17 Toyota Motor Corp Method and device for inspecting quality of product produced by die casting machine
US4493362A (en) * 1982-05-27 1985-01-15 Ex-Cell-O Corporation Programmable adaptive control method and system for die-casting machine
DE3380662D1 (en) * 1983-05-20 1989-11-09 John Mickowski Process for monitoring and controlling intermittently working molding and casting devices and apparatus for performing said process
US4976305A (en) * 1987-12-01 1990-12-11 Honda Giken Kogyo Kabushiki Kaisha Method of and apparatus for controlling die temperature in low-pressure casting process
US5407000A (en) * 1992-02-13 1995-04-18 The Dow Chemical Company Method and apparatus for handling molten metals
DE4444092C2 (de) * 1994-10-12 1997-02-13 Werner Kotzab Verfahren und Anordnung zum Temperieren einer Spritzgießform mit wenigstens einer beheizten Düse oder einem Heißkanal
US5772933A (en) 1994-10-12 1998-06-30 Kotzab; Werner Method for tempering an injection mold having at least one heated nozzle or hot runner
US5758707A (en) * 1995-10-25 1998-06-02 Buhler Ag Method for heating metallic body to semisolid state
US6148899A (en) * 1998-01-29 2000-11-21 Metal Matrix Cast Composites, Inc. Methods of high throughput pressure infiltration casting

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO0012246A1 *

Also Published As

Publication number Publication date
ES2176025T3 (es) 2002-11-16
CA2341264A1 (fr) 2000-03-09
PT1105237E (pt) 2002-09-30
EP1105237B1 (fr) 2002-05-29
ATE218081T1 (de) 2002-06-15
DE59901565D1 (de) 2002-07-04
WO2000012246A1 (fr) 2000-03-09
US6557617B1 (en) 2003-05-06
DK1105237T3 (da) 2002-09-23
EP0982089A1 (fr) 2000-03-01

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