WO2021117050A1 - Ensemble injecteur de coulée sous pression comprenant un mécanisme de liaison - Google Patents

Ensemble injecteur de coulée sous pression comprenant un mécanisme de liaison Download PDF

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Publication number
WO2021117050A1
WO2021117050A1 PCT/IN2020/050185 IN2020050185W WO2021117050A1 WO 2021117050 A1 WO2021117050 A1 WO 2021117050A1 IN 2020050185 W IN2020050185 W IN 2020050185W WO 2021117050 A1 WO2021117050 A1 WO 2021117050A1
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WO
WIPO (PCT)
Prior art keywords
stroke
shot
squeezing
cylinder
length
Prior art date
Application number
PCT/IN2020/050185
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English (en)
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WO2021117050A8 (fr
Inventor
Mangesh PATWARDHAN
Original Assignee
Patwardhan Mangesh
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 Patwardhan Mangesh filed Critical Patwardhan Mangesh
Priority to PCT/IN2020/050185 priority Critical patent/WO2021117050A1/fr
Publication of WO2021117050A1 publication Critical patent/WO2021117050A1/fr
Publication of WO2021117050A8 publication Critical patent/WO2021117050A8/fr

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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
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B22D17/203—Injection pistons
    • 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
    • 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

  • Pressure Die-casting injector assembly comprising link mechanism.
  • the present invention relates to an injection mechanism of Cold Chamber High Pressure Die Casting (HPDC) machine. More specifically it relates to an improvement in conventional machine injection mechanism, conducted by replacing its hydraulic intensifier with a link mechanism.
  • the present invention ensures high degree of utilization of hydraulic potential energy produced by the system and more reliable process.
  • This present invention may be adapted for conventional High Pressure Die Casting Machines of the day.
  • HPDC machine mainly consist of Die closing mechanism, Injection mechanism and Ejector mechanism.
  • Die closing mechanism has the function of closing die halves together and to form die cavity(s). Usually die casting machine capacity is specified in terms of its locking force.
  • Injection mechanism (Shot End) has the function of filling die cavity 82 with molten light metal like Aluminum alloy and squeezing it further.
  • Function of Ejector mechanism is to eject out the casted part.
  • Injection process broadly comprise of three phases.
  • injector velocities are principally monitored as per given manner of shot setting.
  • This segment 88 covers most part of the actual shot stroke.
  • hydraulic intensifier 93 When predetermined pressure or stroke position is reached hydraulic intensifier 93 is actuated. Once die cavity is almost filled, third phase is applied. This phase is also called as intensification phase or squeezing stroke 89. During this phase injector cylinder intensification pressure and in turn specific casting pressure (metal pressure) is monitored.
  • squeezing stroke happens to be up to 1 % of total stroke. For instance, squeezing stroke happens to be less than 10mm for total stroke of 1000mm.
  • the activity prior to injection shot is to pour molten metal quantity into the filling chamber (sleeve) 84. Said activity has unavoidable variation in poured metal quantity.
  • Another drawback of conventional injector mechanism is final intensification force applied on molten metal for the length irrespective of variation in metal quantity. It is applied through the length till injector motion stops itself. This increases flashing tendency and many times flash is controlled by reducing shot force or over tightening of die locking or reducing some other input parameters. Flashing and other adapted preventive remedies have negative effect on casting quality.
  • the aim of this invention is to provide an injector mechanism for pressure die casting systems that overcomes the drawbacks of cited prior art with adherence to the essential requirement that this invention should not require any change in conventional injector control systems used for first two phases (Filling phases), that is except for intensification phase and should have matching injection stroke profile and to finish complete injection stroke in the similar time bound manner.
  • an object of invention is to provide injection mechanism that ensures higher degree of utilization of hydraulic potential energy produced by the system by cutting down energy wastage.
  • Another object is to provide injection mechanism constituted to produce higher momentum during injector motion to make the process most tolerant to external fluctuations.
  • Another object is to provide injector mechanism that is constituted to allow an automatic injection stroke adjustment responding to the variation in metal quantity.
  • Another object is to provide an additional injection stroke control feature that allows die caster to limit the squeezing stroke length. This feature will provide an advantage for the process optimization.
  • the basic idea of present invention solution is to replace conventional hydraulic intensifier at shot end by a link mechanism for injection shot finishing and squeezing stroke operation ⁇ Intensification Phase ).
  • the link mechanism is incorporated in injector mechanism in such a way that it does not make any change in the given manner of operation of first two filling phases.
  • Fig.1 illustrates the schematic diagram of the present invention.
  • upper half portion shows finished injection stroke, whereas lower half portion shows home position before shot operation.
  • the link mechanism 15 is interposed between Shot cylinder piston rod 16 and shot plunger rod 14 with its shot plunger 85 inserted in the sleeve 84.
  • the present invention injector mechanism contains Stroke adjustment mechanism 20.
  • This link mechanism 15 comprises Link assembly 25, Link assembly locking hydraulic cylinders 18, Slip Stroke hydraulic cylinder 21 and Squeeze Stroke Adjustment mechanism.
  • Link mechanism In order to employ Link mechanism’s considerable mechanical advantage exclusively for intensification phase stroke and not to have its effect on prior filling phase stroke (first two phases) a sub mechanism is incorporated, which unlocks link mechanism at predetermined position of stroke. After this unlocking only, links are free to move. Thus no change is required in the given control system for first two filling phases.
  • Shot plunger rod 14 is connected to Slip stroke cylinder piston rod 35, that is Slip stroke cylinder piston rod can move Shot plunger rod and vice versa.
  • Diameter of Slip Stroke Cylinder will be little more than diameter of conventional shot cylinder. This depends on recommended and safe working pressure of hydraulic fluid and the shot force.
  • Slip stroke cylinder body 38 is fixed on Front plate 31 of link mechanism. Squeezing Stroke Adjustment mechanism interposed between Slip stroke cylinder 21 and Cross head plate 17 which is connected to Shot cylinder piston rod 16.
  • Stroke adjustment shafts 19 are connected to Intermediate plate 32 and Lock Wedge mechanism fixed 23 on Shot End Platen 29.
  • the present invention mechanism operation sequence:
  • Shot cylinder stroke starts with Shot cylinder shaft carrying link assembly 25 in locked condition. During this segment of stroke as link mechanism is in the locked condition motion force of shot cylinder piston rod is directly transmitted to shot plunger rod 14.
  • link mechanism 15 is unlocked.
  • Intermediate plate 32 is anchored, Collar nuts 24 on rear side of Length adjustment shafts 19 hits on Shot end platen 29 and are locked in the position by hydraulic wedge lock 23.
  • This Intermediate plate 32 anchoring starts link assembly movement.
  • motion force transmission from Shot cylinder piston rod 16 to shot plunger rod 14 is started trough link mechanism 15, which is indirect motion transmission.
  • Link mechanism geometry is designed in such a way so as to have force multiplication factor of one during this switchover and for next some part of the stroke. Stroke length covered having multiplication factor of one is approximately 92% of total stroke length.
  • Slip stroke cylinder 21 After solidification (cooling) time finished, during die opening Slip stroke cylinder 21 will be filled to its home position. This activity will push out the biscuit 92 (plunger follow through).
  • the present invention consisting link mechanism by virtue of its mechanical advantage provides force multiplication of five plus times for a length well sufficient for intensification phase segment (squeezing Stroke).
  • This characteristic allows for the reduction of Shot Cylinder diameter to less than half of the conventional machine and reduction in its swept volume to approximately half of the conventional machine. Accordingly hydraulic potential energy supplying accumulator capacity also is reduced. It is approximately of half capacity with respect to accumulator of conventional machine.
  • This accumulator capacity reduction ensures higher degree of utilization of hydraulic potential energy created by system, by cutting down energy wastage.
  • the present invention consisting link mechanism has added mass.
  • Total mass of moving parts of the present invention is estimated to be four to five times of total moving mass of conventional injector mechanism. Accordingly when link mechanism is incorporated, filling phase momentum is high, but well within accumulator capacity. This high momentum fills the cavity very effectively overcoming cavity filling turbulences caused due to cavity geometry. This high momentum will even enables to cast less fluid alloy. Also cavity filling process is most tolerant to external fluctuations and capable of casting more intricate geometric shapes with betterment of cavity filling characteristics.
  • the present invention mechanism contains Slip Stroke Cylinder.
  • Primary function of Slip Stroke Cylinder 21 is to disconnect and reconnect the motion force transfer between link mechanism 15 and Shot Plunger rod 14 which injects fluid metal into the die cavity 82.
  • This motion disconnection stroke happens when a predetermined pressure is reached in shot cylinder, said position depends on the quantity of molten metal.
  • Motion transfer reconnection happens as per the preset squeezing stroke length. That is the length of this disconnected stroke segment i.e. slip stroke gets adjusted according to the variation in quantity of molten metal.
  • squeezing stroke happens. This squeezing stroke is consistent despite of the said variation in metal quantity.
  • This novel feature of automatic adjustment of Slip stroke segment length responding to variation of metal quantity provides consistent length squeezing happening thereafter, cuts down flashing tendency. That is the present mechanism provides a consistent volumetric squeezing of casting in formation.
  • This novel feature of varying length Slip stroke of the present invention eliminates the drawback of conventional mechanism which causes intensification force applied on molten metal through the length irrespective of variation in metal quantity.
  • intensification (squeezing) stroke length happens to be as per the corresponding length preset at squeezing stroke adjustment mechanism.
  • This added control feature will enable die caster to use final squeezing stroke of higher force with limited squeezing length than the reduction in shot force. That is the feature allows for the limiting of volumetric squeezing.
  • Said control provides an advantage for casting parts requiring short cavity filling time but less volumetric squeezing and thin wall parts. This is process optimization.
  • Shot cylinder rod side chamber volume is reduced. This will make energy saving during returning of Shot Plunger rod.
  • die casting machine selection is done on the basis of Specified locking force of machine, the total projected area of corresponding die cavity and applied specific casting pressure. Intent is total casting force should not exceed die locking force.
  • Velocity retardation during cavity filling finishing will be delayed by virtue of increased inertia. This will consume the power.
  • slip stroke cylinder draining is stopped by shutting off drain valve system motion force will build pressure inside slip stroke cylinder chamber 36 to initiate squeezing stroke.
  • Shot end side link mechanism holds some advantages. Shot Injection force has to overcome collinear cavity filling counter force and to force squeezing through collinear sleeve Not subjected to any shock force or imbalanced (off-center) force.
  • Stroke adjustment shaft collar nuts will hit shot end platen at relatively high speed. But except intermediate plate anchored at that time, motion of machine’s shot cylinder plunger rod, link mechanism and moving parts ahead of it will be continued hence there will not be any major momentum break. Load on subjected parts will not be higher. (Mass of Intermediate plate, stroke adjustment shafts and Nuts ‘Velocity at that time). Possibility to Increase squeezing stroke length beyond 1% of total stroke:
  • the present invention link mechanism provides increasing force multiplication factor of 4+ for approximately 1.5% of total shot plunger stroke length. Therefore it can be extended up to 1.5% of total shot plunger stroke length.
  • the present invention has biscuit accommodation capacity of about 10% of total stroke length. This may be extended.
  • FIG. 1 is showing schematic top view of the present invention comprising Link mechanism 15 interposed between Shot cylinder piston rod 16 and Injector plunger rod 14. Upper half portion shows finished injection stroke, and lower half portion shows the home position before shot operation.
  • FIG. 2 is showing a section view of Slip stroke cylinder 21, drain duct 37, mechanical shut-off valve 46 and Squeezing stroke length setting hydraulic cylinder 22.
  • FIG. 3 is graph, to be followed for deriving advance length of piston rod 33 of Squeezing stroke length setting cylinder 22 for the desired Squeeze stroke length.
  • This graph is scatter line graph of points joining, positions of Front plate 31 from the end point of total shot stroke (X axis) and corresponding balance gap reduction length at that position (Y axis). Said gap is the distance between Front plate 31 and Cross head plate 17.
  • FIG. 4 is a sectional view showing basic structure of the conventional die casting machine and illustrates the associated details of injector stroke.
  • FIG. 5 is a graph showing respective movement lengths and positions of Shot cylinder piston rod 16, Front plate 31 and Injector plunger rod 14.
  • FIG. 6 is showing estimated injection stroke profile, Velocity curve, Metal pressure curve and Stroke advance of the present invention in comparison with an example of conventional mechanism injection stroke profile of the same parameters.
  • FIG.1 is an overall schematic top view of the present invention shot end containing the link mechanism.
  • All injector motions operated by said shot cylinder will be through pressurized hydraulic fluid supplied by its accumulator and will be regulated by the control system of given conventional injector mechanism. As hydraulic intensifier and its accumulator are eliminated, its associated control system is discarded.
  • FIG. 1 Structure of embodiment mechanism is illustrated in fig. land fig. 2:
  • the Shot cylinder 11 is fixed on Shot End Platen 29.
  • Front end of Shot cylinder piston rod 16 is connected to Cross head plate 17.
  • Link assembly 25 drive end is linked with Cross head plate 17.
  • Rear ends of linked assembly 25 are connected to Intermediate plate 32.
  • Front ends of Link assembly 25 are connected to Front plate 31.
  • Intermediate plate 32 and Front plate 31 slides on guide bars 28.
  • Slip stroke cylinder body 38 is fixed on front plate 31.
  • Injector (shot) plunger rod 14 is connected to Slip Stroke cylinder piston rod 35.
  • Slip stroke cylinder 21 is a single acting cylinder.
  • Piston rod Position detecting hydraulic cylinder 22 is fixed on Cross head plate 17. This cylinder is part of Squeezing stroke length setting mechanism.
  • Two single acting hydraulic cylinders 18 are fixed on rear side of Front plate 31. These cylinders will lock link assembly 25 and also act as stoppers to avoid excess travel of Shot cylinder piston rod 16. Stroke adjustment shafts 19 are connected at rear side of Intermediate plate 32. Hydraulic lock wedges 23 are fitted on rear side of Shot End platen 29.
  • Setting of Stroke length of the present mechanism As illustrated in Fig. 4 Active sleeve length 90 (filling chamber length) is the length of complete travel of shot plunger rod during dry shot (without metal shot). This active sleeve length varies from die to die. According to design of working of the present mechanism it is required to adjust the stroke length of mechanism after every die set-up change or change in active sleeve length 90.
  • Intent of this stroke adjustment is to have complete designed travel movement of link mechanism 15 and its front plate 31 so as to employ Link mechanism’s highest mechanical advantage exclusively for intensification phase stroke 89 and not to have its effect on prior filling phase stroke 88 (first two phases). Accordingly length of indirect stroke of Front Plate is constant for all length strokes. Length of direct shot stroke 76 with locked link mechanism is adjusted as per active sleeve length 90.
  • Active sleeve length is sum of Travel length of Front plate (indirect motion) and Length of direct motion transmission (locked link mechanism) So the length of direct motion transmission is the distance between Shot end platen 29 and collar nuts 24 of stroke adjustment shaft 19.
  • Stroke adjustment shaft 19 length is adjusted by adjusting the positions of collar nuts 24.
  • Non limiting example For Active sleeve length of 850mm and Complete Front Plate travel of 114mm. Distance between Shot end platen 29 and Collar nuts 24 will be 736mm (850-114).
  • Non limiting example According to the graph illustrated in Fig.3, the corresponding advance position of Piston rod 33 of Squeezing stroke length setting cylinder 22 is derived.
  • Piston rod 33 advance position 55 will be 51.3mm.
  • Said advance position of Piston rod 33 is set by actuation of solenoid valve 44, regulated by analog signal of advancement.
  • hydraulic accumulator Prior to die closing hydraulic accumulator is charged with line pressure. This accumulator provides pressurized hydraulic fluid to shot cylinder through hydro-electric control system.
  • Shot cylinder 11 stroke starts with its Piston rod 16 carrying Crosshead plate 17, link assembly 25 in locked condition, Front Plate 31 and Intermediate plate 32 sliding on Guide bars 28. During this segment of stroke as link assembly 25 is in locked condition motion force of shot cylinder piston rod 16 is directly transmitted to shot plunger rod 14.
  • At predetermined stroke position 76 Collar nuts 24 on Stroke adjustment shafts hits on Shot end platen 29.
  • limit switches not shown in Fig.
  • hydraulic locking wedges 23 are actuated and collar nuts are locked in the position.
  • There is sufficient time for wedge locking as there is no back force till intensification phase (squeezing stroke) is triggered.
  • Intermediate plate 32 gets anchored at the position 76 as it cannot move any further and backward.
  • slip stroke restarts indirect motion of Shot plunger rod, but this time motion force transmitted is high by virtue of mechanical advantage of link mechanism.
  • This phase is continued till the end of Shot cylinder piston rod 16 stroke.
  • cylinder body 38 possessing high motion force first compresses the enclosed hydraulic fluid in piston side chamber 36 till it overcomes the counterforce of cavity filling, then its piston rod 35 starts to move.
  • intensification phase squeeze stroke
  • Link assembly geometry 25 is designed to have increasing force multiplication during squeezing stroke, at 5+ times and for last nearly 1 mm above 13 times.
  • Slip stroke cylinder pressure monitored is equal to desired final intensification force divided by surface area of Piston of Slip stroke cylinder. Where intensification force considered is preferably five times of Shot cylinder force (Shot cylinder pressure * Surface area of Piston of Shot cylinder). Shot cylinder pressure may be regulated accordingly.
  • the Slip Stroke time consumption is compensated by reduction in pressure rise time of squeezing phase by virtue of inertia of moving parts.
  • squeezing stroke is finished with preset length.
  • Cross head plate 17 rests on retracted piston rods 27 of link assembly locking cylinders 18. (Cylinder stroke is equal to Gap reduction length)
  • solenoid valve 42 opens and fills Slip stroke cylinder with a line pressure to its home position. This activity pushes out the biscuit 92 (plunger follow through). This length of push-out is equal to the length of Slip stroke happened.
  • the advance position of Piston rod 33 of Squeezing stroke length setting cylinder 22 is reset by actuation of solenoid valve 44, regulated by analog signal of advancement. If there is any error of squeezing stroke length, that may be compensated during resetting advance length of Piston rod. Since the present embodiment is the modification of mechanical mechanism of the conventional injector assembly various non limited system control circuits (electric and hydraulic) and alternate control valves may be adapted for the present invention.
  • the present invention mechanism by virtue of its mechanical advantage provides force multiplication of five plus times.
  • Conventional mechanism has a hydraulic intensifier with pressure multiplication factor of up to 2 times.
  • the high multiplication factor allows for the reduction of Shot cylinder diameter (area).
  • Shot Cylinder of dia.145mm delivers Intensification force of 116 Ton. at shot cylinder pressure of 140 kg per Sq.cm against conventional Intensification force of 109 ton delivered by shot cylinder of dia. 215mm at intensification pressure 300 kg per Sq.cm.
  • Shot cylinder area is reduced to 45% of conventional size.
  • hydraulic accumulator capacity reduced to approx. 50%. Also an accumulator for hydraulic intensifier is eliminated.
  • the present invention has added mass of 500kg (for 1400Ton machine), about four times with respect to estimated 125kg mass of moving parts of conventional injector mechanism.
  • the present invention Injector momentum will be 3125kg. m/s. (625* 5) As illustrated in the Fig. 6:
  • Increased mass will require higher driving force, means higher pressure to create the force. This relatively higher pressure building will take some time resulting in somewhat slow start and lower acceleration 71. This increased moving mass will increase shot motion momentum and inertia.
  • velocity rise position may be shifted short accordingly.
  • slip stroke event 73 This is anticipation for Slip stroke of 40mm, corresponding Shot cylinder piston rod stroke of 81mm is completed in 0.03 sec at the speed 2.7m/s.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Fluid-Pressure Circuits (AREA)

Abstract

Mécanisme d'injecteur destiné à une machine de coulée sous pression comprenant un mécanisme de liaison 15 qui, à son plus grand avantage mécanique, est utilisé exclusivement pour une phase d'intensification de la course d'injecteur. Grâce audit plus grand avantage mécanique, le volume balayé du vérin d'injection et de la capacité d'accumulateur hydraulique sont réduits de 50 %, ce qui assure un degré élevé d'utilisation de l'énergie hydraulique produite par le système. La masse mobile lourde du mécanisme augmente la quantité du mouvement d'injection, ce qui se traduit par un procédé de remplissage de cavité plus tolérant. Il existe une nouvelle caractéristique, une course de glissement de longueur variable se produisant entre une course de remplissage et une course d'intensification. La longueur de la course de glissement varie en réaction à la variation de quantité de métal, et est suivie d'une longueur de course d'intensification constante, ce qui réduit la tendance à la bavure. Il existe une nouvelle commande de processus ajoutée, permettant au fondeur de matrice de limiter la longueur de course d'intensification, ce qui s'avère avantageux pour la mise en oeuvre du procédé.
PCT/IN2020/050185 2020-02-28 2020-02-28 Ensemble injecteur de coulée sous pression comprenant un mécanisme de liaison WO2021117050A1 (fr)

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PCT/IN2020/050185 WO2021117050A1 (fr) 2020-02-28 2020-02-28 Ensemble injecteur de coulée sous pression comprenant un mécanisme de liaison

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PCT/IN2020/050185 WO2021117050A1 (fr) 2020-02-28 2020-02-28 Ensemble injecteur de coulée sous pression comprenant un mécanisme de liaison

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6308766B1 (en) * 1999-03-05 2001-10-30 Alusuisse Technology & Management Ltd. Process for die-casting light-weight metals
US7210517B2 (en) * 2001-02-20 2007-05-01 Toshiba Kikai Kabushiki Kaisha Die casting machine
JP5063081B2 (ja) * 2006-11-02 2012-10-31 東洋機械金属株式会社 ダイカストマシン
US20150266087A1 (en) * 2014-03-21 2015-09-24 Italpresse Industrie S.P.A. Die-casting machine with injection assembly with a shut-off valve

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6308766B1 (en) * 1999-03-05 2001-10-30 Alusuisse Technology & Management Ltd. Process for die-casting light-weight metals
US7210517B2 (en) * 2001-02-20 2007-05-01 Toshiba Kikai Kabushiki Kaisha Die casting machine
JP5063081B2 (ja) * 2006-11-02 2012-10-31 東洋機械金属株式会社 ダイカストマシン
US20150266087A1 (en) * 2014-03-21 2015-09-24 Italpresse Industrie S.P.A. Die-casting machine with injection assembly with a shut-off valve

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