[材料科学]经典的流道与浇口设计系统教材压铸ppt课件

1、流道與澆口設計系統Designing Runner and Gating SystemsT.H. SiauwCastec Australia Pty. Ltd.產品背景Product background u經過CSIRO的15年研發 Over 15 years R&D by CSIROu在 MS-WINDOWS 環境下操作 Operate under MS-WINDOWSu由CASTEC作全球性行銷 Marketed worldwide by Castec Australia模具設計的特性Die Design Featuresq機械特性: 模具分佈&各部界面 Mechanic

2、al features: die layout & parting faceq流動特性: 流道&澆口 Fluid flow features: runner and gateq熱流特性: 冷卻&加熱 Thermal features: cooling & heating模具設計電腦輔助工具Computer-Aided die design toolsq機械性: Autocad, Unigraphics (Mechanical features: Autocad, Unigraphics)q流動特性: CASTFLOW Fluid flow features: C

3、ASTFLOWq熱流特性: CASTHERM Thermal features: CASTHERM模具設計之整合Integrated Die Design 模具設計模具設計Die Design流道設計流道設計:CASTFLOWRunner Design冷卻冷卻&加熱加熱Cooling/HeatingCASTHERMNC 加工加工NC MachiningIGES充填方式法 (Fill Pattern based approach)1.決定充填方式Define fill pattern2. 設計流道&澆口Design runner & gate充填方式達到?Fill pat

4、tern achieved?3.分析 (Analyze)OK?NoNoYes“充填方式 是什么?What is fill pattern?怎樣才是好的充填方式 ?What is a good fill pattern?應防止鎂湯在模穴中旋轉构成旋渦而包夾空氣Avoid metal swirling in cavity forming vortices which trap air應防止两个金属流前面在摸穴中會合Avoids metal fronts meeting in cavity怎樣才是好的充填方式 ?What is a good fill pattern?怎樣才是好的充填方式 ? Wha

5、t is a good fill pattern?防止兩道或多道金屬流在模穴中會合而包夾空氣Avoid two or more metal fronts meeting in cavitywhich trap air包夾空氣Air trap哪一種流道形狀好 ? Which runner geometry?扇形開口Fan/Chisel Gate錐形流道Tapered runner常見的錯誤觀念：浇口速度是一致的Common mistaken idea: Gate velocity is uniform扇形流道Fan/Chisel Gate錐形流道Tapered runner扇形流道:浇口速度不一

6、致Fan gate speed: Not uniform扇形流道Fan/Chisel Gate不一致的澆口速度的結果Consequences of non uniform gate speed扇形流道Fan/Chisel Gate高速會引起模具腐蝕或黏模High speed causes Die erosion and/orsoldering低速會引起澆口堵塞或冷模瑕疵Low speed causes gate blockage and/or cold shut defects扇形流是不被推薦的話!Fan gating system is not recommendable !扇形流道Fan/

7、Chisel Gate高速會引起模具腐蝕或黏模High speed causes Die erosion and/orsoldering低速會引起澆口堵塞或冷模瑕疵Low speed causes gate blockage and/or cold shut defects錐形流道:澆口速度一致Tapered Runner: Gate speed is uniform錐形流道Tapered runner常見的錯誤: 金屬流動的方向是因為撞擊到模壁Common mistaken idea:The change in flow direction is caused by metal imping

8、ing the core 錐形流道Tapered runner流動方向之改變change in flow direction例如:金屬流動的方向没改动Example: metal jets out of gate do not change direction when they impinge the cavity walls澆口速度向量金屬流上与下，但方向大约一样。Metal flows up and down in an approximately the same direction as it first flows out of the gate以模具設計者的角度而言錐形流道的重要

9、性是: 1.) 流角The significance of tapered runner from die designers point of view are:1. Flow Angle錐形流道Tapered runner流角Flow angle2.) 流角將構成充填區:2. Flow angle leads to Zone of fill:錐形流道Tapered runner非直接充填區Ungated zone直接充填區 Gated zone雙錐形流道流道會有三個區The twin tapered runner results in three zone of fillsleftzone

10、Rightzone中區Centre zone三角洲區Delta gate右區左區流道&澆口的形狀大小影響充填區域的分佈Runner & gate geometry affects zone of fillsleftzoneRightzoneCentrezone直接充填區Gated zone非直接充填區Ungated zone充填區域 = 充填方式Zone of fills = Cavity Fill PatternleftzoneRightzoneCentrezone直接充填區Gated zone非直接充填區Ungated zone模穴之充填方式可以定性的Cavity fill

11、 pattern is qualitative 錐形流道 Tapered runner充填區域是可以定量的Zone of fill is Quantitative锥形流道Tapered runner非直接充填區Ungated zone直接充填區Gated zone區域體積 Zone volume與模面接觸之外表積Surface area in contact with die最大充填距離Maximum flow distance样板左边区右边区中间区Castflow流道分析CASTFLOW 流道是三位的Bearing2.dmt非直接充填區steer.dmtHandle.dmt滑快滑快滑快有问题

12、做搞产品？.用 CASTFLOW 流道与浇口的设计就没有问题流向是CASTFLOW预言的box-casting.dmtphone.dmtDOOR-knob.DMT流向是CASTFLOW预言的door-handle.dmtCastflow 流道比较小tap-handle.dmtCastflow流道比较小以前的流道 比 CASTFLOW 流道以前的流道CASTFLOW流道很厚的产品很小的产品設計冷卻與加熱系統Designing cooling and heating systemT.H. SiauwCastec Australia Pty. Ltd.練習, 請依下面指示做?Exercise, Pl

13、ease do the followingu畫出冷卻管 Draw the cooling circuitu標示出與分模面之距離 Show the distance from the parting face問題在哪? The problem?u需求幾個迴路, 在哪裡?How many and circuit layout?u距模面多遠? Cooling distance from die surface?u冷卻劑種類:水/油? Coolant type oil or Water?u冷卻劑流動條件? Coolant flow condition?分什麼要分析?模溫的影響Why analyse?D

14、ie temperature affectsu鑄件品質 Casting Qualityu模具壽命 Die lifeu生產效率 Production rate實驗:利用CASTHERM研讨對下面兩項的影響:An experiment: use CASTHERM to study the effect ofu水流率 water flow rate andu冷卻距離對模面溫度 cooling distance on die surface temperature间隔distance水流率&冷卻距離的效益Effect of water flow rate & cooling dista

15、ncedistance溫度Temperature水流率Flow rate模具冷卻&加熱設計的方法Die Cooling/Heating Design Proceduresu大姆指法(經驗法) Rule of thumb - experience baseduCastherm法 CASTHERM procedureCASTHERM方法CASTHERM Procedure水管定位(Locate channel)計算溫度Calculatetemperature可接受(Acceptable ?)修正(Modify)開模(Build die)2D分析 -CASTHERM2D analysis - CASTHERM為何不是3D?Why not 3D?u模具圖仍未做到3D 3D die drawings are not readily availableu只能鑽直的孔 Drilled holes are straight u導熱區的概念引入已考慮3D:體積&外表積 Thermal zone concept takes into account 3D entiti