经典的流道和浇口设计系统教材压铸培训课件

CastecCastecAUSTRALIAAUSTRALIA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 Australia7/16/20241经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA模具設計的特性Die Design Featuresq機械特性:模具分佈&各部界面 Mechanical 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&heating7/16/20242经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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:CASTFLOWq熱流特性:CASTHERM Thermal features:CASTHERM7/16/20243经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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 MachiningIGES7/16/20244经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA充填模式法(Fill Pattern based approach)1.決定充填模式Define fill pattern2.設計流道&澆口Design runner&gate充填模式達到?Fill pattern achieved?3.分析(Analyze)OK?NoNoYes7/16/20245经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA“充填模式”是什么?What is fill pattern?7/16/20246经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA怎樣才是好的充填模式?What is a good fill pattern?應避免鎂湯在模穴中旋轉形成旋渦而包夾空氣Avoid metal swirling in cavity forming vortices which trap air7/16/20247经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/20248经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA?應避免两个金属流前面在摸穴中會合Avoids metal fronts meeting in cavity怎樣才是好的充填模式?What is a good fill pattern?7/16/20249经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202410经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202411经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA怎樣才是好的充填模式?What is a good fill pattern?避免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 trap7/16/202412经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202413经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA哪一種流道形狀好?Which runner geometry?扇形開口Fan/Chisel Gate錐形流道Tapered runner7/16/202414经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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 runner7/16/202415经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA扇形流道:浇口速度不一致Fan gate speed:Not uniform扇形流道Fan/Chisel Gate7/16/202416经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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 defects7/16/202417经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA扇形流是不被推薦的話!Fan gating system is not recommendable!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 defects7/16/202418经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA錐形流道:澆口速度一致Tapered Runner:Gate speed is uniform錐形流道Tapered runner7/16/202419经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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 impinging the core 錐形流道Tapered runner流動方向之改變change in flow direction7/16/202420经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA例如:金屬流動的方向没改变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，但方向大概一样。Metal flows up and down in an approximately the same direction as it first flows out of the gate7/16/202421经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA以模具設計者的角度而言錐形流道的重要性是: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 angle7/16/202422经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA2.)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 zone7/16/202423经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA雙錐形流道流道會有三個區The twin tapered runner results in three zone of fillsleftzoneRightzone中區Centre zone三角洲區Delta gate右區左區7/16/202424经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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 zone7/16/202425经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA充填區域=充填模式Zone of fills=Cavity Fill PatternleftzoneRightzoneCentrezone直接充填區Gated zone非直接充填區Ungated zone7/16/202426经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA模穴之充填模式可以定性的Cavity fill pattern is qualitative 錐形流道 Tapered runner7/16/202427经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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與模面接觸之表面積Surface area in contact with die最大充填距離Maximum flow distance7/16/202428经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA样板7/16/202429经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202430经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA左边区右边区中间区7/16/202431经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIACastflow流道分析7/16/202432经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIACASTFLOW 流道是三位的7/16/202433经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIABearing2.dmt7/16/202434经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA非直接充填區7/16/202435经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIAsteer.dmt7/16/202436经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIAHandle.dmt滑快滑快滑快7/16/202437经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA有问题做搞产品？.用 CASTFLOW 流道与浇口的设计就没有问题流向是CASTFLOW预言的box-casting.dmt7/16/202438经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIAphone.dmt7/16/202439经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIADOOR-knob.DMT流向是CASTFLOW预言的7/16/202440经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIAdoor-handle.dmtCastflow 流道比较小7/16/202441经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIAtap-handle.dmtCastflow流道比较小7/16/202442经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202443经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202444经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA7/16/202445经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA以前的流道 比 CASTFLOW 流道以前的流道CASTFLOW流道7/16/202446经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA很厚的产品7/16/202447经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA很小的产品7/16/202448经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA設計冷卻與加熱系統Designing cooling and heating systemT.H.SiauwCastec Australia Pty.Ltd.7/16/202449经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA練習,請依下面指示做?Exercise,Please 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 face7/16/202450经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA問題在哪?The problem?u需要幾個迴路,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?7/16/202451经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA分什麼要分析?模溫的影響Why analyse?Die temperature affectsu鑄件品質 Casting Qualityu模具壽命 Die lifeu生產效率 Production rate7/16/202452经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA實驗:利用CASTHERM研究對下面兩項的影響: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距离distance7/16/202453经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA水流率&冷卻距離的效益Effect of water flow rate&cooling distancedistance溫度Temperature水流率Flow rate7/16/202454经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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 procedure7/16/202455经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIACASTHERM方法CASTHERM Procedure水管定位(Locate channel)計算溫度Calculatetemperature可接受(Acceptable?)修改(Modify)開模(Build die)7/16/202456经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA2D分析-CASTHERM2D analysis-CASTHERM7/16/202457经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA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&表面積 Thermal zone concept takes into account 3D entities-volume&surface areau根據經驗:五個剖面就足夠 Experience suggests up to 5 die sections are sufficient7/16/202458经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA樣品1:2D已足夠 Sample 1:2D sections are sufficient7/16/202459经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA樣品1:2D已足夠 Sample 2:2D sections are sufficient7/16/202460经典的流道和浇口设计系统教材压铸CastecCastecAUSTRALIAAUSTRALIA樣品1:2D已足夠 Sample 3:Three 2D sections are sufficient7/16/202461经典的流道和浇口设计系统教材压铸