大型复杂压铸模模温控制关键技术的研究与开发
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摘要
压铸模温度对于金属液的填充、凝固过程以及压铸模使用寿命和铸件质量的稳定性有着非常大的影响,是必须要控制的参数之一。通常压铸模的温度控制包括预热和冷却两个方面,本文针对目前压铸模在预热时存在的速度慢、耗能大、污染环境;冷却时无法对模具细小型芯针部位进行有效控制、芯针温度高、寿命短等缺点,开发了基于高压过热水的压铸模预热控制装置和基于高压冷却循环水的压铸模型芯针温度控制装置,满足了现代大型复杂压铸模的生产要求,取得了良好的效果。
本文设计并制作了一种多通道的压力为0.6MPa、最高加热温度为160℃、流量为50L/min的高压过热水模温控制装置(简称水式模温机)。该装置具有模具预热、模具冷却、自动补水、自动稳压和自动温控等功能。试验结果表明:在短时间内,该装置能迅速将模具温度预热到100℃以上,在同一加热时间内比传统的油式模温机提高约60℃;将模具预热到同一温度时,其加热时间比油式模温机减少约50%左右,节能约40%。水式模温机具有很好的模具预热效率和预热速度,使用方便、节能、不污染现场环境等优点。该装置现已成功地应用于某复杂通讯框体压铸件的生产上,效果良好,可取代油式模温机。
本文设计并制作的压铸模型芯针冷却控制装置包括水温自动控制功能、制冷功能、循环水冷却功能和吹气冷却功能等。该装置设置了手动工作模式和自动工作模式,同时针对不同的工作模式设置了独立的控制系统,用户可以通过模式转换开关方便的进行选择。该装置的制冷量为18KW,冷却水流量为50L/min,最大工作压力为1Mpa。试验结果表明:在某国产自主品牌轿车的后副车架压铸技术开发中,不使用型芯针冷却装置时,芯针的温度高达200～260℃;而使用该装置的自动冷却功能时,芯针温度可降低到100～150℃;当使用手动冷却模式时,芯针温度可进一步降低至65～120℃。三种模式下的铸件X光照片对比显示,自动冷却功能下,芯针部位的缩松及裂纹缺陷最小。
Temperature control has significant impact on filling and solidification of molten metal, die span-life and casting defects. It must be one of the parameters controlled by users. There are pre-heating and cooling two parts in temperature control. In order to solve these problems ,such as low speed, heavy energy cost, and pollution of the environment in pre-heating stage, temperture of the fine core needles hardly effective controlled, high temperature of core needles, short life in cooling stage, in this paper , the die temperature control equipment based on overheated water with high presuure and the die core needle temperature control equipment based on cycle cooling-water with high pressure have been developed, which will meet the present production need in large valume dies and have significant impacts.
In this paper, a kind of temperature controller based on high pressure and overheated water (Water Temperature Controller for short) has been designed and producted, with the pressure of 0.6MPa, maximum heated temperature of 160℃and flow rate of 50L/min. It owns some functions such as pre-heating, automatic cooling, water charging automatically, keeping constant pressure and temperature control. The experimental results showed that die temperature had been preheated over 100℃by in the short time, higher approximately 60℃than that of oil temperature controller. Meanwhile, pre-heated time of die had been reduced 50%, compared to oil temperature controller under the same temperature. Consequently, the equipment has some advantages with higher heating efficiency, faster heating-velocity , energy saving and no pollution etc. The apparatus was successfully applied to a complicated communication frame casting instead of oil temperature controller.
Core needle cooling controller which have been designed and manufacuted in this paper includes several functions such as water temperature controlling automatically, regrigeration, circulation water cooling and air blow cooling. The equipment sets up manual operation and automatically operation, meanwhile set up independent control system for respective mode. Consumer can choose modes conveniently by using change-over switch. Refrigerating capacity is 18KW, flow rate is 50L/min and the maximum work presure is 1 Mpa. The experimental results demonstrated that in the process of developing a complicated sub-frame casting in one domestic pcv, the temperature of core needle can be high to 200～260℃without using the cooling controller; it will be reduced to 100～150℃in the condition of using controller in automatically mode; it will further reduced to 65～120℃in the condition of using controller in manual mode.Meanwhile,compared with X ray pictures in three modes , we can conclude that porositys and cracks in core needle parts were ideal.
本文设计并制作了一种多通道的压力为0.6MPa、最高加热温度为160℃、流量为50L/min的高压过热水模温控制装置(简称水式模温机)。该装置具有模具预热、模具冷却、自动补水、自动稳压和自动温控等功能。试验结果表明:在短时间内,该装置能迅速将模具温度预热到100℃以上,在同一加热时间内比传统的油式模温机提高约60℃;将模具预热到同一温度时,其加热时间比油式模温机减少约50%左右,节能约40%。水式模温机具有很好的模具预热效率和预热速度,使用方便、节能、不污染现场环境等优点。该装置现已成功地应用于某复杂通讯框体压铸件的生产上,效果良好,可取代油式模温机。
本文设计并制作的压铸模型芯针冷却控制装置包括水温自动控制功能、制冷功能、循环水冷却功能和吹气冷却功能等。该装置设置了手动工作模式和自动工作模式,同时针对不同的工作模式设置了独立的控制系统,用户可以通过模式转换开关方便的进行选择。该装置的制冷量为18KW,冷却水流量为50L/min,最大工作压力为1Mpa。试验结果表明:在某国产自主品牌轿车的后副车架压铸技术开发中,不使用型芯针冷却装置时,芯针的温度高达200～260℃;而使用该装置的自动冷却功能时,芯针温度可降低到100～150℃;当使用手动冷却模式时,芯针温度可进一步降低至65～120℃。三种模式下的铸件X光照片对比显示,自动冷却功能下,芯针部位的缩松及裂纹缺陷最小。
Temperature control has significant impact on filling and solidification of molten metal, die span-life and casting defects. It must be one of the parameters controlled by users. There are pre-heating and cooling two parts in temperature control. In order to solve these problems ,such as low speed, heavy energy cost, and pollution of the environment in pre-heating stage, temperture of the fine core needles hardly effective controlled, high temperature of core needles, short life in cooling stage, in this paper , the die temperature control equipment based on overheated water with high presuure and the die core needle temperature control equipment based on cycle cooling-water with high pressure have been developed, which will meet the present production need in large valume dies and have significant impacts.
In this paper, a kind of temperature controller based on high pressure and overheated water (Water Temperature Controller for short) has been designed and producted, with the pressure of 0.6MPa, maximum heated temperature of 160℃and flow rate of 50L/min. It owns some functions such as pre-heating, automatic cooling, water charging automatically, keeping constant pressure and temperature control. The experimental results showed that die temperature had been preheated over 100℃by in the short time, higher approximately 60℃than that of oil temperature controller. Meanwhile, pre-heated time of die had been reduced 50%, compared to oil temperature controller under the same temperature. Consequently, the equipment has some advantages with higher heating efficiency, faster heating-velocity , energy saving and no pollution etc. The apparatus was successfully applied to a complicated communication frame casting instead of oil temperature controller.
Core needle cooling controller which have been designed and manufacuted in this paper includes several functions such as water temperature controlling automatically, regrigeration, circulation water cooling and air blow cooling. The equipment sets up manual operation and automatically operation, meanwhile set up independent control system for respective mode. Consumer can choose modes conveniently by using change-over switch. Refrigerating capacity is 18KW, flow rate is 50L/min and the maximum work presure is 1 Mpa. The experimental results demonstrated that in the process of developing a complicated sub-frame casting in one domestic pcv, the temperature of core needle can be high to 200～260℃without using the cooling controller; it will be reduced to 100～150℃in the condition of using controller in automatically mode; it will further reduced to 65～120℃in the condition of using controller in manual mode.Meanwhile,compared with X ray pictures in three modes , we can conclude that porositys and cracks in core needle parts were ideal.
引文
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[6]吴春苗.压铸实用技术[M].广州:广东科技出版社,2003:150～151
[7]黄泽雄.冷/热循环模具注塑技术[J].国外塑料,2008(26),8:64～66
[8] Henry Hu,Fang Chen,Xiang Chen.Effect of cooling water flow rates on local temperatures and heat transfer of casting dies . Journal of Materials Processing Technology, 2004(148):
[9] T.Nguyen , L. Wang ,P.Rohan etc . Recent innovative developments in die casting research . Proceedings of 10 Asian Foundry Congress . Nagoya,Japan , May 21-24, 2008
[10]吴春苗.压铸技术手册(第二版).广州:广东科技出版社,2007, 270～330
[11] ROBAMAT. The application of heating/cooling units in Die casting processing. Automatisierungstechnik GmbH. 2005.8
[12]赖厚裕.模具加热及冷却的装置.实用新型专利.专利号:200720000424. 2007.6.27
[13]钟秉义.油循环模温控制结构.实用新型发明专利.专利号:200420006901 . 2005.4.6
[14]张百在,万里,董军刚等.一种压铸模模温控制方法及装置.中国专利,专利申请号:2010101202356
[15]刘仕平主编.液压与气压传动.郑州:黄河水利出版社,2003,02:71～102
[16]董军刚,万里,张百在等.基于高压过热水的压铸模模温控制装置的开发与研究.沈阳:铸造杂志社,2011.1.10(第一期)
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[18]张利平.镁合金高温熔体定量输送系统的研究. [硕士学位论文].武汉:华中科技大学,2008
[19]潘欢.铝合金压铸用高真空技术的开发与应用. [硕士学位论文].武汉:华中科技大学,2008
[20]何伟.高真空压铸用真空控制技术的开发. [硕士学位论文].武汉:华中科技大学,2009
[21]秦曾煌主编.电工学(第六版)(上册)电工技术[M].北京:高等教育出版社,2004.01:268～330
[22] AutoCAD Electrical 2008 relaxed to layout electrical circuit. Electrical equipment manufacutured , 2007, (06) :88~89
[23]杨世兴主编.现代电气自动控制技术.北京:人民邮电出版社. 2006,57～156
[24]邓志良,刘维亭编著.电气控制技术与PLC.南京:东南大学出版社. 2002,26～102
[25]冯晓,刘仲恕编著.电机与电器控制.北京:机械工业出版社. 2005,32～157
[26]齐占伟编著.电气控制设备故障维修.北京:机械工业出版社. 2004,57～212
[27]姜忠良,陈秀云等编著.温度的控制与测量.北京:清华大学出版社. 2005,101～189
[28]徐灏主编.机械设计手册(第一卷).北京:机械工业出版社,1991,135～158
[29]徐灏主编.机械设计手册(第五卷).北京:机械工业出版社,1991,275～308
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