High-performance die-casting aluminum alloy cylinder head flexible intelligent machining system and method thereof

Abstract

The application provides a high-performance flexible intelligent processing system for die-casting aluminum alloy cylinder heads and a processing method thereof. The system optimizes the mold and the cylinder head processing technology to solve the existing problems of air entrapment, shrinkage cavity and dead corners in overflow. The die-casting mold is provided with a mold cavity. The inner runner, the straight runner, the cross runner and the overflow groove are connected with the mold cavity. The cross runner and the inner runner are matched with each other. The thickness of the inner runner is 5-8 times the thickness of the cross runner. The straight runner is composed of a compression chamber and a gate sleeve. The overall shape is an integrated inverted conical structure. The taper angle of the straight runner is 4-12°. The cross-sectional area of the straight runner is 3-4 times the cross-sectional area of the inner runner. The overflow groove is arranged on the movable die of the die-casting mold. All the overflow grooves are combined together and designed as an integrated structure. The cooling device is used to improve the cooling efficiency of the wall thickness area and balance the solidification temperature of each part. The heating device is used to improve the local temperature rise of the wall thickness area and reduce the die-casting deformation.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of die casting cylinder head, in particular to a high-performance die casting aluminum alloy cylinder head flexible intelligent processing system and method thereof. BACKGROUND

[0002] With the rapid development of southwest die casting technology, and the adjustment of China's industry layout, the output of die casting in southwest China will have a very significant increase. How to improve the quality, so that the southwest region, especially Chongqing manufacturing mobile phones, laptops, cars and machine accessories in the market to occupy a higher share, one of which is to improve the quality of die casting.

[0003] In the preparation process of aluminum alloy cylinder head, at least the following problems are found: first, there is a gas wrapping phenomenon in the filling process, the gas wrapping amount is 0.00248g / cm3, which causes the increase of internal void of the part, and affects the hardness of the casting; second, affected by the solidification rate, tensile stress will be formed in the part, leading to shrinkage cavity phenomenon, making the aluminum alloy bracket prone to fracture, and reducing the tensile property of the part; third, there is a dead angle area in the overflow control, which causes the molten metal to be unable to quickly cover the mold, and even large-scale holes appear, causing serious defect problems. SUMMARY

[0004] The purpose of the present application is to provide a high-performance die casting aluminum alloy cylinder head flexible intelligent processing system and processing method thereof, which solves the existing problems of gas wrapping, shrinkage cavity and overflow dead angle by optimizing the mold and optimizing the cylinder head processing technology.

[0005] The embodiment of the present application is implemented as follows:

[0006] A high-performance die casting aluminum alloy cylinder head flexible intelligent processing system, the processing system comprises: a die casting mold, a cooling device and a heating device, the die casting mold is provided with a mold cavity, and the mold cavity is connected with an ingate, a sprue, a cross runner and an overflow groove; the ingate is provided with an exhaust groove connected to the overflow groove; the cross runner and the ingate are matched with each other, and the thickness of the ingate is 5-8 times the thickness of the cross runner; the sprue is composed of a compression chamber and a sprue bush, and the overall shape is a one-piece inverted conical structure, the taper angle of the sprue is 4-12°, and the cross-sectional area of the sprue is 3-4 times the cross-sectional area of the ingate; the overflow groove is arranged on the movable die of the die casting mold, and all the overflow grooves are combined together as an integrated design; the cooling device is used to improve the cooling efficiency of the wall thickness area, so that the solidification temperature of each part can be balanced; the heating device is used to increase the local temperature of the wall thickness area and reduce the die casting deformation.

[0007] A high-performance die casting aluminum alloy cylinder head flexible intelligent processing method, comprising the above processing system, the processing method comprises:

[0008] The aluminum alloy cylinder head is analyzed by using a simulation model, the die casting process is simulated, and the suitable die casting scheme is obtained after judging the die casting effect;

[0009] The metal is filled in the front side first, and then in both sides after reaching the front side, until the filling is completed, the convergence of multiple metal flows is formed, and the dead angle of filling is eliminated;

[0010] In the solidification stage, the cooling device is used to cool the wall thickness area, so that the solidification temperature of each part can be balanced, and the inhibition effect on shrinkage hole problem is enhanced;

[0011] After the aluminum alloy cylinder head is die cast, the unqualified aluminum alloy cylinder head is selected out through flaw detection.

[0012] In the preferred embodiment of the present application, the pouring temperature of the aluminum alloy cylinder head is 650-700℃, the mold preheating temperature is 250℃, and the injection speed is 4.5-5.0m / s.

[0013] In the preferred embodiment of the present application, the die casting mold has a stepped mold core.

[0014] In the preferred embodiment of the present application, before using the die casting mold, stress relief is carried out first, then annealing is carried out, and then quenching is carried out

[0015] In the preferred embodiment of the present application, the mold is stress tempered once at 5000-10000 times, and the interval of each subsequent tempering is 15000-20000 times.

[0016] In the preferred embodiment of the present application, the overall shape of the sprue is a groove pile, the groove bottom angle is 100°, the height is 22mm, and the long bottom side is 51.7mm.

[0017] The beneficial effects of the embodiment of the present application are: the high-performance die-casting aluminum alloy cylinder head flexible intelligent processing system and processing method in the present application optimizes and improves the die casting mold, optimizes the air wrapping problem by setting an integrated overflow groove; the cooling device is introduced to specifically cool the area of the mold wall thickness, so that the solidification temperature of each part can be balanced, and the inhibition effect on shrinkage hole problem is enhanced; the filling mode of the cylinder head is optimized to eliminate the dead angle area after filling, which can improve the cost qualification rate of the high-performance die-casting aluminum alloy cylinder head. DETAILED DESCRIPTION

[0018] In the description of the present application, it should be pointed out that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship, or the orientation or positional relationship of the product of the present application when in use, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", "third" and the like are only used for differentiation and cannot be understood as indicating or implying relative importance.

[0019] In addition, the terms "horizontal", "vertical", "overhanging" and the like do not mean that the components must be absolutely horizontal or overhanging, but can be slightly inclined. For example, "horizontal" only means that it is more horizontal relative to "vertical", and does not mean that the structure must be completely horizontal, but can be slightly inclined.

[0020] In the description of the present application, it should be pointed out that unless otherwise explicitly specified and limited, the terms "arrangement", "installation", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0021] First embodiment

[0022] The present embodiment provides a high-performance die-casting aluminum alloy cylinder head flexible intelligent processing system, characterized in that the processing system comprises:

[0023] A die-casting mold is provided with a mold cavity, an inner runner, a straight runner, a cross runner and an overflow groove connected with the mold cavity; an exhaust groove is arranged on the inner runner, and the exhaust groove is connected to the overflow groove; the cross runner and the inner runner are matched with each other, and the thickness of the inner runner is 5-8 times the thickness of the cross runner; the straight runner is composed of a pressure chamber and a sprue bush, and the overall shape is an integral inverted conical structure, the taper angle of the straight runner is 4-12°, and the cross-sectional area of the straight runner is 3-4 times the cross-sectional area of the inner runner; due to the existence of air wrapping phenomenon during the filling process, the air wrapping amount is 0.00248 g / cm3, which causes the increase of internal voids of the part and affects the hardness of the casting; the overflow groove is arranged on the movable die of the die-casting mold, all the overflow grooves are combined together as an integral design, the air wrapping amount after improvement is 0.00112 g / cm3, which is more than half of the original air wrapping amount, indicating that the air wrapping problem is optimized, and the improvement of the overflow groove plays a role.

[0024] Cooling device is used to improve the cooling efficiency of the wall thickness area, so that the solidification temperature of each part can be balanced; the improved front solidification time is 18s, and the improved one is 15s, the solidification time of the wall thickness area is significantly shortened, so that the overall solidification time is shortened, and the shrinkage hole problem does not occur, which shows that the introduction of the cooling system is successful.

[0025] Heating device is used to improve the local temperature rise of the wall thickness area and reduce the deformation of die casting.

[0026] The inner gate is realized by feeding, and the inner gate structure needs to be designed to make the position and direction of the inner gate reasonable, ensure that the metal liquid can flow smoothly, quickly fill the mold, and shorten the flow time of the metal liquid. The metal liquid flows through parts including deep cavity parts, exhaust valves, parting surfaces, etc., and the flow path of the metal liquid should be shortened to reduce the degree of heat loss, so that the inner gate can work stably.

[0027] Gas exists in the inner gate cavity, which will form a blocking force to the filling of the metal liquid. The exhaust groove design is used to improve the exhaust effect, improve the flowability of exhaust control, and reduce the flow resistance of the metal liquid. The design of the cross gate is based on the principle of easy processing and cleaning, which ensures the flowability of the metal liquid while reducing heat loss and enhancing the propulsion of the metal liquid flow. The design of the cross gate follows two principles: first, it needs to ensure the smoothness of the filling shape, and the overall shape is a groove pile with a groove bottom angle of 100°, a height of 22mm, and a long bottom edge of 51.7mm, which ensures the smooth flow of the metal liquid. Second, it needs to control the heat loss, reduce the energy loss in the pouring process, avoid the large drop of the metal liquid temperature, and reduce the loss of the metal liquid processing temperature.

[0028] The cross gate should focus on shape design and match with the inner gate to ensure good connection and meet the flow requirements of the metal liquid. The thickness of the inner gate should be 5-8 times the thickness of the cross gate, so the heating and cooling devices act on the inner gate. This can ensure that the size of the cross gate meets the requirements, improve the rationality of the process design, and ensure the matching of the process parameter design.

[0029] The straight gate has the function of guiding the metal liquid to flow downward, reducing the fluid resistance by gravity, and ensuring the smoothness of the pouring process. The straight gate is composed of a pressure chamber and a gate sleeve, and the overall shape is inverted conical. The two need to become an integral structure, and the control of the cooperation gap needs to be done well to achieve good coaxiality. The straight gate also has a buffering effect, which makes the metal liquid flow along the surface, prevents the metal liquid from impacting the bottom, avoids the splashing of the metal liquid, and improves the flow distribution of the metal liquid, making it have a good flow state. The taper angle of the straight gate is 4-12°, and the cross-sectional area is 3-4 times that of the inner gate, which helps to control the connection of the two and ensures that the straight gate has a good inlet shape.

[0030] The overflow groove is a key structure for preventing metal liquid overflow, can guide the overflow process, prevent vortex of the metal liquid locally, and ensure the metal liquid has a good filling state. In order to ensure that the overflow groove can play a role, on the one hand, the temperature needs to be controlled to ensure that the metal liquid can melt and overflow, and the mold is in a state of thermal equilibrium; on the other hand, the compression effect on the casting needs to be enhanced to improve the effect of the aluminum alloy bracket casting mold, so that the excess metal can overflow, and the casting is compressed into a specified shape. The overflow groove needs to be arranged on the movable mold to provide a clamping force for the movable mold, so as to ensure that the casting can be taken out with the movable mold after the mold is opened, and the internal quality of the casting is improved.

[0031] The embodiment also provides a high-performance flexible intelligent processing method for die-casting aluminum alloy cylinder heads, which comprises the processing system and a specific processing method.

[0032] First, the aluminum alloy cylinder head is analyzed by using a simulation model, the die-casting process is simulated, and a suitable die-casting scheme is obtained after the die-casting effect is judged; the overflow groove and the ingate in the mold are optimized by using computer-aided design technology, so as to reduce the erosion effect in the casting process, thereby prolonging the service life of the mold.

[0033] Before using the die-casting mold, stress relief is performed, and then annealing and quenching are performed. Specifically, the mold is stress tempered once at 5000-10000 times, and then the interval of each tempering is 15000-20000 times.

[0034] The metal is filled in the front side first, and then filled in both sides after reaching the front side, until it is filled, forming a convergence of multiple metal flows, and eliminating the filling dead angle; specifically, the pouring temperature of the aluminum alloy cylinder head is 650-700 DEG C, the mold preheating temperature is 250 DEG C, and the injection speed is 4.5-5.0 m / s. The die-casting mold has a stepped mold core. The overall shape of the cross runner is a groove pile, the groove bottom angle is 100 DEG, the height is 22 mm, and the long bottom side is 51.7 mm. After the filling mode is improved, the stability of the metal liquid flow is improved, so that it can flow uniformly to all parts of the casting, and finally guide the metal liquid to the overflow groove, so that the filling mode is effectively optimized.

[0035] In the solidification stage, the cooling device is used to cool the wall thickness area, so that the solidification temperature of each part can be balanced, and the inhibition effect on the shrinkage hole problem is enhanced;

[0036] The die casting test is the key to test the actual effect, after setting the appropriate die casting parameters, the metal liquid is die casting forming, test whether the die casting defect problem is solved, according to the actual situation, reoptimization. The die casting test takes the forming effect of the casting as the test standard, such as the appearance is complete, the surface is smooth, etc. If necessary, the aluminum alloy support needs to be detected, the defects invisible to the naked eye are tested, whether the metal internal damage such as crack, slag inclusion exists, the quality of the engine support is ensured. Through the die casting test, the trial production of the aluminum alloy support is carried out, the qualified rate of the casting is tested, the die casting test can play a role, the engine support can meet the qualified standard, and the support has good fixing effect. After the aluminum alloy cylinder head is die casting, the flaw detection is carried out, and the unqualified aluminum alloy cylinder head is selected.

[0037] To sum up, the flexible intelligent machining system and machining method of the high-performance die-casting aluminum alloy cylinder head in the application optimize and improve the die-casting mold, the air wrapping problem is optimized by setting an integrated overflow groove; the cooling device is introduced to specifically cool the area of the mold wall thickness, so that the solidification temperature of each part can be balanced, and the inhibition effect on the shrinkage hole problem is enhanced; the filling mode of the cylinder head is optimized to eliminate the dead angle area after filling, and the cost qualified rate of the high-performance die-casting aluminum alloy cylinder head can be improved.

[0038] The specification describes examples of embodiments of the application and does not mean that these embodiments illustrate and describe all possible forms of the application. It should be understood that the embodiments in the specification can be implemented in various alternative forms. The combined features of the description provide representative embodiments for typical applications. However, various combinations and variations of features consistent with the teachings of the application can be used as needed for specific applications or implementations.

[0039] The above is only the preferred embodiment of the application, and is not used to limit the application. For those skilled in the art, the application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. within the spirit and principle of the application shall be included in the protection scope of the application.

Claims

1. A high-performance die-cast aluminum alloy cylinder head flexible intelligent machining method, characterized in that, The high-performance flexible intelligent processing system for die-casting aluminum alloy cylinder head comprises: A die-casting die is provided with a die cavity, an inner runner, a straight runner, a cross runner and an overflow groove connected with the die cavity; the inner runner is provided with an exhaust groove connected to the overflow groove; the cross runner is matched with the inner runner, and the thickness of the inner runner is 5-8 times of the thickness of the cross runner; the straight runner is composed of a pressure chamber and a sprue bush, and has an integrated inverted conical structure, the taper angle of the straight runner is 4-12°, and the cross-sectional area of the straight runner is 3-4 times of the cross-sectional area of the inner runner; the overflow groove is arranged on the movable die of the die-casting die, and all the overflow grooves are combined together as an integrated design; A cooling device is used to improve the cooling efficiency of the thick wall area and balance the solidification temperature of each part; A heating device is used to increase the local temperature of the thick wall area and reduce the die-casting deformation; The processing method comprises: The aluminum alloy cylinder head is analyzed by using a simulation model, the die-casting process is simulated, and the die-casting effect is judged to obtain a suitable die-casting scheme; The metal is filled from one side to the other side, and then filled from both sides until it is filled, forming a convergence of multiple metal flows and eliminating the filling dead angle; In the solidification stage, the cooling device is used to cool the thick wall area, so that the solidification temperature of each part can be balanced, and the inhibition effect on shrinkage hole problem can be enhanced; After the aluminum alloy cylinder head is die-cast, the unqualified aluminum alloy cylinder head is selected out through flaw detection.

2. The flexible intelligent machining method for high-performance die-cast aluminum alloy cylinder head according to claim 1, characterized in that, The pouring temperature of the aluminum alloy cylinder head is 650-700℃, the mold preheating temperature is 250℃, and the injection speed is 4.5-5.0m / s.

3. The flexible intelligent machining method of high-performance die-cast aluminum alloy cylinder head according to claim 1, characterized in that, The die-casting die has a stepped die core.

4. The flexible intelligent machining method of high-performance die-cast aluminum alloy cylinder head according to claim 1, characterized in that, Before using the die-casting die, stress relief is performed, and then annealing and quenching are performed.

5. The flexible intelligent machining method of high-performance die-cast aluminum alloy cylinder head according to claim 4, characterized in that, The mold is stress tempered once at 5000-10000 times, and then the interval of each tempering is 15000-20000 times.

6. The flexible intelligent machining method of high-performance die-cast aluminum alloy cylinder head according to claim 1, characterized in that, The cross runner has a concave groove shape, the groove bottom angle is 100°, the height is 22mm, and the long bottom side is 51.7mm.