Inspection and solution method for hole site of wall thickness part of die casting

Abstract

The invention belongs to the technical field of workpiece manufacturing, and provides a die casting wall thickness part hole site checking and solving method which comprises the steps that S1, three-dimensional simulation analysis is conducted on a die casting through three-dimensional software, and a first area is marked; s2, carrying out hot spot analysis on the die of the die casting by utilizing die flow analysis software, and marking a second area; s3, marking a third area on the die casting after trial production; detecting the third area by using X-ray flaw detection equipment, marking a fourth area, and carrying out the step S4; s4, the fourth area of the die casting is cut, and the cut hole site is measured to judge whether the hole site is qualified or not; s5, for the unqualified die castings in the S4, a fifth area is marked on the die corresponding to the casting; s6, the mold is corrected; s7, the corrected die is used, the step S1, the step S2, the step S3 and the step S4 are repeated in sequence, and if the die casting is qualified, the working procedure is completed; and if the die casting is unqualified, the inspection steps are repeated in sequence until the die casting is qualified.

Description

Technical Field

[0001] The invention belongs to the technical field of workpiece manufacturing, and in particular relates to an inspection and solution method for hole positions in a thick wall portion of a die casting. Background Art

[0002] To meet the trend of lightweight and electrification of automobiles, new energy vehicles will gradually become mainstream products, and the automobile industry will gradually realize the transformation to electrification. "Three-electric" (battery, motor and electronic control system) technology has become a new core technology for automobiles. As the core component of new energy vehicles, the motor housing has an increasingly high degree of integration of parts, and the structure of castings is becoming more and more complex. In order to ensure product strength and assembly requirements, the local wall thickness of the die casting needs to be designed to be thicker. Therefore, shrinkage cavities and shrinkage defects are prone to occur during the solidification process (such as Figure 1 The circled area) affects the product strength and poses a risk of leakage.

[0003] At present, the inspection of the hole position in the wall thickness of die castings mainly relies on traditional detection methods, such as visual inspection and dimensional measurement. Although these methods are simple and easy to use, it is difficult to accurately detect some minor defects. At the same time, these methods cannot deeply understand the internal structure of the hole position and cannot comprehensively evaluate the quality of the hole position. Therefore, it is of great practical significance to develop an efficient and accurate inspection and solution method for the hole position in the wall thickness of die castings. Summary of the invention

[0004] In order to overcome the problems existing in the prior art, the purpose of the present invention is to provide a method for inspecting and solving the hole position of the thick wall portion of a die casting.

[0005] The technical solution adopted by the present invention to solve the technical problem is: a method for checking and solving the hole position of the wall thickness part of a die casting, comprising:

[0006] S1. Performing a three-dimensional simulation analysis on the die casting using three-dimensional software. The three-dimensional simulation analysis marks the wall thickness area of ​​the die casting as the first area;

[0007] S2. Performing a thermal node analysis on the die of the die casting using mold flow analysis software, wherein the position of the die casting corresponding to the first region of the die casting needs to be filled, and the region with excessively high temperature is found according to the temperature displayed in the thermal node analysis, and the region with excessively high temperature is marked as the second region;

[0008] S3, take the die casting that has been completed in trial production, mark the area of ​​the die casting that corresponds to the second area, and record it as the third area; use X-ray flaw detection equipment to detect the third area, if the detection hole position meets the standard, the die casting is qualified, otherwise it will be marked as the fourth area, and proceed to step S4;

[0009] S4, cutting the fourth area of ​​the die casting, and measuring the hole positions after cutting. If the cut hole positions meet the standards, the die casting is qualified; otherwise, the die casting is unqualified;

[0010] S5. For the unqualified die castings in S4, mark the area of ​​the die corresponding to the fourth area of ​​the casting as the fifth area;

[0011] S6, modifying the mold by arranging a gate, arranging a cold spot, arranging a cooling water channel, or arranging an extrusion pin in the fifth area of ​​the mold;

[0012] S7. Use the corrected mold and repeat steps S1, S2, S3, and S4 in sequence. If the die casting is qualified, the process is completed; if the die casting is unqualified, repeat steps S5, S6, S1, S2, S3, and S4 in sequence until the die casting is qualified.

[0013] Preferably, in S2, if the temperature of some areas in the thermal node analysis exceeds a set threshold, they are marked as the second area.

[0014] Preferably, the standard described in S3 is the ASTM E505 quality standard.

[0015] Preferably, the standard in S4 is that when the wall thickness of the die-casting is less than 9.5 mm, the hole diameter does not exceed 2 mm, and when the wall thickness of the die-casting is greater than 9.5 mm, the hole diameter does not exceed 4 mm.

[0016] Preferably, in S5, when the fifth area is a flat area of ​​the mold, a gate is added at the fifth area to fill and compensate for shrinkage in the thick wall area of ​​the die casting.

[0017] Preferably, in S5, when the fifth area is an oil channel hole, a threaded hole or a core hole of the mold, a spot cooling point is arranged in the fifth area to locally cool the thick wall area.

[0018] Preferably, in S5, when the fifth region is a complex inner cavity of the mold, a cooling water channel is arranged in the fifth region to perform large-area cooling on the complex inner cavity.

[0019] Preferably, in S5, when the fifth area is a thick-walled area of ​​the mold, an extrusion pin is arranged outside the fifth area to extrude the mold locally.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The inspection and solution of the hole position of the thick wall part of the die casting provided by the present invention realizes the accurate inspection and effective correction of the hole position of the thick wall part of the die casting through the cyclic iteration of multiple links such as simulation analysis, actual detection, and mold correction. This method not only improves the quality and qualified rate of the die casting, reduces the defective rate, but also improves the production efficiency and economic benefits. At the same time, the method also has strong applicability and flexibility, and can be adjusted and optimized according to different die castings and specific requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying any creative work.

[0023] Figure 1 It is the shrinkage state diagram;

[0024] Figure 2 This is a flow chart for the inspection and solution of the hole position in the thick wall part of the die casting. DETAILED DESCRIPTION

[0025] In order to more clearly understand the above-mentioned objects, features and advantages of the present invention, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that, in the absence of conflict, the embodiments of the present application and the features in the embodiments can be combined with each other. In the following description, many specific details are set forth in order to fully understand the present invention, and the embodiments described are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in the art without making creative work are within the scope of protection of the present invention.

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0027] Example 1

[0028] The present invention provides a method for checking and solving the hole position of the thick wall part of a die casting. Figure 2 As shown, the following steps are included:

[0029] S1. Use 3D software to perform 3D simulation analysis on the die casting, mark the wall thickness area of ​​the die casting, and record it as the first area. This step uses simulation analysis to understand the possible distribution of the wall thickness area of ​​the die casting in advance, providing a basis for subsequent analysis and testing.

[0030] S2. Use mold flow analysis software to perform heat section analysis on the die casting mold, fill the position of the mold corresponding to the first area of ​​the die casting, find the area with too high temperature according to the temperature displayed in the heat section analysis, and mark the area with too high temperature. Specifically, the area with too high temperature can be understood as the last condensation area, where shrinkage cavities are more likely to occur, and marked as the second area. This step determines the area where problems may occur by analyzing the heat section of the mold during the casting process.

[0031] S3. Take the die castings that have been trial-produced and mark the area corresponding to the second area of ​​the die castings as the third area. Use X-ray flaw detection equipment to detect the third area. If the detection hole position meets the standard, the die casting is qualified; otherwise, it will be marked as the fourth area and proceed to step S4. This step verifies the accuracy of the simulation analysis through actual testing and finds out the areas where there are actual problems.

[0032] S4. Cut the fourth area of ​​the die casting and measure the hole position after cutting. If the cut hole position meets the standard, the die casting is qualified; otherwise, the die casting is unqualified. This step further verifies the severity of the problem through cutting measurement and provides a basis for subsequent mold correction.

[0033] S5. For the unqualified die castings in S4, the area of ​​the die corresponding to the fourth area of ​​the casting is marked as the fifth area. This step is to determine the specific location of the die correction.

[0034] S6. Correct the fifth area of ​​the mold by arranging a gate, arranging a cold spot, arranging a cooling water channel, arranging an extrusion pin, etc. In this step, a suitable correction method is selected according to the specific situation of the problem to improve the quality of the die casting.

[0035] S7, use the corrected mold and repeat S1, S2, S3, S4 in sequence until the die casting is qualified. This step continuously improves the quality of the die casting through cyclic testing and correction until it meets the requirements.

[0036] Specifically, it can be understood that shrinkage cavities are inevitable defects in actual production, which means that not all die-castings with shrinkage cavities are defective products. If the degree of shrinkage cavities is within a reasonable range, the die-castings are still qualified products. Therefore, the inspection and solution are not to completely offset the shrinkage cavities, but to identify defective products through continuous inspection and optimize the processing procedures, thereby improving the product qualification rate.

[0037] In some optional implementations, in S2, a temperature threshold may be set according to actual needs. When the temperature of a part of the area exceeds the set threshold, it is marked as the second area. Specifically, the threshold is 180°C-280°C.

[0038] In some optional implementations, in S3, the standard is the ASTM E505 quality standard.

[0039] In some optional implementations, in S4, a suitable hole diameter standard can be set based on actual measurement results. Specifically, the standard is that when the wall thickness of the die-casting is less than 9.5 mm, the hole diameter does not exceed 2 mm, and when the wall thickness of the die-casting is greater than 9.5 mm, the hole diameter does not exceed 4 mm.

[0040] In some optional implementations, in S5 and S6, a suitable correction method and correction position may be selected according to the specific situation of the problem.

[0041] Specifically, when setting the gate filling and shrinkage compensation for the flat area of ​​the mold, it is necessary to optimize the gate design. According to the wall thickness, material and shape of the die-casting, design the appropriate gate size, shape and position to ensure that the molten metal can be evenly and quickly filled into the wall thickness area to avoid defects such as cold shut and shrinkage cavity. At the same time, by adjusting the injection speed and pressure of the die-casting machine, the filling speed of the molten metal is controlled to avoid turbulence caused by too fast filling and temperature drop caused by too slow filling. In addition, during the die-casting process, the temperature of the mold and the molten metal is monitored in real time to ensure that the temperature is in the optimal range during the gate filling and shrinkage compensation process.

[0042] When setting spot cooling for the oil channel holes, threaded holes or core hole areas of the mold, optimize the location and number of the spot cooling points. According to the size, location and number of the holes, determine the best location and number of the spot cooling points to ensure the maximum local cooling effect on the wall thickness area. At the same time, high-pressure spot cooling equipment can be used to enhance the cooling effect. In terms of cooling medium selection, choose a suitable cooling medium (such as water, coolant, etc.) to ensure the cooling effect while avoiding adverse effects on the mold and die castings. At the same time, it is necessary to control the cooling speed by adjusting the flow, temperature and pressure of the cooling medium to control the cooling speed and avoid defects caused by too fast or too slow.

[0043] When arranging cooling water channels for complex inner cavities of molds, the design of cooling water channels needs to be based on the shape and size of the complex inner cavities, and a reasonable cooling water channel layout should be designed to ensure large-area and uniform cooling of the complex inner cavities. And choose appropriate water channel materials and sizes to ensure that the water channels can withstand high pressure and high temperature while ensuring cooling effect. During the cooling system monitoring die-casting process, the operating status of the cooling system is monitored in real time to ensure the smooth flow of cooling water channels and the stability of cooling effect.

[0044] When arranging the extrusion pins in the thick-walled area of ​​the mold, the extrusion pin design needs to be based on the size and shape of the thick-walled area, and the appropriate extrusion pin size, shape and number should be designed to ensure effective local extrusion. In terms of extrusion force and time control, it is necessary to control the extrusion effect by adjusting the force and extrusion time of the extruder to avoid deformation or cracking caused by excessive extrusion. Finally, the mold is protected. During the extrusion process, measures are taken to protect the mold to prevent the extrusion pins from damaging the mold.

[0045] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Therefore, any modification, equivalent change and modification made to the above embodiment according to the technical essence of the present invention without departing from the technical solution of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A method for checking and solving the hole position in the thick wall part of a die casting. It is characterized in that include: S1. Performing a three-dimensional simulation analysis on the die casting using three-dimensional software. The three-dimensional simulation analysis marks the wall thickness area of ​​the die casting as the first area; S2. Performing a thermal node analysis on the die of the die casting using mold flow analysis software, wherein the position of the die casting corresponding to the first region of the die casting needs to be filled, and the region with excessively high temperature is found according to the temperature displayed in the thermal node analysis, and the region with excessively high temperature is marked as the second region; S3, take the die casting that has been completed in trial production, mark the area of ​​the die casting that corresponds to the second area, and record it as the third area; use X-ray flaw detection equipment to detect the third area, if the detection hole position meets the standard, the die casting is qualified, otherwise it will be marked as the fourth area, and proceed to step S4; S4, cutting the fourth area of ​​the die casting, and measuring the hole positions after cutting. If the cut hole positions meet the standards, the die casting is qualified; otherwise, the die casting is unqualified; S5. For the unqualified die castings in S4, mark the area of ​​the die corresponding to the fourth area of ​​the casting as the fifth area; S6, modifying the mold by arranging a gate, arranging a cold spot, arranging a cooling water channel, or arranging an extrusion pin in the fifth area of ​​the mold; S7. Use the corrected mold and repeat steps S1, S2, S3, and S4 in sequence. If the die casting is qualified, the process is completed; if the die casting is unqualified, repeat steps S5, S6, S1, S2, S3, and S4 in sequence until the die casting is qualified.

2. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that In S2, if the temperature of some areas in the thermal node analysis exceeds the set threshold, it is marked as the second area.

3. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that The standard described in S3 is the ASTM E505 quality standard.

4. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that The standard stated in S4 is that when the wall thickness of the die casting is less than 9.5 mm, the hole diameter does not exceed 2 mm, and when the wall thickness of the die casting is greater than 9.5 mm, the hole diameter does not exceed 4 mm.

5. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that In S5, when the fifth area is a flat area of ​​the mold, a gate is added at the fifth area to fill and compensate for shrinkage in the thick wall area of ​​the die casting.

6. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that In S5, when the fifth area is an oil channel hole, a threaded hole or a core hole of the mold, a spot cooling point is arranged in the fifth area to locally cool the thick wall area.

7. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that In S5, when the fifth area is a complex inner cavity of the mold, a cooling water channel is arranged in the fifth area to perform large-area cooling on the complex inner cavity.

8. The inspection and solution of the hole position of the thick wall part of the die casting according to claim 1, It is characterized in that In S5, when the fifth area is a thick-walled area of ​​the mold, an extrusion pin is arranged outside the fifth area to locally extrude the mold.

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