A split structure high-strength aluminum alloy wheel hub integrated die forging forming combined die structure

Abstract

The present application belongs to the technical field of wheel hub forging, and relates to a split structure high-strength aluminum alloy wheel hub integrated die forging forming combined die structure, which comprises a machining table and a die unit arranged on the machining table. The die unit is composed of an upper die, a lower die and a side die. The upper die is internally provided with a composite cooling module corresponding to thick parts of the wheel hub. The composite cooling module comprises a passive heat storage unit and an active cooling unit. The passive heat storage unit is internally provided with a phase change material, and the active cooling unit is provided with an independent cooling flow channel. An intelligent temperature control system comprises first and second temperature sensors arranged at different positions of the die, and a controller connected with the sensors. In operation, the phase change material first absorbs heat to delay solidification, and after the latent heat is exhausted, the controller starts forced cooling. The system monitors the overall temperature difference in real time, and ensures that the cooling process is carried out within a safe range. The present application can effectively eliminate shrinkage defects, reduce casting deformation, and improve product quality and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of wheel hub forging technology, specifically to a combined die structure for integral forging of high-strength aluminum alloy wheel hubs with a split structure. Background Technology

[0002] Wheel hub casting molds are large, complex, and high-precision hot-working molds. Their core function is to shape molten liquid metal under pressure, and after cooling, obtain wheel hub blanks with specific shapes, dimensions, and mechanical properties.

[0003] Uneven cooling is a common problem in automotive wheel casting molds, especially in thicker sections. Due to slow heat dissipation, these thicker sections often solidify last, leading to defects such as shrinkage cavities and porosity. Existing molds often employ external air cooling or simple water cooling channels with poorly designed cooling paths, failing to achieve differentiated cooling for different areas. While the thicker sections are still liquid, the thinner sections have already solidified. This asynchronous solidification not only causes internal defects but also generates thermal stress, resulting in casting deformation and severely impacting the quality and production efficiency of wheel castings.

[0004] To address this, we propose a combined die structure for integral forging of high-strength aluminum alloy wheel hubs with a split structure. Summary of the Invention

[0005] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0006] A combined die structure for integral forging of high-strength aluminum alloy wheel hubs with a split structure includes a processing table. The processing table is equipped with a die unit, which includes an upper die, a lower die, and a side die. The upper die is equipped with at least one composite cooling module, which is positioned to correspond to the thicker parts of the wheel hub casting. The composite cooling module integrates an active cooling unit and a passive heat storage unit. The die also includes an intelligent temperature control system for coordinating and controlling the cooling behavior of each composite cooling module.

[0007] Preferably, the passive heat storage unit includes a cavity, which is opened in the upper mold corresponding to the thick part of the wheel hub casting. The cavity is encapsulated with PCM phase change material. The phase change temperature Tr of the PCM phase change material is higher than the solidus temperature of the wheel hub alloy. The cavity is provided with a filling channel for replacing the phase change material. The filling channel is opened in the upper mold and is sealed by a sealing post.

[0008] Preferably, the active cooling unit is a cooling channel that is located inside the composite cooling module and runs through the cavity. The cooling channel is equipped with an independent cooling medium inlet and outlet and a flow regulating valve. The cooling medium inlet is connected to the main channel, which is located in the middle of the upper mold. The outlet is fixedly connected to the manifold to form a circulating cooling path. The inlet, the outlet, the flow regulating valve, and the manifold are all located inside the upper mold.

[0009] Preferably, the intelligent temperature control system includes:

[0010] Multiple first temperature sensors are respectively set inside the composite cooling module or in the upper mold area adjacent to it to monitor the local real-time temperature of the corresponding thick part and the phase change state of the PCM.

[0011] Multiple second temperature sensors are installed in the upper mold corresponding to the non-thick cooling area and the base of the wheel hub casting to monitor the overall temperature field and cooling process of the mold.

[0012] The controller is fixedly connected to the upper end face of the upper mold and electrically connected to all the first temperature sensors, the second temperature sensors and each of the flow regulating valves.

[0013] Preferably, the controller is configured to receive a signal from the first temperature sensor and, based on the PCM phase change state it monitors, independently control the opening and closing of the corresponding flow regulating valve and its opening degree to trigger or adjust the active cooling intensity of the corresponding thick part.

[0014] Preferably, the controller is configured to: when the first temperature sensor detects that the temperature reaches and is maintained at the phase change temperature Tr of the PCM phase change material for a preset time t1, determine that the PCM phase change material is in the phase change period; when the temperature is detected to start rising from Tr, determine that the latent heat of the PCM phase change material is exhausted, and instruct to increase the opening of the corresponding flow regulating valve to implement quenching.

[0015] Preferably, the controller is further configured to receive and process the signal from the second temperature sensor to calculate the overall temperature difference of the mold and execute a global safety strategy based on the analysis results.

[0016] Preferably, the controller executes the global security policy by including:

[0017] After generating a chilling command based on the signal from the first temperature sensor and before executing the command, the real-time global temperature difference data calculated by the second temperature sensor is first verified.

[0018] When the real-time global temperature difference exceeds a preset safety threshold, the quenching command is prohibited from being executed.

[0019] When the real-time global temperature difference does not exceed the preset safety threshold, the quenching command is allowed to be executed.

[0020] Preferably, the controller is further configured to: determine the overall cooling stage of the mold based on the signal from the second temperature sensor, and thereby coordinate the start and end points of the cooling process of all composite cooling modules.

[0021] Preferably, the controller is further configured to: cross-compare the data of each of the first temperature sensors and the second temperature sensors; when the deviation between the data of a single first temperature sensor and the overall trend reflected by the second temperature sensor exceeds a preset tolerance range, the first temperature sensor is determined to be faulty and an alarm is triggered.

[0022] The beneficial effects of this invention are:

[0023] This invention achieves precise temperature control during the wheel hub casting process through the synergistic effect of a composite cooling module and an intelligent temperature control system. The phase change material absorbs a large amount of heat in the early stages of solidification, slowing down the solidification rate of thicker sections and creating favorable conditions for molten metal feeding. After the latent heat is exhausted, the system immediately initiates forced cooling, allowing the affected area to quickly pass through the mushy zone, effectively eliminating shrinkage defects. A dual-temperature sensor layout monitors local and overall temperatures in real time, and the controller dynamically adjusts the cooling intensity based on temperature differences, ensuring both the density of the casting's internal structure and preventing thermal cracking caused by excessively rapid cooling. Attached Figure Description

[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] in:

[0026] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0027] Figure 2 for Figure 1 Enlarged schematic diagram of the structure at point A;

[0028] Figure 3 This is a schematic diagram of the connection structure of the demolding unit;

[0029] Figure 4 This is a schematic diagram of the connection structure of a passive heat storage unit;

[0030] Figure 5 Figure 4 Enlarged schematic diagram of the structure at point B;

[0031] Figure 6 This is a schematic diagram of the connection structure between the composite cooling module and the upper mold;

[0032] Figure 7 for Figure 6 Enlarged schematic diagram of the structure at point C;

[0033] Figure 8 This is a schematic diagram of the connection structure between the second sensor and the upper mold;

[0034] Figure 9 for Figure 8 An enlarged schematic diagram of the structure at point D.

[0035] In the picture:

[0036] 1. Processing table;

[0037] 2. Mold unit; 21. Side mold; 22. Lower mold; 23. Side cylinder; 24. Upper mold; 25. Upper cylinder;

[0038] 3. Composite cooling module; 31. Passive heat storage unit; 311. Cavity; 312. Filling channel; 313. Sealing column; 32. Active cooling unit; 321. Cooling channel; 322. Flow regulating valve; 323. Main channel; 324. Outlet; 325. Manifold; 326. Inlet;

[0039] 4. Demolding unit; 41. Ejector rod; 42. Electric telescopic rod;

[0040] 5. Intelligent temperature control system; 51. First temperature sensor; 52. Second temperature sensor;

[0041] 6. Controller; 7. Injection system. Detailed Implementation

[0042] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0043] Example:

[0044] This embodiment takes the casting of an aluminum alloy sports wheel hub as an example. The solidus temperature of this alloy is about 555°C and the liquidus temperature is about 615°C.

[0045] like Figure 1-9 As shown, a combined die structure for integral forging of high-strength aluminum alloy wheel hubs with a split structure includes a processing table 1. The processing table 1 is equipped with a die unit 2, which includes an upper die 24, a lower die 22, and a side die 21. The upper die 24 contains at least one composite cooling module 3, which corresponds to the thicker parts of the wheel hub casting. Each composite cooling module 3 integrates an active cooling unit 32 and a passive heat storage unit 31. The die also includes an intelligent temperature control system 5 for coordinating the cooling behavior of each composite cooling module 3. The die includes a robust processing table 1. The processing table 1 is equipped with the die unit 2, which includes the upper die 24 driven by an upper cylinder 25, the lower die 22, and the side die 21 driven by a side cylinder 23. The core innovation of this design lies in the fact that nine composite cooling modules 3 are correspondingly arranged inside the upper die 24 for the thicker parts of the wheel hub. Each composite cooling module 3 integrates a passive heat storage unit 31 and an active cooling unit 32. The mold is also equipped with an intelligent temperature control system 5, which is used to uniformly command and coordinate the work of the nine composite cooling modules 3, and realizes precise targeted management of the hot spot of the wheel hub.

[0046] Furthermore, the passive heat storage unit 31 includes a cavity 311, which is located in the upper mold 24 corresponding to the thick section of the wheel hub casting. The cavity 311 encapsulates PCM phase change material, the phase change temperature Tr of which is higher than the solidus temperature of the wheel hub alloy. The cavity 311 is provided with a filling channel 312 for replacing the phase change material, which is located inside the upper mold 24 and sealed by a sealing post 313. The passive heat storage unit 31 includes a cavity 311, which is machined from heat-resistant mold steel and directly located inside the upper mold 24, directly opposite the thick section of the wheel hub casting. The cavity 311 encapsulates a metal-based PCM phase change material with a phase change temperature Tr of 580°C, which is higher than the solidus temperature (555°C) of A356 aluminum alloy. To facilitate replacement of the PCM after its performance deteriorates (or when replacing it with a corresponding PCM phase change material for processing other metals), a filling channel 312 is machined within the upper mold 24, extending directly from the outer surface of the mold to the cavity 311. During normal operation, the filling channel 312 is sealed by a high-temperature resistant sealing post 313 that is interference-fitted with it. The PCM material absorbs a large amount of latent heat during the phase change process while maintaining a relatively constant temperature. This characteristic provides a strong "thermal buffer" effect for thicker areas, significantly slowing down the solidification rate in these regions. This creates a valuable time window for the molten metal to fully compensate for shrinkage during the early stages of solidification, reducing the tendency for shrinkage porosity at its source. The replaceable design greatly improves the maintainability and economy of the mold.

[0047] Furthermore, the active cooling unit 32 is a cooling channel 321 located inside the composite cooling module 3 and penetrating the cavity 311. The cooling channel 321 is equipped with an independent cooling medium inlet 326 and outlet 324, as well as a flow regulating valve 322. The cooling medium inlet 326 is connected to the main channel 323, which is located in the middle of the upper mold 24. The outlet 324 is fixedly connected to the manifold 325, forming a circulating cooling path. The inlet 326, outlet 324, flow regulating valve 322, and manifold 325 are all located inside the upper mold 24. The active cooling unit 32 is a section of cooling channel 321 that passes through the cavity 311. The cooling channel 321 has an independent cooling medium inlet 326 and outlet 324. A high-frequency response electromagnetic flow regulating valve 322 is installed at the inlet 326 to precisely control the flow rate of the cooling oil. The cooling medium inlet 326 is connected to a main channel 323 machined inside the upper mold 24, and the main channel 323 is connected to an external cooling oil supply system. The cooling medium outlet 324 is fixedly connected to a manifold 325, and the cooling oil eventually flows back to the external cooling system through the manifold 325, thus forming a complete and independent circulating cooling path.

[0048] Furthermore, the intelligent temperature control system 5 includes:

[0049] Multiple first temperature sensors 51 are respectively set inside the composite cooling module 3 or in the upper mold 24 area adjacent to it, to monitor the local real-time temperature of the corresponding thick part and the phase change state of the PCM.

[0050] Multiple second temperature sensors 52 are installed in the upper mold 24 in the non-thick cooling area and base part corresponding to the wheel hub casting to monitor the overall temperature field and cooling process of the mold.

[0051] The controller 6 is fixedly connected to the upper end face of the upper mold 24 and is electrically connected to all the first temperature sensors 51, the second temperature sensors 52 and each flow regulating valve 322.

[0052] The intelligent temperature control system 5 includes multiple sensors and a controller 6. Nine first temperature sensors 51 are embedded one-to-one around the cavities 311 of the nine composite cooling modules 3, directly monitoring the local real-time temperature of the corresponding thick nodule regions. The temperature data is used to characterize the phase transition state of the PCM. Nine second temperature sensors 52 are respectively located in the base of the upper mold 24 corresponding to the thin-walled area of ​​the hub, monitoring the overall temperature field distribution and cooling process of the mold. The controller 6 uses an industrial PLC, which is fixedly mounted on the upper surface of the upper mold 24 and electrically connected to all the first temperature sensors 51, second temperature sensors 52, and multiple flow regulating valves 322 via high-temperature resistant cables.

[0053] Furthermore, the controller 6 is configured to receive a signal from the first temperature sensor 51 and, based on the PCM phase change state it monitors, independently control the opening and closing of the corresponding flow regulating valve 322 to trigger or adjust the active cooling intensity of the corresponding thick part.

[0054] Furthermore, the controller 6 is configured to: when the first temperature sensor 51 detects that the temperature reaches and is maintained at the PCM phase change material phase change temperature Tr for a preset time t1, it determines that the PCM phase change material is in the phase change period; when it detects that the temperature starts to rise from Tr, it determines that the latent heat of the PCM phase change material is exhausted, and instructs to increase the opening of the corresponding flow regulating valve 322 to implement quenching.

[0055] One of the core control logics of controller 6 is based on the signal from the first temperature sensor 51. During the casting process, molten aluminum at approximately 710°C is injected into the mold cavity through the injection system 7, and the heat is transferred to the composite cooling module 3. Controller 6 continuously receives data from each of the first temperature sensors 51. Taking one of the nodules as an example: when the temperature at this point is detected to rise to 580°C and remain at this temperature for a preset time t1 (e.g., 35 seconds), controller 6 determines that the PCM phase change material at this point is in the melting and endothermic phase change period. At this time, it keeps the corresponding flow regulating valve 322 closed or at a very low opening. This ensures that the PCM can fully exert its thermal buffering effect, allowing thick parts to cool slowly in the early stage of solidification, maintaining the fluidity of the internal molten metal for a long time, effectively filling the voids caused by solid shrinkage, and greatly promoting the densification of the casting.

[0056] When the controller 6 detects that the temperature at this point is continuously rising from the 580℃ plateau, it determines that the latent heat of the PCM at this location has been exhausted. It immediately issues a command to increase the opening of the corresponding flow regulating valve 322, allowing 20℃ cooling oil to flow into the cooling channel 321 at maximum flow rate. This implements "delayed quenching" at this location. After the basic feeding is completed, the powerful "quenching" effect causes the molten metal in this area to solidify rapidly, quickly passing through the pasty region most prone to intergranular shrinkage defects. This seals the remaining liquid phase, forming a dense crystalline structure. This "slow then fast" cooling curve perfectly matches the ideal solidification path of the alloy and is an effective means of eliminating shrinkage defects.

[0057] Furthermore, the controller 6 is also configured to receive and process the signal from the second temperature sensor 52 to calculate the overall temperature difference of the mold and execute a global safety strategy based on the analysis results.

[0058] Furthermore, controller 6 executes global security policies including:

[0059] After generating a cooling command based on the signal from the first temperature sensor 51 and before executing the command, the real-time global temperature difference data calculated by the second temperature sensor 52 is first verified.

[0060] When the real-time global temperature difference exceeds a preset safety threshold, the quench command is prohibited.

[0061] If the real-time global temperature difference does not exceed the preset safety threshold, the quench command is allowed to be executed.

[0062] Another core task of controller 6 is to execute the global safety strategy. It simultaneously processes the signal from the second temperature sensor 52 and calculates the maximum temperature difference across the entire mold. Specifically, when controller 6 generates a chilling command for a specific location based on the above logic, it does not execute it immediately. Before execution, it first verifies the real-time global temperature difference data calculated by the second temperature sensor 52. Safety interlock process: If the real-time global temperature difference calculated by the system exceeds a preset safety threshold (e.g., 120℃), controller 6 will prohibit the execution of the chilling command to prevent thermal cracking of the casting due to excessive temperature difference. This safety interlock mechanism is a key safeguard for ensuring production reliability. It effectively prevents casting cracking or mold damage caused by chilling under abnormal operating conditions (such as overcooling in other areas), greatly improving the safety and stability of the production process. If the real-time global temperature difference is within the safety threshold, controller 6 allows the execution of the chilling command.

[0063] Furthermore, the controller 6 is also configured to: determine the overall cooling stage of the mold based on the signal from the second temperature sensor 52, and coordinate the start and end points of the cooling process of all composite cooling modules 3 accordingly; the controller 6 coordinates the global cooling rhythm based on the signal from the second temperature sensor 52. For example, when all the second temperature sensors 52 show that the mold temperature is below a certain set value (such as 300°C), the controller 6 can determine that the casting has basically solidified, and thus command all cooling systems to enter low-power operation or standby mode.

[0064] Furthermore, the controller 6 is configured to cross-compare the data from each of the first temperature sensors 51 and the second temperature sensors 52; when the deviation between the data from a single first temperature sensor 51 and the overall trend reflected by the second temperature sensor 52 exceeds a preset tolerance range, the controller 6 determines that the first temperature sensor 51 has failed and triggers an alarm; the controller 6 also has a system self-diagnostic function. It cross-compares the data from each of the first temperature sensors 51 and the second temperature sensors 52. For example, if the temperature value displayed by a certain first temperature sensor 51 deviates significantly from the overall heating / cooling trend reflected by the other eight first sensors and the second sensors, and this deviation exceeds a preset tolerance range (e.g., ±50℃), the controller 6 can determine that the first temperature sensor 51 may have failed or been damaged, and immediately trigger an audible and visual alarm.

[0065] After molding, in the demolding unit 4, the ejector rod 41 is driven upward by the electric telescopic rod 42 to eject the casting and complete the demolding.

[0066] The workflow is as follows:

[0067] Metal liquid filling and system startup:

[0068] High-temperature molten metal is injected into the cavity formed by the upper mold 24, lower mold 22, and side mold 21 through the injection system 7. Heat is rapidly transferred to the mold, and the intelligent temperature control system 5 is activated. The controller 6 begins to continuously receive and process temperature signals from all the first temperature sensors 51 and the second temperature sensor 52.

[0069] PCM heat storage and buffer cooling:

[0070] The heat from the molten metal is concentrated and transferred to the thicker part of the wheel hub, where the corresponding composite cooling module 3 begins to work. The PCM phase change material in the passive heat storage unit 31 absorbs heat and undergoes a phase change when the temperature reaches its phase change temperature. During this process, it absorbs a large amount of latent heat while the temperature remains basically constant.

[0071] Effect: This process provides a powerful thermal buffering effect, significantly slowing down the solidification rate of thick sections, allowing the molten metal in this area to maintain its fluidity for a longer period, creating ideal conditions for subsequent sufficient feeding, and fundamentally inhibiting shrinkage porosity. During this period, the controller 6 keeps the corresponding flow regulating valve 322 closed or at a very small opening, and there is no forced cooling in the cooling channel 321.

[0072] Chill Triggering and Security Verification:

[0073] When a thick section of PCM completely melts and its latent heat is exhausted, its first temperature sensor 51 detects a continuous rise in temperature from the phase transition temperature plateau. Based on this, the controller 6 generates a quenching command. Before execution, the controller 6 verifies the real-time global temperature difference calculated by the second temperature sensor 52.

[0074] Active quenching and rapid solidification:

[0075] After obtaining safety clearance, controller 6 instructs to increase the opening of the corresponding flow regulating valve 322. The cryogenic cooling medium then flows into the cooling channel 321 at maximum flow rate, entering through inlet 326 and exiting through outlet 324, forming a high-efficiency cooling circuit.

[0076] System coordination and cooling termination:

[0077] The above process is carried out asynchronously and independently on multiple composite cooling modules 3. The controller 6 independently controls the corresponding flow regulating valves 322 based on the feedback from each first temperature sensor 51 to achieve precise cooling based on time and intensity. When the signal from the second temperature sensor 52 indicates that the casting has completely solidified and cooled to below the predetermined temperature, the controller 6 closes all flow regulating valves 322, ending the cooling process.

[0078] Mold opening, ejection, and cycle completion:

[0079] When mold unit 2 opens, the ejector rod 41 is driven upward by the electric telescopic rod 42 to eject the casting, completing the demolding and ending a complete work cycle.

[0080] Continuous system self-diagnosis:

[0081] Throughout the operation, the controller 6 continuously cross-compares the data trends of each first temperature sensor 51 and second temperature sensor 52. If it is found that the reading of a certain first temperature sensor 51 continuously and significantly deviates from the overall trend and exceeds the tolerance range, it is determined to be faulty and an alarm is triggered.

[0082] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of protection claimed by the present invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A combined die structure for integral forging of high-strength aluminum alloy wheel hubs with a split structure, comprising a processing table (1), wherein a die unit (2) is provided on the processing table (1), and the die unit (2) comprises an upper die (24), a lower die (22) and a side die (21), characterized in that, The upper mold (24) is provided with at least one composite cooling module (3), which is provided for the thick part of the wheel hub casting. The composite cooling module (3) integrates an active cooling unit (32) and a passive heat storage unit (31). The mold also includes an intelligent temperature control system (5) for coordinating the cooling behavior of each composite cooling module (3). The passive heat storage unit (31) includes a cavity (311) which encapsulates a PCM phase change material; The active cooling unit (32) is a cooling channel (321) opened inside the composite cooling module (3) and passing through the cavity (311). The cooling channel (321) is equipped with an independent cooling medium inlet (326) and outlet (324) and a flow regulating valve (322). The intelligent temperature control system (5) includes: Multiple first temperature sensors (51) are respectively set inside the composite cooling module (3) or in the upper mold (24) area adjacent to it, for monitoring the local real-time temperature of the corresponding thick part and the phase change state of the PCM; Multiple second temperature sensors (52) are installed in the upper mold (24) in the non-thick cooling area and base part corresponding to the wheel hub casting, for monitoring the temperature field and cooling process of the mold as a whole; The controller (6) is fixedly connected to the upper end face of the upper mold (24) and electrically connected to all the first temperature sensors (51), the second temperature sensors (52) and each of the flow regulating valves (322); The controller (6) is configured as follows: When the temperature is detected to rise from the phase change temperature Tr of the PCM phase change material, it is determined that the latent heat of the PCM phase change material is exhausted, and the opening of the corresponding flow regulating valve (322) is increased to implement quenching. The controller (6) executes the global security policy including: After generating a cooling command based on the signal from the first temperature sensor (51) and before executing the command, the real-time global temperature difference data calculated by the second temperature sensor (52) is first verified. When the real-time global temperature difference exceeds a preset safety threshold, the quenching command is prohibited from being executed. When the real-time global temperature difference does not exceed the preset safety threshold, the quenching command is allowed to be executed.

2. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 1, characterized in that, The cavity (311) is opened in the upper mold (24) corresponding to the thick part of the wheel hub casting. The phase transformation temperature Tr of the PCM phase transformation material is higher than the solidus temperature of the wheel hub alloy. The cavity (311) is provided with a filling channel (312) for replacing the phase transformation material. The filling channel (312) is opened in the upper mold (24). The filling channel (312) is blocked and sealed by a sealing post (313).

3. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 2, characterized in that, The inlet (326) and the main channel (323) of the cooling medium are connected. The main channel (323) is located in the middle of the upper mold (24). The outlet (324) and the manifold (325) are fixedly connected to form a circulating cooling passage. The inlet (326), the outlet (324), the flow regulating valve (322) and the manifold (325) are all located inside the upper mold (24).

4. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 3, characterized in that, The controller (6) is configured to receive the signal from the first temperature sensor (51) and, based on the PCM phase change state it monitors, independently control the opening and closing of the corresponding flow regulating valve (322) to trigger or adjust the active cooling intensity of the corresponding thick part.

5. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 4, characterized in that, The controller (6) is configured to determine that the PCM phase change material is in the phase change period when the first temperature sensor (51) detects that the temperature reaches and is maintained at the phase change temperature Tr of the PCM phase change material for a preset time t1.

6. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 3, characterized in that, The controller (6) is also configured to receive and process the signal from the second temperature sensor (52) to calculate the overall temperature difference of the mold and execute the global safety strategy based on the analysis result.

7. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 3, characterized in that, The controller (6) is also configured to: determine the overall cooling stage of the mold based on the signal of the second temperature sensor (52), and coordinate the start and end points of the cooling process of all composite cooling modules (3) accordingly.

8. The combined die structure for integral forging of high-strength aluminum alloy wheel hubs with split structure as described in claim 3, characterized in that, The controller (6) is also configured to: cross-compare the data of each of the first temperature sensor (51) and the second temperature sensor (52); when the deviation between the data of a single first temperature sensor (51) and the overall trend reflected by the second temperature sensor (52) exceeds a preset tolerance range, the first temperature sensor (51) is determined to be faulty and an alarm is triggered.

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