Ultra-large integrated one-mold two-cavity mold

Abstract

The invention discloses an ultra-large type integrated one-die two-cavity die, and belongs to the field of die casting, the number of cavities is two, the two cavities are communicated with a runner and are symmetrically arranged relative to the runner, the cavities extend in the vertical direction and are divided into sky sides and ground sides, the sky sides are located at the top of the ground sides, the sky sides are communicated with the ground sides, and the ground sides are located at the top of the runner; the liquid inlet is located at the bottom end of the main runner and communicated with the main runner, the two secondary pouring gates are located on the two sides of the main runner respectively and communicated with the main runner, each secondary pouring gate is communicated with one cavity, the depth of the rotary cavity is smaller than that of the main runner, and the width of the rotary cavity is larger than that of the main runner. Molten metal rotates in the rotation cavity, the process of filling the secondary pouring gates on the two sides is more uniform, and the flow ratio of the runners to the sky side and the ground side is controlled in an auxiliary mode, so that the distribution of the runners is closer to 50%; and the rotary cavity can also collect cold materials in the main pouring gate and surface oxides brought into the pressure chamber, so that the cold materials and the oxides are prevented from being filled into the cavity to influence the product quality.

Description

Technical Field

[0001] This invention relates to the field of die casting, and in particular to ultra-large integrated two-cavity molds. Background Technology

[0002] In automobile production, the integrated die-casting process reduces the weight and number of automotive parts. Simultaneously, automakers are increasing the integration of die-cast parts, leading to their ever-growing size. With the maturation of integrated die-casting technology in recent years, the integration of major ultra-large integrated die-cast parts such as the front compartment, rear floor, and battery tray has become widespread. During die-casting, molten aluminum is filled into the cavity of a mold for shaping. Most existing molds are single-cavity structures, meaning one mold produces one product at a time. This type of mold has low production efficiency and is prone to insufficient output.

[0003] Existing technologies include ultra-large integrated two-cavity molds, where one mold has two cavities. However, in existing molds, the two cavities are arranged vertically and symmetrically. In the vertical direction, the upper part of each cavity is called the top side and the lower part is called the bottom side. Due to gravity and the direction of molten metal flow, the top side is always filled first, followed by the bottom side. This results in the top side filling too early, and the filling synchronization between the top and bottom sides is inconsistent. Later, the molten metal from the top side is squeezed towards the bottom side, making it difficult for the cold material at the end of the other runners to be discharged. The pressure on the bottom side is too concentrated, leading to severe flash on the bottom side. Furthermore, the accumulation of cold material at the edge of the main runner and its concentrated filling onto the bottom side of the cavity causes an excessive temperature difference between the top and bottom sides, resulting in uneven distribution of the product's mechanical properties. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, one of the objectives of this invention is to provide an ultra-large integrated two-cavity mold with simultaneous filling on the top and bottom sides, small temperature difference in the cavity, uniform overall temperature distribution, and uniform distribution of product mechanical properties.

[0005] One of the objectives of this invention is achieved through the following technical solution:

[0006] An ultra-large integrated two-cavity mold includes a fixed mold and a moving mold. A cavity and a runner are formed between the fixed mold and the moving mold. There are two cavities, both of which are connected to the runner and symmetrically arranged about the runner. Each cavity extends vertically, and its depth direction is horizontal. Each cavity has a top side and a bottom side along the vertical direction. The top side is located at the top of the bottom side and is connected to the bottom side. The runner includes an inlet, a main runner, a rotary cavity, and secondary runners. The rotary cavity is located at the top of the main runner and is connected to it. The inlet is located at the bottom of the main runner and is connected to it. The two secondary runners are located on either side of the main runner and are connected to it. Each secondary runner is connected to one cavity. The depth of the rotary cavity is less than the depth of the main runner, and the width of the rotary cavity is greater than the width of the main runner.

[0007] Furthermore, the depth of the rotary cavity is greater than or equal to half the depth of the main channel.

[0008] Furthermore, the width of the rotary cavity is greater than or equal to twice the width of the main channel.

[0009] Furthermore, the liquid inlet, the main flow channel, and the rotary chamber are located on the same straight line.

[0010] Furthermore, the two secondary runners are symmetrically arranged about the main runner, and the angle between the side of the secondary runner near the liquid inlet and the main runner is A, where 80°≤A≤85°.

[0011] Furthermore, the intersection of the secondary runner and the main runner on one side of the moving mold has a rounded corner structure.

[0012] Furthermore, the radius of the rounded corner is 10-15 mm.

[0013] Furthermore, the flow channel also includes two first branch gating channels and two second branch gating channels. Each of the secondary gating channels is connected to the top side through the first branch gating channel, and each of the secondary gating channels is connected to the ground side through the second branch gating channels. The first branch gating channels are located above the second branch gating channels.

[0014] Furthermore, the cross-sectional area of ​​the first branch gating is smaller than that of the second branch gating.

[0015] Furthermore, along the cavity depth direction, the upper surface of the rotary cavity and the upper surface of the main channel are located on the same plane.

[0016] Compared to existing technologies, the two cavities of this invention's ultra-large integrated two-cavity mold are both connected to and symmetrically arranged about the runner. Each cavity extends vertically, and its depth direction is horizontal. Each cavity has a top side and a bottom side vertically, with the top side located at the top of the bottom side and connected to it. The runner includes an inlet, a main runner, a rotary cavity, and secondary runners. The rotary cavity is located at the top of the main runner and connected to it. The inlet is located at the bottom of the main runner and connected to it. The secondary runners are located at the two ends of the main runner. The rotary cavity is connected to the main runner on the side, and each secondary runner is connected to a cavity. The depth of the rotary cavity is less than the depth of the main runner, and the width of the rotary cavity is greater than the width of the main runner. Through the above design, the molten metal rotates in the rotary cavity, which plays a buffering role in the filling of the molten metal. The filling process to the secondary runners on both sides is more uniform, and the flow ratio of the flow channel to the top and bottom sides of the product is controlled to be closer to 50%. The rotary cavity can also collect cold material inside the main runner and surface oxides brought in from inside the pressure chamber, avoiding the backfilling of cold material and oxides from affecting product quality. Attached Figure Description

[0017] Figure 1 This is a perspective view of the ultra-large integrated two-cavity mold of the present invention;

[0018] Figure 2 for Figure 1 A 3D view of the moving mold of an ultra-large integrated two-cavity mold;

[0019] Figure 3 for Figure 1 A 3D view of the flow channels of an ultra-large integrated two-cavity mold;

[0020] Figure 4 for Figure 3 A three-dimensional view of the flow channel from another perspective;

[0021] Figure 5 for Figure 3 A three-dimensional view of the flow channel from another perspective;

[0022] Figure 6 for Figure 3 A schematic diagram of the liquid flow direction in the flow channel.

[0023] In the diagram: 10. Fixed mold; 11. Sprue; 20. Moving mold; 30. Runner; 31. Inlet; 32. Main runner; 33. Rotary cavity; 34. Secondary runner; 35. First branch runner; 36. Second branch runner; 40. Cavity; 41. Top side; 42. Bottom side. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] It should be noted that when a component is said to be "fixed to" another component, it can be directly on the other component or it can be fixed through another intermediate component. When a component is said to be "connected to" another component, it can be directly connected to the other component or it may be fixed through another intermediate component. When a component is said to be "set on" another component, it can be set directly on the other component or it may be set through another intermediate component. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0027] Please see Figures 1 to 2 The ultra-large integrated two-cavity mold is used to manufacture ultra-large integrated die-cast parts. The ultra-large integrated two-cavity mold can manufacture two products at once, improving production efficiency.

[0028] The ultra-large integrated two-cavity mold includes a fixed mold 10 and a moving mold 20. The fixed mold 10 is provided with a sprue 11. The fixed mold 10 and the moving mold 20 are closed to form a runner 30 and a cavity 40. There are two cavities 40, and the runner 30 is located between the two cavities 40 and communicates with them. Each cavity 40 is vertically arranged. In this application, "vertically arranged" means that the depth direction of the cavity 40 is horizontal, the length direction of the cavity 40 is along the height direction, and the molded product is vertically arranged. Each cavity 40 includes a top side 41 and a bottom side 42. The top side 41 is located at the top, and the bottom side 42 is located at the bottom. The top side 41 and the bottom side 42 communicate with each other and together form the cavity 40. In this embodiment, the centerline of the secondary sprue 34 is used as the dividing line. The part located above the centerline of the secondary sprue 34 is the top side 41, and the part located below the centerline of the secondary sprue 34 is the bottom side 42.

[0029] Please continue reading. Figures 3 to 6The flow channel 30 includes an inlet 31, a main flow channel 32, a rotary cavity 33, a secondary gating system 34, two first branch gating systems 35, and two second branch gating systems 36. The inlet 31, main flow channel 32, and rotary cavity 33 are arranged vertically in a straight line, with the rotary cavity 33 located at the top of the main flow channel 32 and the inlet 31 at the bottom. The molten metal entering through the inlet 31 flows upwards along the main flow channel 32. The depth of the rotary cavity 33 is less than the depth of the main flow channel 32, and the width of the rotary cavity 33 is greater than the width of the main flow channel 32, forming a wide and flat end structure at the end of the main flow channel 32. Specifically, in addition to being less than the depth of the main flow channel 32, the depth of the rotary cavity 33 must be greater than or equal to half the depth of the main flow channel 32; preferably, the width of the rotary cavity 33 is greater than or equal to twice the width of the main flow channel 32. In this embodiment, the depth of the main channel 32 is 60 mm, and the depth of the rotary cavity 33 is 30 mm. The width of the main channel 32 is 180 mm, and the width of the rotary cavity 33 is 360 mm. In terms of depth, the top of the rotary cavity 33 and the top of the main channel 32 are on the same horizontal plane. The inlet 31 is connected to the gating 11. The molten metal entering from the gating 11 flows to the inlet 31, moves upward in a straight line along the main channel 32, rotates after reaching the rotary cavity 33, and then flows to the secondary gating 34. At this time, the direction of movement of the molten metal in the secondary gating 34 is approximately the same as the extension direction of the secondary gating 34, making the filling process of the molten metal into the secondary gating 34 on both sides more uniform, and helping to control the flow ratio of the flow channel to the product top side 41 and bottom side 42 to make it closer to a 50% distribution. During the flow of molten metal, cold material inside the gating channel 11 and surface oxides brought in from inside the pressure chamber are collected. The cold material and surface oxides converge in the rotary cavity 33, which can prevent the backfilling of components such as oxides and cold material that are prone to affecting product quality. At the same time, the rotary cavity 33 plays a role in buffering and mixing materials, and also plays an auxiliary role in balancing the temperature of molten metal in the cavity 40.

[0030] The secondary runners 34 are connected to both sides of the main runner 32, and are symmetrically arranged about the main runner 32. The angle between the secondary runner 34 near the inlet 31 and the main runner 32 is A, 80°≤A≤85°. This angle design allows the molten metal to mix with the cold material accumulated on the side of the main runner 32, preventing it from concentrating inside the bottom side 42 of the product and avoiding an excessive temperature difference of more than 30°C between the top side 41 and the bottom side 42, which would result in uneven distribution of the product's mechanical properties. The improved temperature difference between the top side 41 and the bottom side 42 is within 15°C, meeting casting requirements. The intersection of the secondary runner 34 and the main runner 32 on the moving mold 20 side has a rounded corner structure with a radius of 10-15mm.

[0031] Each stage gating 34 is connected to a first branch gating 35 and a second branch gating 36. The first branch gating 35 is located above the second branch gating 36, and is connected to the top side 41. The second branch gating 36 is connected to the bottom side 42, and the cross-sectional area of ​​the first branch gating 35 is smaller than that of the second branch gating 36. In this embodiment, the cross-sectional area of ​​the first branch gating 35 on the top side 41 is 2295 mm². 2 The cross-sectional area of ​​the second branch gutter 36 on the ground side 42 is 2395 mm². 2 By controlling the cross-sectional areas of the first branch gating 35 and the second branch gating 36, the flow rate of molten metal input to the top side 41 is limited, thereby controlling the aluminum molten filling speed of the top side 41 of the product and improving the overall synchronization of product filling.

[0032] This application sets up a rotary cavity 33, in which the molten metal rotates, making the filling process of the secondary gating channels 34 on both sides more uniform. It also helps to control the flow ratio of the flow channel to the product top side 41 and bottom side 42, making it closer to a 50% distribution. The rotary cavity 33 can also collect the cold material inside the main channel 32 and the surface oxides brought in from inside the pressure chamber, avoiding the backfilling of cold material and oxides from affecting product quality.

[0033] The above embodiments merely illustrate several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the invention patent. It should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the concept of the present invention. These are all equivalent modifications and improvements made to the above embodiments based on the essential technology of the present invention, and all of these fall within the protection scope of the present invention.

Claims

1. A super-large integrated two-cavity mold, comprising a fixed mold and a moving mold, wherein a cavity and a runner are formed between the fixed mold and the moving mold, the number of cavities is two, both cavities are connected to the runner and are symmetrically arranged about the runner, each cavity extends vertically, the depth direction of the cavity is horizontal, each cavity has a top side and a bottom side in the vertical direction, the top side is located at the top of the bottom side, and the top side is connected to the bottom side, characterized in that: The flow channel includes an inlet, a main channel, a rotary cavity, and two secondary runners. The rotary cavity is located at the top of the main channel and is connected to the main channel. The inlet is located at the bottom of the main channel and is connected to the main channel. The two secondary runners are located on both sides of the main channel and are connected to the main channel. Each secondary runner is connected to a cavity. The depth of the rotary cavity is less than the depth of the main channel, and the width of the rotary cavity is greater than the width of the main channel.

2. The ultra-large integrated two-cavity mold according to claim 1, characterized in that: The depth of the rotary cavity is greater than or equal to half the depth of the main channel.

3. The ultra-large integrated two-cavity mold according to claim 1, characterized in that: The width of the rotary cavity is greater than or equal to twice the width of the main channel.

4. The ultra-large integrated two-cavity mold according to any one of claims 1-3, characterized in that: The inlet, the main channel, and the rotary chamber are located on the same straight line.

5. The ultra-large integrated two-cavity mold according to claim 1, characterized in that: The two secondary runners are symmetrically arranged about the main runner, and the angle between the side of the secondary runner near the liquid inlet and the main runner is A, where 80°≤A≤85°.

6. The ultra-large integrated two-cavity mold according to claim 5, characterized in that: The intersection of the secondary runner and the main runner on one side of the moving mold has a rounded corner structure.

7. The ultra-large integrated two-cavity mold according to claim 6, characterized in that: The radius of the fillet is 10-15mm.

8. The ultra-large integrated two-cavity mold according to claim 1, characterized in that: The flow channel also includes two first branch gating channels and two second branch gating channels. Each of the secondary gating channels is connected to the top side through the first branch gating channel, and each of the secondary gating channels is connected to the ground side through the second branch gating channel. The first branch gating channel is located above the second branch gating channel.

9. The ultra-large integrated two-cavity mold according to claim 8, characterized in that: The cross-sectional area of ​​the first branch gating is smaller than that of the second branch gating.

10. The ultra-large integrated two-cavity mold according to claim 1, characterized in that: Along the cavity depth direction, the upper surface of the rotary cavity and the upper surface of the main channel are located on the same plane.

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