Matching analysis method for die-casting machine, die-casting mold and die-casting process

Abstract

The invention discloses a matching analysis method for a die-casting machine, a die-casting die and a die-casting process, and relates to the technical field of die-casting. The method comprises the following steps: inputting information of a casting, a die-casting machine, an alloy and a die by taking Excel as a carrier; on the basis of the input parameters, automatically calculating mold clamping force, a material pipe filling rate, expected mold filling speed and time, an atomization speed, a speed increasing ratio, a mold DL line, a die casting machine ML line and system working point parameters; generating and displaying a P-Q chart including a mold DL line, a die-casting machine ML line and a process window; judging whether a system working point is located in the process window and whether each parameter is reasonable; and outputting the optimal die-casting process and die design parameters. According to the method, through systematic calculation and dynamic visualization, the die casting theory and engineering experience are combined, the problem that machines, dies and technologies are difficult to match is effectively solved, dependence on personnel experience is remarkably reduced, and the production efficiency and the product yield are improved.

Description

Technical Field

[0001] This invention relates to the field of die casting technology, and in particular to a method for analyzing the compatibility of die casting machines, die casting molds and die casting processes. Background Technology

[0002] Die casting technology is a complex technology that organically combines die casting machines, die casting molds, and die casting processes. It involves knowledge from many disciplines such as mechatronics, PLC control, hydraulic transmission, materials science, heat treatment, fluid mechanics, metal forming theory, degassing technology, and gas control technology.

[0003] A stable and efficient die-casting production system requires a high degree of matching among the aforementioned elements. Most of these knowledge areas require technicians with at least a bachelor's degree. However, due to the harsh working environment of die casting, it is difficult to recruit highly educated personnel. Most technicians only have a junior high school education. The vast majority of die-casting plant technicians rely on experience to solve problems, lack research direction, innovative spirit, and the ability to master the complete set of die-casting knowledge. They can only specialize in one or two techniques, mainly relying on personal experience to set process parameters and design molds. This leads to a lack of perfect matching between the die-casting machine, die-casting mold, and die-casting process. The result is unstable production, high defect rates, high production costs, and the inability to resolve many die-casting defects. Specifically, the existing technology in the industry has the following shortcomings:

[0004] 1. Reliance on experience and lack of theoretical support: Process parameters such as clamping force, injection speed, and gating system dimensions are largely based on the experience of experienced technicians, making them difficult to replicate and optimize. Some technicians may look up traditional calculation formulas in textbooks / manuals, such as clamping force formulas and flow rate calculation formulas, but these formulas are isolated and scattered, still requiring technicians to manually calculate and judge their rationality based on experience.

[0005] 2. Fragmented knowledge and lack of systematic matching: Technicians are often only proficient in one aspect of die casting machine, mold or process, making it difficult to optimize from a system perspective, resulting in a disconnect between "machine", "mold" and "process".

[0006] 3. High trial-and-error costs: Mismatched parameter settings can lead to die-casting defects, requiring adjustments through multiple trial moldings, which wastes a lot of time, materials, and manpower.

[0007] 4. The configuration software provided by die-casting machine manufacturers has a high barrier to entry: Some high-end die-casting machines are equipped with process setting software, but these are usually limited to parameter optimization of that brand's die-casting machine and are a "black box," not revealing the core algorithm or involving the specific calculation and matching of mold DL lines. On the other hand, CAE simulation-based analysis, such as Flow-3D and MAGMA, is powerful and allows for precise analysis using simulation software, but it has a high learning curve, long calculation time, and high price, making it unsuitable for rapid debugging and initial solution selection by on-site technicians.

[0008] Therefore, there is an urgent need in this field for a parameter matching analysis method that can integrate theoretical calculations and engineering experience, is easy to operate, and can quickly guide die-casting production. Summary of the Invention

[0009] In view of this, the present invention addresses the deficiencies of existing technologies. Its main objective is to provide a matching analysis method for die casting machines, die casting molds, and die casting processes. Using Excel as a medium, it takes metal forming theory as its foundation and combines it with the performance parameters of the die casting machine to present the complex mold design and die casting process in the form of an Excel spreadsheet. In this way, through Excel calculation and dynamic visualization, it combines die casting theory with engineering experience, making it easy to operate and quickly guiding die casting production. It effectively solves the problems of poor stability and high defect rate caused by the difficulty in matching "machine, mold, and process," significantly reduces the over-reliance on the experience of technical personnel, and improves production efficiency and product yield.

[0010] To achieve the above objectives, the present invention adopts the following technical solution:

[0011] A matching analysis method for die casting machine, die casting mold and die casting process is implemented in an Excel spreadsheet. The Excel spreadsheet includes a product and die casting machine parameter input area, a mold design parameter and die casting process parameter display area, and a PQ chart display area.

[0012] The method includes the following steps:

[0013] Step S1: Input parameters in the product and die casting machine parameter input areas. The parameters include at least casting data parameters, die casting machine data parameters, alloy data parameters, mold steel data parameters, and mold data parameters.

[0014] Step S2: Based on the input parameters, the mold design parameters and die-casting process parameters are automatically calculated and displayed in the display area;

[0015] The mold design parameters and die casting process parameters include at least: die casting machine clamping force, mold tube filling rate, desired filling speed, desired filling time, atomization speed, speed ratio, mold DL line, die casting machine set ML line, system working point filling pressure, system working point filling flow rate, system working point filling speed, system working point filling time, injection speed and injection position.

[0016] Step S3: Based on the mold design parameters and die-casting process parameters, generate and display the PQ chart in the PQ chart display area;

[0017] The PQ chart includes at least: a mold DL line representing mold requirements, a die casting machine setting ML line representing die casting machine performance, and a process window enclosed by preset minimum and maximum filling time lines and preset maximum and minimum speed lines.

[0018] Step S4: Determine whether the conditions are met, and obtain the final mold design parameters and die-casting process parameters;

[0019] Condition 1 is to determine whether the intersection of the mold DL line and the die-casting machine set ML line, which is also the system working point, is within the process window; Condition 2 is to determine whether each calculation parameter is within the preset reasonable threshold range.

[0020] If the judgment results of both conditions 1 and 2 are "yes", then the current parameter is determined to be the best matching parameter, and the output is used as the final mold design parameter and die casting process parameter.

[0021] If at least one of the judgment conclusions in condition 1 and condition 2 is "no", then the input parameters are changed in the product and die-casting machine parameter input area. The mold design parameters and die-casting process parameters displayed in the mold design parameters and die-casting process parameters display area are changed accordingly. The system working point in the PQ chart display area moves accordingly until the judgment conclusions in condition 1 and condition 2 are both "yes". Then the current parameter is determined to be the best matching parameter, and the output is used as the final mold design parameters and die-casting process parameters.

[0022] As a preferred embodiment, the die-casting machine clamping force in step S2 is calculated using the following formula:

[0023] F 锁 = K×P×A / 1000, where F 锁 is the clamping force; K is the safety factor, which is 1.1 when the injection position is at point 0 and 1.25 when it is at other positions; A is the projected area of ​​the whole mold product; P is the injection pressure.

[0024] As a preferred embodiment, the mold tube filling rate in step S2 is calculated and verified using the following formula:

[0025] K1 = 4×V1 / [π×D 2 ×(L + h)], where K1 is the filling rate of the material tube, and it needs to satisfy 30% < K1 < 50%; V1 is the volume of the liquid metal; D is the diameter of the material tube; L is the position where the injection ends; h is the thickness of the slug.

[0026] As a preferred solution, the desired filling speed in step S2 is calculated by the following piecewise function based on the typical thickness x of the appearance surface at the end of the product filling:

[0027] When x > 4, the minimum desired filling speed y = -2x + 42, and the maximum desired filling speed y1 = y + 15;

[0028] When x ≤ 4, the minimum desired filling speed y = -4x + 50, and the maximum desired filling speed y1 = y + 15.

[0029] As a preferred solution, the desired filling time in step S2 is calculated by the following formula:

[0030] t = 1000×k2×x×(T1 - 30 - T2 + S×Z) / (T2 - T3), where t is the desired filling time; k2 is the empirical constant of the mold steel; x is the typical thickness of the appearance surface at the end of the product filling; T1 is the temperature of the molten metal in the holding furnace; T2 is the lowest temperature at which the molten metal can flow; T3 is the temperature of the mold cavity surface; S is the solid phase rate. When the appearance requirements of the product are high, S takes 10 to 20. When the internal requirements of the product are high, S takes 15 to 25; Z is the unit conversion factor 4.8.

[0031] As a preferred solution, the atomization speed in step S2 is calculated by the following formula, and the minimum filling speed of the product must be greater than this atomization speed:

[0032] Vg = J×D1 / (ρ×L1×L2), where Vg is the atomization speed; J is the atomization determination value 985; D1 is the equivalent diameter of the inner gate at the gate; ρ is the density of the liquid metal; L1 is the thickness of the gate; L2 is the width of the gate.

[0033] As a preferred solution, the speed increase ratio in step S2 is calculated and verified by the following formula:

[0034] K3 = π×D 2 / (4×S), where K3 is the speed increase ratio and needs to be controlled between 9 and 30; D is the diameter of the material tube; S is the gate area.

[0035] As a preferred solution, the mold DL line in step S2 is calculated by the following formula:

[0036]

[0037] The die-casting machine setting ML line in step S2 is calculated using the following formula:

[0038]

[0039] Where Pc is the pressure applied to the molten metal by the punch; Pb is the pressure of the die-casting machine's accumulator; Qc is the filling flow rate; Qcmax is the flow rate of the die-casting machine at the maximum dry-firing speed; Ag is the cross-sectional area of ​​the ingate; A0 is the piston area of ​​the injection cylinder; Ac is the cross-sectional area of ​​the punch; ρ is the density of the molten metal; Cd is the flow coefficient, which needs to be 0.6 to 0.8 in the designed flow channel.

[0040] The system operating point filling pressure in step S2 is calculated using the following formula:

[0041] P1=P2 / [1+(P2 / 500 / ρ)×(Cd×S×cosθ / Q2) 2 Where, P1 is the working point filling pressure; P2 is the set maximum filling pressure; Q2 is the set air injection flow rate; θ is the injection angle; S is the actual gate area; P is the metal liquid density; Cd is the flow coefficient, which needs to be 0.6 to 0.8 in the designed flow channel;

[0042] The system operating point filling flow rate in step S2 is calculated using the following formula:

[0043] Where Q is the working point filling flow rate; P1 is the working point filling pressure; θ is the jet angle; S is the actual gate area; ρ is the density of the molten metal; Cd is the flow coefficient, which needs to be 0.6 to 0.8 in the designed flow channel;

[0044] The system operating point filling speed in step S2 is calculated using the following formula:

[0045] v = 1000 × Q / (S × cosθ), where v is the filling velocity at the working point; Q is the filling flow rate at the working point; θ is the jet angle; and S is the actual gate area.

[0046] The system operating point filling time in step S2 is calculated using the following formula: t1 = V1 / Q, where t1 is the operating point filling time; Q is the operating point filling flow rate; and V1 is the volume of liquid metal.

[0047] As a preferred embodiment, the injection speed and injection position in step S2 include:

[0048] The working point injection velocity is calculated using the following formula: V2=4×V×S×cosθ / (π×D) 2 ), where V2 is the injection velocity at the working point; v is the filling velocity at the working point; D is the diameter of the material tube; θ is the jet angle; and S is the actual gate area;

[0049] The injection velocity is calculated using the following formula:

[0050]

[0051] Where V(first speed) is the first injection speed; V1 is the volume of liquid metal; D is the diameter of the feed tube; L is the injection termination position; and h is the thickness of the pellet.

[0052] The position of the first injection velocity is calculated using the following formula: P(first velocity) = L - 4 × V1 / (π × D) 2 )-250×t 加 ×[V(first speed) + V(second speed)] + L3, where P(first speed) is the position of the first injection speed; V(first speed) is the first injection speed; V(second speed) is the second injection speed; V1 is the volume of liquid metal; D is the tube diameter; L is the injection termination position; L3 is the first speed correction value; t 加 Accelerate the die-casting machine's time;

[0053] The position of the second injection velocity is calculated using the following formula: P(second velocity) = L - 4 × V² / (π × D) 2 )-250×t 加 ×[V(first speed) + V(second speed)] + L4, where P(second speed) is the second speed injection position; V(first speed) is the first injection speed; V(second speed) is the second injection speed; V2 is the filling volume; D is the tube diameter; L is the injection termination position; L3 is the second speed correction value, which is related to the performance of the die-casting machine; t 加 Accelerate the die-casting machine's time;

[0054] The boost pressure position is calculated using the following formula: P (boost pressure) = L - 320 × t 加 ×t 建 +L5, where P (pressure boost) is the injection pressure boost position; L is the injection termination position; L5 is the pressure boost correction value, which is related to the performance of the die-casting machine; t 加 Acceleration time for die-casting machine; t 建 The pressure build-up time for the die-casting machine.

[0055] As a preferred embodiment, in step S4, the parameter judgment result is visually fed back through a human-computer interaction interface using color changes:

[0056] Mark the product and die-casting machine parameter input areas with the first color;

[0057] The parameters that are automatically generated and within a reasonable range in the mold design parameters and die casting process parameters display area are marked with the second color;

[0058] Parameters that are automatically generated in the mold design parameters and die casting process parameters display area but are outside the reasonable range will be marked with a third color as a warning.

[0059] Compared with existing technologies, this invention has significant advantages and beneficial effects. Specifically, as can be seen from the above technical solution, it mainly uses Excel as the carrier. The Excel spreadsheet includes input areas for product and die-casting machine parameters, display areas for mold design parameters and die-casting process parameters, and a PQ chart display area. Through steps S1 to S4, based on metal forming theory and combined with the performance parameters of the die-casting machine, the complex mold design and die-casting process are presented in the form of an Excel spreadsheet. Utilizing Excel calculations and dynamic visualization, die-casting theory is combined with engineering experience, effectively solving the problem of mismatch between "machine, mold, and process," and significantly reducing reliance on the experience of technical personnel. This solution is simple, practical, and easy to operate. Technical personnel using this Excel spreadsheet as an auxiliary design tool can greatly improve the first-time success rate, opening up new solutions for the die-casting industry and effectively improving production efficiency and product yield.

[0060] To more clearly illustrate the structural features and effects of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0061] Figure 1 This is a matching analysis table of the die casting machine, die casting mold and die casting process according to an embodiment of the present invention (when no parameters are entered);

[0062] Figure 2 This is a diagram showing the relationship between the process window and the system working points in the PQ chart display area;

[0063] Figure 3 This is a matching analysis table of the die casting machine, die casting mold and die casting process according to an embodiment of the present invention (taking the five-star chair leg die casting as an example to obtain the optimal matching parameters);

[0064] Figure 4 yes Figure 3 The PQ chart display area in the middle;

[0065] Figure 5 This is a matching analysis table of the die casting machine, die casting mold and die casting process according to an embodiment of the present invention (taking the five-star chair leg die casting as an example, the optimal matching parameters were not obtained);

[0066] Figure 6 yes Figure 5 The PQ chart display area in the middle. Detailed Implementation

[0067] Please refer to Figures 1 to 6 As shown, it illustrates a specific embodiment of the present invention.

[0068] A matching analysis method for die casting machine, die casting mold and die casting process is implemented in an Excel spreadsheet. Specifically, a computer is used as hardware, and Excel software is installed and run on the computer to create an Excel data spreadsheet. The Excel spreadsheet includes an input area for product and die casting machine parameters, a display area for mold design parameters and die casting process parameters, and a PQ chart display area.

[0069] The method includes the following steps:

[0070] Step S1: Input parameters in the product and die casting machine parameter input areas. The parameters include at least casting data parameters, die casting machine data parameters, alloy data parameters, mold steel data parameters, and mold data parameters.

[0071] Step S2: Based on the input parameters, the mold design parameters and die-casting process parameters are automatically calculated and displayed in the display area;

[0072] The mold design parameters and die casting process parameters include at least: die casting machine clamping force, mold tube filling rate, desired filling speed, desired filling time, atomization speed, speed ratio, mold DL line, die casting machine set ML line, system working point filling pressure, system working point filling flow rate, system working point filling speed, system working point filling time, injection speed and injection position.

[0073] Step S3: Based on the mold design parameters and die-casting process parameters, generate and display the PQ chart in the PQ chart display area;

[0074] The PQ chart includes at least: a mold DL line representing mold requirements, a die casting machine setting ML line representing die casting machine performance, and a process window enclosed by preset minimum and maximum filling time lines and preset maximum and minimum speed lines.

[0075] The PQ chart in step S3 is a dynamic interactive chart. In response to changes in the input parameters, the mold DL line, the die-casting machine setting ML line, and the system working point are updated in real time and move dynamically in the chart.

[0076] Step S4: Determine whether the conditions are met, and obtain the final mold design parameters and die-casting process parameters;

[0077] Condition 1 is to determine whether the intersection of the mold DL line and the die-casting machine set ML line, which is also the system working point, is within the process window; Condition 2 is to determine whether each calculation parameter is within the preset reasonable threshold range.

[0078] If the judgment results of both conditions 1 and 2 are "yes", then the current parameter is determined to be the best matching parameter, and the output is used as the final mold design parameter and die casting process parameter.

[0079] If at least one of the judgment conclusions in condition 1 and condition 2 is "no", then the input parameters are changed in the product and die-casting machine parameter input areas. The mold design parameters and die-casting process parameters displayed in the mold design parameter and die-casting process parameter display areas are changed accordingly, and the system working point in the PQ chart display area moves accordingly, until the judgment conclusions in condition 1 and condition 2 are both "yes". Then, the current parameters are determined to be the best matching parameters, and the output is used as the final mold design parameters and die-casting process parameters. Preferably, in step S4, the parameter judgment results are visually fed back through color changes via the human-computer interaction interface: the parameter area that requires manual input is marked with the first color; the automatically generated parameters that are within a reasonable range are marked with the second color; and the automatically generated parameters that exceed the reasonable range are marked with the third color as a warning.

[0080] Step S5: Output the final die-casting process parameters and mold design parameters, which will be used by technicians as the die-casting process parameters and mold design parameters.

[0081] It should be noted that steps S1 to S5, which follow the process of "input-calculation-PQ diagram-judgment-output confirmation," are not limited to specific calculation formulas in practice. Based on some basic parameters of the die-casting machine, die-casting mold, and product, a systematic parameter calculation and matching analysis method is formed in an Excel spreadsheet (which has formula editing and calculation functions), combined with metal forming theory, machine performance, mold design, process window, etc. The Excel spreadsheet is simple and intuitive; for example, it uses color blocks to indicate anomalies (such as red warnings) and dynamically displays the relationship between the system's working points and the process window through charts, allowing for intuitive judgment of parameter rationality and assisting technicians in optimizing the design.

[0082] like Figure 1 As shown, this is a matching analysis table for the die casting machine, die casting mold, and die casting process. The Excel spreadsheet contains casting data parameters, die casting machine data parameters, alloy data parameters, mold steel data parameters, mold data parameters, cavity filling data parameters, die casting process parameters, and mold information. The yellow sections represent manually entered parameters, the orange sections represent parameters of key interest, and the white and green sections represent automatically generated parameters.

[0083] like Figure 2 and Figure 3 As shown, taking the die-casting of a five-star chair leg as an example, when designing the mold design parameters and die-casting process parameters, first input the parameters in the product and die-casting machine parameter input areas:

[0084] Casting data parameters (casting weight 2992g, overflow weight 1161g, number of cavities 1, liquid metal volume 2151885mm²) 3 Average wall thickness 3mm, injection pressure 50MPa, total mold projection area 1175cm² 2 (Cake thickness 20mm);

[0085] Die casting machine data parameters (equipment model DCC800, standard punch diameter 100mm, maximum air injection speed 7m / s, set punch diameter 120mm, set air injection punch speed 4.18m / s);

[0086] Alloy data parameters (see table below):

[0087] Alloy Name A380 Solid alloy density 2.68 <![CDATA[g / cm 3 ]]> Liquid alloy density 2.5 <![CDATA[g / cm 3 ]]> solidus temperature 538 ℃ Minimum temperature of liquid flow 570 ℃ Liquidus temperature 593 ℃ Flow coefficient 0.6 Specific heat capacity 960 J / kg℃ Latent heat 388440 J / kg Atomization Flow Judgment Value 985 J

[0088] Die steel data parameters (die core material H13, die steel constant K 0.0346 s / mm);

[0089] Mold data parameters (gate thickness 2.62mm, single cavity gate width 370mm, jet angle 0°);

[0090] In addition, some die-casting process parameters are shown in the table below.

[0091]

[0092]

[0093] Based on the input parameters, the mold design parameters (including cavity filling parameters) and die casting process parameters are automatically calculated and displayed in the mold design parameters and die casting process parameters display area. Furthermore, based on the mold design parameters (including cavity filling parameters) and die casting process parameters, a PQ chart is generated and displayed in the PQ chart display area. The table contains a PQ chart representing the relationship between pressure and flow rate in die casting production. Different colored lines in the chart represent the die casting machine's nominal ML line, die casting machine's set ML line, set maximum speed line, set minimum speed line, shortest filling time line, longest filling time line, mold DL line, and process window, respectively. The intersection point within the process window represents the system operating point. It can be seen that the intersection point of the mold DL line and the die casting machine's set ML line, which also indicates the system operating point, is located within the process window. Moreover, all calculated parameters are within the preset reasonable threshold range (the parameters in the table do not have red indicators). Therefore, this indicates that the optimal mold design parameters and die casting process parameters have been obtained.

[0094] like Figure 5 and Figure 6As shown, when the generated parameters are unreasonable, they will automatically turn red, indicating to the technician that the design is unreasonable and other design parameters need to be modified. When the system operating point is outside the process window, it also indicates that the design is unreasonable. The technician can change the parameters in the yellow part. When one or more parameters are modified, the corresponding lines in the P-Q chart and the system operating point will automatically move. When the system operating point is within the process window and there is no red prompt for the parameters in the table, it indicates that the optimal die design parameters and die-casting process parameters have been obtained.

[0095] In this embodiment, the clamping force of the die-casting machine in step S2 is calculated by the following formula:

[0096] F 锁 = K × P × A / 1000, where F 锁 is the clamping force (unit: kN); K is the safety factor, K takes 1.1 when the injection position is at point 0, and K takes 1.25 at other positions; A is the projected area of the whole mold product (unit: cm 2 ); P is the injection specific pressure (unit: MPa). The common injection specific pressure values are as follows in the table:

[0097]

[0098] The filling rate of the mold sprue in step S2 is calculated and verified by the following formula:

[0099] K1 = 4 × V1 / [π × D 2 × (L + h)], where K1 is the sprue filling rate, and it needs to satisfy 30% < K1 < 50%; V1 is the volume of liquid metal (unit: mm 3 ); D is the sprue diameter (unit: mm); L is the injection end position (unit: mm); h is the thickness of the sprue cake (unit: mm).

[0100] Taking the LK and Yizumi die-casting machines commonly used in the die-casting industry as examples, the sprue filling rate needs to be controlled between 30% and 50%; when the appearance requirements of the product are very high, the sprue filling rate is preferably controlled between 30% and 40%, and when the internal requirements of the product are very high, the sprue filling rate is controlled between 40% and 50%.

[0101] The expected filling speed in step S2 is calculated by the following piecewise function based on the typical thickness x (unit: mm) of the appearance surface at the end of product filling:

[0102] When x > 4, the minimum expected filling speed y = -2x + 42 (unit: m / s), and the maximum expected filling speed y1 = y + 15 (unit: m / s);

[0103] When x≤4, the minimum expected filling speed y=-4x+50 (unit: m / s) and the maximum expected filling speed y1=y+15 (unit: m / s).

[0104] The expected filling time in step S2 is calculated using the following formula:

[0105] t = 1000 × k2 × x × (T1 - 30 - T2 + S × Z) / (T2 - T3), where t is the expected filling time (unit: ms); k2 is the empirical constant of the mold steel (unit: s / mm); x is the typical thickness of the surface of the product at the filling end (unit: mm); T1 is the temperature of the molten metal in the holding furnace (unit: ℃); T2 is the minimum temperature at which the molten metal can flow (unit: ℃); T3 is the surface temperature of the mold cavity (unit: ℃); S is the solid fraction (unit: %), which is 10 to 20 when the product appearance requirements are high, and 15 to 25 when the product internal requirements are high; Z is the unit conversion factor of 4.8 (℃ / %).

[0106] The atomization rate in step S2 is calculated using the following formula, and the minimum filling rate of the product must be greater than this atomization rate:

[0107] Vg = J × D1 / (ρ × L1 × L2), where Vg is the atomization velocity (unit: m / s); J is the atomization judgment value 985; D1 is the equivalent diameter of the ingate at the gating point (unit: m); ρ is the density of the liquid metal (unit: kg / m³). 3 L1 is the gate thickness (unit: m); L2 is the gate width (unit: m).

[0108] The growth rate ratio in step S2 is calculated and verified using the following formula:

[0109] K3=π×D 2 / (4×S), where K3 is the growth rate ratio, which needs to be controlled between 9 and 30; D is the pipe diameter (unit: mm); S is the gate area (unit: mm²). 2 ).

[0110] When the product is relatively thick, the growth rate should be relatively small; when the product is relatively thin, the growth rate should be relatively large.

[0111] The calculation of the mold DL line and the die-casting machine setting ML line in step S2 are calculated using the following formulas:

[0112] Mold DL line calculation:

[0113] Die casting machine ML line setting:

[0114] Where Pc is the pressure applied by the punch to the molten metal (unit: Pa); Pb is the pressure of the die-casting machine's accumulator (unit: Pa); Qc is the filling flow rate (unit: cm³). 3 / s); Qcmax is the metal flow rate of the die-casting machine at the maximum dry-firing speed (unit: cm). 3 / s); Ag is the cross-sectional area of ​​the ingate (unit: cm²); A0 is the piston area of ​​the injection cylinder (unit: cm²); Ac is the cross-sectional area of ​​the punch (unit: cm²); ρ is the density of the molten metal (unit: g / cm³). 3 Cd is the flow coefficient, and the designed flow channel needs to achieve a flow rate of 0.6 to 0.8.

[0115] The system operating point filling pressure in step S2 is calculated using the following formula:

[0116] P1=P2 / [1+(P2 / 500 / ρ)×(Cd×S×cosθ / Q2) 2 Where, P1 is the working point filling pressure (unit: Pa); P2 is the set maximum filling pressure (unit: Pa); Q2 is the set air injection flow rate (unit: L / s); θ is the injection angle (unit: °); S is the actual gate area (unit: mm). 2 P represents the density of the molten metal (unit: g / cm³). 3 Cd is the flow coefficient, and the designed flow channel needs to achieve a flow rate of 0.6 to 0.8.

[0117] The system operating point filling flow rate in step S2 is calculated using the following formula:

[0118] Where Q is the working point filling flow rate (unit: L / s); P1 is the working point filling pressure (unit: Pa); θ is the jet angle (unit: °); and S is the actual gate area (unit: mm). 2 ); ρ is the density of the molten metal (unit: g / cm³) 3 Cd is the flow coefficient, and the designed flow channel needs to achieve a flow rate of 0.6 to 0.8.

[0119] The system operating point filling speed in step S2 is calculated using the following formula:

[0120] v = 1000 × Q / (S × cosθ), where v is the filling velocity at the working point (unit: m / s); Q is the filling flow rate at the working point (unit: L / s); θ is the jet angle (unit: °); and S is the actual gate area (unit: mm). 2 );

[0121] The system operating point filling time in step S2 is calculated using the following formula: t1 = V1 / Q, where t1 is the operating point filling time (unit: ms); Q is the operating point filling flow rate (unit: L / s); and V1 is the volume of liquid metal (unit: cm³). 3 );

[0122] The injection velocity and injection position calculations in step S2 are performed using the following formulas:

[0123] Calculation of injection velocity at the working point: V2=4×V×S×cosθ / (π×D) 2 Where V2 is the working point injection velocity (unit: m / s); v is the working point filling velocity (unit: m / s); D is the material tube diameter (unit: mm); θ is the jet angle (unit: °); and S is the actual gate area (unit: mm²). 2 );

[0124] Calculation of the first injection velocity:

[0125]

[0126] Where V(primary velocity) is the primary injection velocity (unit: m / s); V1 is the volume of liquid metal (unit: mm). 3 D is the diameter of the feed tube (unit: mm); L is the injection termination position (unit: mm); h is the thickness of the feed cake (unit: mm);

[0127] Calculation of the position of the first injection velocity: P(first velocity) = L - 4 × V1 / (π × D) 2 )-250×t 加 ×[V(first velocity) + V(second velocity)] + L3, where P(first velocity) is the position of the first injection velocity (unit: mm); V(first velocity) is the first injection velocity (unit: m / s); V(second velocity) is the second injection velocity (unit: m / s); V1 is the volume of liquid metal (unit: mm). 3 D is the diameter of the feed tube (unit: mm); L is the injection termination position (unit: mm); L3 is the first-speed correction value, which is related to the performance of the die-casting machine (unit: mm); t 加 Acceleration time of the die-casting machine (unit: s);

[0128] Calculation of the position of the second velocity of the injection: P(second velocity) = L - 4 × V² / (π × D) 2 )-250×t 加 ×[V(first speed) + V(second speed)] + L4, where P(second speed) is the position of the second injection speed (unit: mm); V(first speed) is the first injection speed (unit: m / s); V(second speed) is the second injection speed (unit: m / s); V2 is the filling volume (unit: mm). 3D is the diameter of the feed tube (unit: mm); L is the injection termination position (unit: mm); L3 is the second-speed correction value, which is related to the performance of the die-casting machine (unit: mm); t 加 Acceleration time of the die-casting machine (unit: s);

[0129] Calculation of boost pressure position: P (boost pressure) = L - 320 × t 加 ×t 建 +L5, where P (pressure boost) is the injection pressure boost position (unit: mm); L is the injection termination position (unit: mm); L5 is the pressure boost correction value, which is related to the performance of the die-casting machine (unit: mm); t 加 Acceleration time of die-casting machine (unit: s); t 建 Pressure build-up time for the die-casting machine (unit: seconds).

[0130] In this embodiment, as can be seen from the above calculation formulas, it provides a series of specific and interrelated calculation formulas from clamping force, filling time, atomization speed to working point pressure / flow rate / speed, etc. Furthermore, it integrates the originally scattered and experience-based judgment criteria (such as material tube filling rate 30-50%, speed-up ratio 9-30, flow coefficient 0.6-0.8) into a complete calculation system. It introduces the concepts of "PQ chart" and "process window," dynamically displaying the system's working points through charts to intuitively determine whether parameter matching is optimal, and visually showing the gap between the current design state and the ideal state, providing technicians with a clear direction for optimization. Utilizing the common office software Excel, which all technicians are familiar with, its conditional formatting and other functions enable automatic parameter calculation and anomaly alarms (red prompts), achieving automated calculation and feedback to guide technicians in optimization. Furthermore, this Excel spreadsheet for matching die-casting machines, die-casting molds, and die-casting processes combines PQ chart theory with actual process parameter calculations and Excel's interactive functions to form a dynamic decision support tool. It is low-cost, highly universal, and easy to implement. As long as the input parameters are accurate, it can be applied to different brands of die-casting machines and molds. The results are obtained immediately upon input, with a high success rate. Unreasonable parameters can be dynamically modified and optimized, making it easy to obtain a set of optimized die-casting process parameters that can be applied industrially. Even inexperienced technicians can make professional decisions under the guidance of the Excel spreadsheet, reducing the skill requirements for technicians.

[0131] The key design feature of this invention lies in its use of Excel as the medium. The Excel spreadsheet includes input areas for product and die-casting machine parameters, display areas for mold design parameters and die-casting process parameters, and a PQ chart display area. Through steps S1 to S4, based on metal forming theory and combined with the performance parameters of the die-casting machine, the complex mold design and die-casting process are presented in the form of an Excel spreadsheet. Utilizing Excel's calculation and dynamic visualization capabilities, die-casting theory is combined with engineering experience, effectively solving the problem of mismatch between "machine, mold, and process," and significantly reducing reliance on the experience of technical personnel. This solution is simple, practical, and easy to operate. Technical personnel using this Excel spreadsheet as an auxiliary design tool can greatly improve the first-time success rate, opening up new solutions for the die-casting industry and effectively improving production efficiency and product yield.

[0132] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A method for matching die-casting machine, die-casting mold, and die-casting process, characterized in that, It is implemented in an Excel spreadsheet, which includes an input area for product and die-casting machine parameters, a display area for mold design parameters and die-casting process parameters, and a PQ chart display area. The method includes the following steps: Step S1: Input parameters in the product and die casting machine parameter input areas. The parameters include at least casting data parameters, die casting machine data parameters, alloy data parameters, mold steel data parameters, and mold data parameters. Step S2: Based on the input parameters, the mold design parameters and die-casting process parameters are automatically calculated and displayed in the display area; The mold design parameters and die casting process parameters include at least: die casting machine clamping force, mold tube filling rate, desired filling speed, desired filling time, atomization speed, speed ratio, mold DL line, die casting machine set ML line, system working point filling pressure, system working point filling flow rate, system working point filling speed, system working point filling time, injection speed and injection position. Step S3: Based on the mold design parameters and die-casting process parameters, generate and display the PQ chart in the PQ chart display area; The PQ chart includes at least: a mold DL line representing mold requirements, a die casting machine setting ML line representing die casting machine performance, and a process window enclosed by preset minimum and maximum filling time lines and preset maximum and minimum speed lines. Step S4: Determine whether the conditions are met, and obtain the final mold design parameters and die-casting process parameters; Condition 1 is to determine whether the intersection of the mold DL line and the die-casting machine set ML line, which is also the system working point, is within the process window; Condition 2 is to determine whether each calculation parameter is within the preset reasonable threshold range. If both conditions 1 and 2 are "yes", then the current parameter is determined to be the best matching parameter, and the output is used as the final mold design parameter and die casting process parameter. If at least one of the judgment conclusions in condition 1 and condition 2 is "no", then the input parameters are changed in the product and die-casting machine parameter input area. The mold design parameters and die-casting process parameters displayed in the mold design parameters and die-casting process parameters display area are changed accordingly. The system working point in the PQ chart display area moves accordingly until the judgment conclusions in condition 1 and condition 2 are both "yes". Then the current parameter is determined to be the best matching parameter, and the output is used as the final mold design parameters and die-casting process parameters.

2. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The die-casting machine clamping force in step S2 is calculated using the following formula: F 锁 = K×P×A / 1000, where F 锁 is the clamping force; K is the safety factor, which is 1.1 when the injection position is at point 0 and 1.25 when it is at other positions; A is the projected area of ​​the whole mold product; P is the injection pressure.

3. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The mold tube filling rate in step S2 is calculated and verified using the following formula: K1 = 4 × V1 / [π × D 2 × (L + h)], where K1 is the filling rate of the material tube, and it needs to satisfy 30% < K1 < 50%; V1 is the volume of the liquid metal; D is the diameter of the material tube; L is the position where the injection ends; h is the thickness of the material cake.

4. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The desired filling speed in step S2 is calculated based on the typical thickness x of the surface at the end of the product filling end using the following piecewise function: When x>4, the minimum expected filling rate y=-2x+42, and the maximum expected filling rate y1=y+15; When x≤4, the minimum expected filling rate is y=-4x+50, and the maximum expected filling rate is y1=y+15.

5. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The expected filling time in step S2 is calculated using the following formula: t = 1000 × k2 × x × (T1 - 30 - T2 + S × Z) / (T2 - T3), where t is the desired filling time; k2 is the empirical constant of the mold steel; x is the typical thickness of the surface of the product at the filling end; T1 is the temperature of the molten metal in the holding furnace; T2 is the minimum temperature at which the molten metal can flow; T3 is the surface temperature of the mold cavity; S is the solid fraction, which is 10 to 20 when the product appearance requirements are high, and 15 to 25 when the product internal requirements are high; Z is the unit conversion factor of 4.

8.

6. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The atomization rate in step S2 is calculated using the following formula, and the minimum filling rate of the product must be greater than this atomization rate: Vg=J×D1 / (ρ×L1×L2), where Vg is the atomization rate; J is the atomization judgment value 985; D1 is the equivalent diameter of the inner gate at the gate; ρ is the density of the liquid metal; L1 is the gate thickness; and L2 is the gate width.

7. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The growth rate ratio in step S2 is calculated and verified using the following formula: K3=π×D 2 / (4×S), where K3 is the growth rate ratio, which needs to be controlled between 9 and 30; D is the diameter of the material pipe; and S is the gate area.

8. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The mold DL line in step S2 is calculated using the following formula: The die-casting machine setting ML line in step S2 is calculated using the following formula: Where Pc is the pressure applied to the molten metal by the punch; Pb is the pressure of the die-casting machine's accumulator; Qc is the filling flow rate; Qcmax is the flow rate of the die-casting machine at the maximum dry-firing speed; Ag is the cross-sectional area of ​​the ingate; A0 is the piston area of ​​the injection cylinder; Ac is the cross-sectional area of ​​the punch; ρ is the density of the molten metal; Cd is the flow coefficient, which needs to be 0.6 to 0.8 in the designed flow channel. The system operating point filling pressure in step S2 is calculated using the following formula: P1=P2 / [1+(P2 / 500 / ρ)×(Cd×S×cosθ / Q2) 2 Where, P1 is the working point filling pressure; P2 is the set maximum filling pressure; Q2 is the set air injection flow rate; θ is the injection angle; S is the actual gate area; P is the metal liquid density; Cd is the flow coefficient, which needs to be 0.6 to 0.8 in the designed flow channel; The system operating point filling flow rate in step S2 is calculated using the following formula: Where Q is the working point filling flow rate; P1 is the working point filling pressure; θ is the jet angle; S is the actual gate area; ρ is the density of the molten metal; Cd is the flow coefficient, which needs to be 0.6 to 0.8 in the designed flow channel; The system operating point filling speed in step S2 is calculated using the following formula: v = 1000 × Q / (S × cosθ), where v is the filling velocity at the working point; Q is the filling flow rate at the working point; θ is the jet angle; and S is the actual gate area. The system operating point filling time in step S2 is calculated using the following formula: t1 = V1 / Q, where t1 is the operating point filling time; Q is the operating point filling flow rate; and V1 is the volume of liquid metal.

9. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, The injection velocity and injection position in step S2 include: The working point injection velocity is calculated using the following formula: V2=4×V×S×cosθ / (π×D) 2 ), where V2 is the injection velocity at the working point; v is the filling velocity at the working point; D is the diameter of the material tube; θ is the jet angle; and S is the actual gate area; The injection velocity is calculated using the following formula: Where V(first speed) is the first injection speed; V1 is the volume of liquid metal; D is the diameter of the feed tube; L is the injection termination position; and h is the thickness of the pellet. The position of the first injection velocity is calculated using the following formula: P(first velocity) = L - 4 × V1 / (π × D) 2 )-250×t 加 ×[V(first speed) + V(second speed)] + L3, where P(first speed) is the position of the first injection speed; V(first speed) is the first injection speed; V(second speed) is the second injection speed; V1 is the volume of liquid metal; D is the tube diameter; L is the injection termination position; L3 is the first speed correction value; t 加 Accelerate the die-casting machine's time; The position of the second injection velocity is calculated using the following formula: P(second velocity) = L - 4 × V² / (π × D) 2 )-250×t 加 ×[V(first speed) + V(second speed)] + L4, where P(second speed) is the second speed injection position; V(first speed) is the first injection speed; V(second speed) is the second injection speed; V2 is the filling volume; D is the tube diameter; L is the injection termination position; L3 is the second speed correction value, which is related to the performance of the die-casting machine; t 加 Accelerate the die-casting machine's time; The boost pressure position is calculated using the following formula: P (boost pressure) = L - 320 × t 加 ×t 建 +L5, where P (pressure boost) is the injection pressure boost position; L is the injection termination position; L5 is the pressure boost correction value, which is related to the performance of the die-casting machine; t 加 Acceleration time for die-casting machine; t 建 The pressure build-up time for the die-casting machine.

10. The matching analysis method for die casting machine, die casting mold and die casting process according to claim 1, characterized in that, In step S4, the parameter judgment result is visually fed back through a human-computer interaction interface using color changes: Mark the product and die-casting machine parameter input areas with the first color; The parameters that are automatically generated and within a reasonable range in the mold design parameters and die casting process parameters display area are marked with the second color; Parameters that are automatically generated in the mold design parameters and die casting process parameters display area but are outside the reasonable range will be marked with a third color as a warning.

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