Design device and method for side trimming die of aluminum alloy casting

Abstract

The invention provides a design device and method for an aluminum alloy casting side trimming die, and belongs to the technical field of automobile engine cooling water pump trimming dies. Comprising an edge trimmer, an upper die assembly and a lower die assembly, the edge trimmer is provided with an upper die plate, the upper die assembly is installed on the upper die plate and used for moving towards the lower die assembly in a reciprocating mode, the lower die assembly is used for containing a component to be trimmed, and the edge trimmer further comprises a main trimming module and a side trimming module; the main trimming module comprises a cutter plate to extrude horizontal leftover materials of a to-be-trimmed component; the side cutting module comprises a material pressing column and a riser ejector rod, the material pressing column is arranged on the upper die assembly, and the riser ejector rod is arranged on the lower die assembly so as to extrude the vertical leftover materials which are bent downwards to be bent upwards. Through the collaborative design of the main edge cutting module and the side cutting module, removal operation of a horizontal cinder ladle, a pouring gate and a vertical pouring gate of an aluminum alloy casting can be synchronously completed, multiple procedures or additional equipment are not needed, the production efficiency is greatly improved, and the labor intensity is reduced.

Description

Technical Field

[0001] This invention belongs to the technical field of automotive engine cooling water pump edge trimming molds, specifically relating to a design device and method for an aluminum alloy casting side trimming mold. Background Technology

[0002] In automotive engine cooling systems, water pump die-casting components (such as pump bodies and brackets) are mostly formed using aluminum alloy die-casting. After casting, the surrounding area of ​​the blank inevitably forms slag pockets and runners, which need to be removed by trimming to meet subsequent assembly and usage requirements. The runners are divided into horizontal and vertical types. Horizontal runners and slag pockets can be directly removed using conventional trimming dies, but vertical runners, due to their special structural orientation, require side-cutting.

[0003] Chinese invention patent application number "CN201811160265.2" proposes "a side-cutting device and composite mold for removing edge scraps". Its main structure includes two fixed seats, and an ejection mechanism, mold base, clamping plate, and stripper plate connected sequentially from top to bottom between the fixed seats. A cutting punch is fixed on the mold base, and a cutting blade punch and slide are located below the stripper plate, enabling simultaneous side-cutting with other processes. However, this existing device has significant shortcomings: its structural design cannot simultaneously remove the horizontal and vertical (lateral) material stalks and slag from die-cast aluminum alloy parts, requiring multiple processes or additional equipment to handle edge scraps in different directions. This not only increases the complexity of the production process and extends the production cycle but also increases the intensity of manual labor. Furthermore, the multiple positioning and operations during the step-by-step cutting process can easily cause product damage, affecting product quality stability. Therefore, this paper proposes a design device and method for a side-cutting mold for aluminum alloy castings to solve the above problems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the device cannot simultaneously remove the material stalk or slag bag in both the horizontal and vertical directions of the die-cast aluminum alloy parts. In view of the shortcomings of the prior art, the present invention provides a design device and method for a side-cutting mold for aluminum alloy castings.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a design device for a side-cutting mold of aluminum alloy castings, including a cutting machine, an upper mold assembly, and a lower mold assembly. The cutting machine has an upper template, the upper mold assembly is installed on the upper template and is used to reciprocate toward the lower mold assembly, and the lower mold assembly is used to place the component to be cut. The device is characterized by further including a main cutting module and a side-cutting module; the main cutting module includes a cutting blade plate, which is disposed on the upper mold assembly and is used to move with the upper mold assembly to squeeze the horizontal scrap of the component to be cut; the side-cutting module includes a pressure post and a riser rod, the pressure post is disposed on the upper mold assembly and spaced apart from the cutting blade plate, the pressure post is used to move with the upper mold assembly to squeeze the vertical scrap of the component to be cut downwards, and the riser rod is disposed on the lower mold assembly and is used to move up and down to squeeze the downwardly bent vertical scrap upwards.

[0006] Furthermore, the upper mold assembly also includes an upper mold base, a die, a fixing plate, and an ejector rod; the upper mold base is fixedly connected to the upper mold plate, the fixing plate is fixed to the lower part of the upper mold base by fasteners, the cutting plate is embedded in the bottom of the die and fixedly connected to the die, one end of the ejector rod is threadedly connected to the ejector block, and the other end is movably inserted into the ejector rod mounting and limiting hole opened in the upper mold base, and the pressure column is fixed to the lower part of the upper mold base by a threaded connection and located on one side of the ejector block.

[0007] Furthermore, the upper mold assembly also includes a material ejection mechanism, which includes an ejection block, a spring plate, a rectangular spring, a spring guide post, and an upper cover plate. The ejection block is disposed inside the cavity mold, the spring plate is fixed to the upper side of the upper mold base by fasteners, the two ends of the spring guide post are fixedly connected to the spring plate and the upper mold base respectively, the rectangular spring is sleeved on the outside of the spring guide post, and the upper cover plate is fixed to the upper side of the spring plate by fasteners and abuts against the upper end of the rectangular spring.

[0008] Furthermore, the lower die assembly also includes a positioning support mechanism and a guide limiting mechanism; the positioning support mechanism includes a lower die base, a lower pad, a punch assembly, and a positioning mandrel. The lower die base is fixedly installed on the lower die plate, the lower pad is fixed above the lower die base by fasteners, the punch assembly is positioned and engaged with the positioning mandrel by a cylindrical pin, and the punch assembly is fixed above the lower pad by fasteners. The positioning mandrel is disposed on the punch assembly and is used for positioning the component to be cut.

[0009] Furthermore, the guiding and limiting mechanism includes an adjusting block, a limiting sleeve, and a sliding guide post. The adjusting block and the limiting sleeve are both sleeved on the outside of the sliding guide post, and the lower end of the sliding guide post is fixedly connected to the lower mold base.

[0010] Furthermore, the lower mold assembly also includes a cylinder bracket and a thin-arm cylinder. The cylinder bracket is fixed to one side of the lower mold base by fasteners, and the thin-arm cylinder is fixed to the cylinder bracket by hexagon socket head cap screws. The riser ejector rod is threadedly connected to the piston rod of the thin-arm cylinder, and the air passage of the thin-arm cylinder is connected to the air passage of the trimming machine through an air pipe.

[0011] Furthermore, the ejector block has three evenly arranged ejector rod mounting holes, the ejector rod passes through the mounting holes and connects to the ejector block, and the ejector rod is installed in the ejector rod mounting limiting hole opened in the upper mold base; the end face of the ejector block is flush with the end face of the cutter plate or 2-3mm higher than the cutter plate.

[0012] Furthermore, the upper mold assembly is also provided with a sliding guide sleeve, which is embedded in the upper mold base by an interference fit. The lower mold assembly is also provided with a sliding guide post, which is fixed to the lower mold base by an interference fit. There are three sets of sliding guide sleeves and sliding guide posts with clearance fit.

[0013] Furthermore, the upper mold assembly also includes punches, which include punch A and punch B. Two punch mounting holes are provided on the fixing plate. Punch A and punch B are both installed in the punch mounting holes and are used to remove the diaphragm inside the hole of the product during the edge trimming process in the blank forming process.

[0014] Furthermore, a method for side trimming of a water pump die-casting part includes the following steps: Step 1: After assembling the upper mold assembly according to the connection relationship, fix it to the upper template of the edge cutting machine. After assembling the lower mold assembly according to the connection relationship, fix it to the lower template of the edge cutting machine. Correct the relative coaxial position of the upper mold assembly and the lower mold assembly and lock them in place. Connect the air circuit of the thin arm cylinder of the side cutting module to the control air circuit of the edge cutting machine through the air pipe and complete the air circuit debugging. Step 2: Place the blank on the positioning mandrel of the lower die assembly, so that the blank is in contact with the upper surface of the punch assembly, and the upper die assembly is in the initial position; Step 3: Start the trimming machine. The upper mold assembly moves downward. The sliding guide sleeve and the sliding guide post are guided by a clearance fit. The lower end face of the ejector block is in contact with the upper surface of the blank. The upper mold continues to move downward. The rectangular spring is compressed. The ejector block remains in contact with the blank. The cutting blade edge contacts and cuts off the slag bag and horizontal runner of the blank. At the same time, the pressure column contacts the upper end face of the vertical runner and bends it downward. Step 4: The upper mold continues to move downward until the sliding guide sleeve contacts the limiting sleeve to form a mold closing state. At this time, the cutting edge of the cutter plate extends 3-5mm beyond the lower end face of the lowest slag bag. Step 5: The thin-arm cylinder is activated, and its piston rod drives the riser push rod to move upward, causing the vertical runner to bend upward; Step 6: The upper mold assembly returns upwards, removes the blank, and places it in the designated position.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention, through the collaborative design of the main cutting module and the side cutting module, can simultaneously complete the removal of slag pockets, gating channels, and vertical gating channels in the horizontal direction of aluminum alloy castings. It eliminates the need for multiple processes or additional equipment, saving 5 minutes of manual cutting time per piece, greatly improving production efficiency and reducing labor intensity.

[0016] 2. This invention adopts a one-sided two-pin positioning structure and a small-gap cutting edge design, combined with a secondary bending method to remove the vertical sprue, avoiding product damage caused by manual grinding, ensuring that burrs after edge trimming are controllable and no subsequent deburring process is required. It is also compatible with a one-mold two-cavity structure, resulting in high product quality stability and easy application to similar die-casting edge trimming scenarios. Attached Figure Description

[0017] The present invention will now be described in further detail with reference to the accompanying drawings.

[0018] Figure 1 : A schematic diagram of the structure of Embodiment 1 of the present invention; Figure 2 : Schematic diagram of the cross-sectional structure of the present invention; Figure 3 : Schematic diagram of the overall device structure of the present invention.

[0019] The components include: 1. Adjusting block; 2. Limiting sleeve; 3. Positioning mandrel; 4. Punch assembly one; 5. Socket head cap screw; 6. Punch assembly two; 7. Punch assembly three; 8. Cylindrical pin; 9. Lower pad; 10. Lower die base; 11. Punch assembly; 12. Sliding guide post; 13. Cutting plate; 14. Die; 15. Fixing plate; 16. Sliding guide sleeve; 17. Upper die base; 18. Ejector pin. 19. Top cover plate; 20. Support plate; 21. Unloading block; 22. Rectangular spring; 23. Spring plate; 24. Thin-arm cylinder; 25. Pressure column; 26. Riser rod; 27. Cylinder bracket; 28. Socket head screw; 29. ​​Bushing; 30. Spring guide post A; 31. Spring guide post B; 32. Punch A; 33. Punch B; 34. Bearing hole punch; 35. Socket head screw. Detailed Implementation

[0020] To better understand the present invention, the content of the invention is further clearly illustrated below with reference to embodiments and accompanying drawings. However, the scope of protection of the present invention is not limited to the embodiments described below. Numerous specific details are set forth in the following description to provide a more thorough understanding of the invention. However, it will be apparent to those skilled in the art that the present invention can be practiced without one or more of these details. Example 1

[0021] See Figure 1-3 A design device for a side-cutting mold for aluminum alloy castings includes a cutting machine, an upper mold assembly, and a lower mold assembly. The cutting machine has an upper template, and the upper mold assembly is mounted on the upper template and is used to reciprocate toward the lower mold assembly. The lower mold assembly is used to place the component to be cut. The device also includes a main cutting module and a side-cutting module. The main cutting module includes a cutting blade 13, which is disposed on the upper mold assembly and is used to move with the upper mold assembly to squeeze the horizontal scrap of the component to be cut. The side-cutting module includes a pressure post 25 and a riser rod 26. The pressure post 25 is disposed on the upper mold assembly and spaced apart from the cutting blade 13. The pressure post 25 is used to move with the upper mold assembly to squeeze the vertical scrap of the component to be cut downwards and bend it. The riser rod 26 is disposed on the lower mold assembly and is used to move up and down to squeeze the downwardly bent vertical scrap upwards and bend it.

[0022] It should be noted that the upper mold assembly is installed on the bottom surface of the upper mold plate. Its purpose is to enable the upper mold assembly to move downwards when the upper mold plate moves downwards, thereby removing the slag packs in the vertical and horizontal directions of the blank. The lower mold assembly is installed on the upper surface of the lower mold plate. The horizontal scrap of the component to be cut consists of the horizontal runner and slag pack of the blank. The main cutting module is mainly used to remove the horizontal runner and slag pack of the blank. The vertical scrap of the component to be cut consists of the vertical runner of the blank. The side cutting module is mainly used to remove the vertical runner of the blank. The riser ejector 26 and the pressure column 25 are located in the same vertical direction. The purpose is to enable the riser ejector 26 to bend the vertical scrap upwards after the pressure column 25 bends the vertical scrap downwards, thereby achieving a first downward bend and a second upward bend of the scrap.

[0023] The cutting plate 13 is a contouring structure, arranged in a ring along the outermost parting line of the water pump die-casting blank. Its cutting edge precisely matches the cutting boundary of the slag pocket and gating in the horizontal direction of the blank, completely covering all areas of the blank where horizontal scrap needs to be removed. It is the outermost cutting functional component in the upper mold assembly. The pressure column 25 is arranged in the inner area of ​​the cutting plate 13 and is directly opposite the preset bending center point of the vertical gating of the blank. It is coaxial with the axis of the vertical gating of the blank. The horizontal projection of the pressure column 25 falls completely within the blank outline and does not exceed the contouring range of the cutting plate. Because the mold is a two-cavity design, the cutting plate 13 is a double-cavity integrated contouring structure, which simultaneously covers the horizontal cutting areas of the two blanks. The pressure column 25 is arranged symmetrically with two columns. The two pressure columns 25 are respectively aligned with the bending points of the vertical gating of the two blanks and correspond one-to-one with the double-cavity contouring area of ​​the cutting plate 13, ensuring the synchronicity of the double-cavity operation.

[0024] Optionally, the upper mold assembly also includes an upper mold base 17, a die 14, a fixing plate 15, and an ejector pin 18; the upper mold base 17 is fixedly connected to the upper mold plate, the fixing plate 15 is fixed to the lower part of the upper mold base 17 by fasteners, the cutter plate 13 is embedded in the bottom of the die 14 and fixedly connected to the die 14, one end of the ejector pin 18 is threadedly connected to the ejector block 21, and the other end is movably inserted into the ejector pin 18 mounting and limiting hole opened in the upper mold base 17, and the pressure post 25 is fixed to the lower part of the upper mold base 17 by a threaded connection and located at the ejector block. On one side of 21, the upper mold assembly also includes a material ejection mechanism, which includes a material ejection block 21, a spring plate 23, a rectangular spring 22, a spring guide post, and an upper cover plate 19. The material ejection block 21 is disposed inside the cavity mold 14. The spring plate 23 is fixed to the upper side of the upper mold base 17 by fasteners. The two ends of the spring guide post 30 are fixedly connected to the spring plate 23 and the upper mold base 17, respectively. The rectangular spring 22 is sleeved on the outside of the spring guide post. The upper cover plate 19 is fixed to the upper side of the spring plate 23 by fasteners and abuts against the upper end of the rectangular spring 22.

[0025] In addition, the shape of the cutting edge of the cutter plate 13 is the same as the outer contour of the outermost parting line of the blank. The small gap design between the cutting edge and the blank must simultaneously meet the requirements of controllable burr range at the slag bag and material shank after blank trimming, without cutting the inner wall of the blank, and without requiring manual deburring after trimming. The inner cavity shape of the die 14 is consistent with the cutting edge shape of the cutter plate 13. The ejector block 21, the cutter plate 13 and the die 14 have relative movement, with a single-sided movement gap of 0.2mm. The upper die base 17 is designed with a mounting limit hole for the ejector pin 18, which is not only used for mounting the ejector pin 18 but also... The time limit for the downward movement of the ejector pin 18 is set at its extreme position. The die 14 mainly guides the ejector block 21 during its up-and-down movement, ensuring that the ejector block 21 presses the product downwards and ejects the product upwards, always remaining within the effective contact length of the die 14. This ensures smooth and unobstructed movement, effectively pressing the product and guaranteeing the completion of the trimming action and the effective ejection process. Simultaneously, the upper cover plate 19 on the upper side of the rectangular spring 22 limits its movement. The rectangular spring 22 is guided up and down by the spring guide post to prevent it from jamming. The spring assembly structure in this device is an external spring structure: the spring assembly is located on the upper outer side of the upper die base 17, facilitating timely observation of the rectangular spring 22's movement and preventing jamming, allowing for timely maintenance and replacement in case of damage.

[0026] It should be added that the ejection action of the ejector block 21 is not independent, but forms a continuous "press first, then eject" linkage process with the blank clamping action before trimming. Both actions rely on the compression and rebound of the rectangular spring 22, which is specifically divided into four steps: Step 1, initial state, spring pre-compression + ejector block 21 in position. When the mold is in the initial position, the rectangular spring 22 is already in the pre-compression state, storing basic elastic force. After the ejector block 21 is installed, its end face is flush with or 2-3mm higher than the cutter plate 13, preparing the position for subsequent contact and clamping of the blank. The mounting limit holes of the ejector rod 18, ejector block 21, and upper mold base 17 are not stuck and can move freely up and down; Step 2, before trimming, The upper die compresses the rectangular spring 22 as it moves downwards, and the ejector block 21 presses the blank. The upper die moves downwards with the trimming machine. Because the end face of the ejector block 21 is higher than or flush with the cutting plate 13, the ejector block 21 contacts the upper surface of the blank before the cutting plate 13. The upper die assembly continues to move downwards, and the blank forms an upward reaction force on the ejector block 21, pushing the ejector block 21 upwards to compress the rectangular spring 22. The rectangular spring 22 further stores elastic potential energy until the cutting plate 13 begins to contact the blank and perform trimming. Under the reaction force of the rectangular spring 22, the ejector block 21 continues to press the blank, ensuring that the blank does not move during trimming and bending. This is the energy storage stage of the rectangular spring 22. In step 3, during trimming, the ejector block 21 remains pressed. Throughout the entire trimming process, with no movement, the cutting plate 13 removes the horizontal slag bag / sprue, the pressure column 25 completes one downward bend, the upper mold closes, and the side cutting module completes a second upward bend. During this entire trimming process, the upper mold remains at its lower limit position, the rectangular spring 22 remains compressed, and the ejector block 21, guided by the die 14, always presses the blank firmly without any up-and-down movement, ensuring the positional accuracy of the trimming operation. In step 4, after trimming, the upper mold returns, and the rectangular spring 22 rebounds, driving the ejector block 21 to complete the ejection. After all trimming operations are completed, the upper mold moves upward with the trimming machine. As the upper mold base 17 moves upward, the previously compressed rectangular spring 22 loses its downward pressure and begins to elastically rebound, releasing its potential energy. The rebound force of spring 22 is transmitted downward through spring plate 23 to ejector rod 18, and ejector rod 18 then transmits the downward thrust to ejector block 21. Under the thrust of ejector rod 18, ejector block 21 moves downward along the guide direction of the inner cavity of die 14. At this time, cutter plate 13 has been disengaged from blank with the upper die. The downward movement of ejector block 21 directly acts on the blank after trimming, smoothly pushing the blank out from the cutting edge of cutter plate 13 until the blank is completely separated from the cutting surface of cutter plate 13 and die 14, completing the ejection. During the return stroke, die 14 always provides guidance for ejector block 21, ensuring that it moves within the effective contact length without deviation or jamming, avoiding the blank being stuck at the cutting edge or being damaged by collision during ejection.

[0027] Optionally, the lower die assembly also includes a positioning support mechanism and a guide limiting mechanism; the positioning support mechanism includes a lower die base 10, a lower pad 9, a punch assembly 11 and a positioning mandrel 3. The lower die base 10 is fixedly installed on the lower die plate, the lower pad 9 is fixed above the lower die base 10 by fasteners, the punch assembly 11 is positioned and engaged with the positioning mandrel 3 by a cylindrical pin, and the punch assembly 11 is fixed above the lower pad 9 by fasteners. The positioning mandrel 3 is located on the punch assembly 11 and is used for positioning the component to be cut.

[0028] When using the device, the blank is installed on the punch assembly 11 and positioned on the punch assembly 11 by two mandrels on one side. The ejector block 21 is installed on the upper die assembly. The upper die assembly drives the ejector block 21 to move downward. The ejector block 21 presses against the blank assembly. The blank is trimmed under the pressing state of the ejector block 21.

[0029] Optionally, the guide limiting mechanism includes an adjusting block 1, a limiting sleeve 2, and a sliding guide post 12. The adjusting block 1 and the limiting sleeve 2 are both sleeved on the outside of the sliding guide post 12, and the lower end of the sliding guide post 12 is fixedly connected to the lower mold base 10.

[0030] Optionally, the lower mold assembly also includes a cylinder bracket 27 and a thin-arm cylinder 24. The cylinder bracket 27 is fixed to one side of the lower mold base 10 by fasteners, and the thin-arm cylinder 24 is fixed to the cylinder bracket 27 by hexagon socket head cap screws 28. The riser rod 26 is threadedly connected to the piston rod of the thin-arm cylinder 24, and the air passage of the thin-arm cylinder 24 is connected to the air passage of the trimming machine through an air pipe.

[0031] The thin-arm cylinder 24 is a double-acting cylinder (requiring air intake for extension and exhaust for retraction, or reverse air intake for retraction). Its air circuit draws air from the external air circuit interface reserved on the edge trimming machine, and connects to the main control air circuit of the edge trimming machine through dedicated pneumatic components and pipelines. The specific connections and accessories are as follows: 1. Air circuit interface of the trimming machine: air intake and signal control end. The side of the trimming machine body / worktable is reserved with industrial standard pneumatic quick connectors (usually PC type / quick plug type), which are divided into air source connectors (providing 0.4-0.6MPa compressed air) and control signal connectors (controlled by the limit switch / proximity switch of the trimming machine, corresponding to the mold closing position signal), providing power and action trigger signals for the cylinder air circuit; 2. Air passage interface at the end of thin-arm cylinder 24: The air port of the thin-arm cylinder 24 body. The cylinder body of the thin-arm cylinder 24 has an air inlet / exhaust port at both ends, corresponding to the piston rod extension end and retraction end, respectively, for connecting the air passage hose to realize the input and discharge of compressed air; 3. Intermediate air circuit components (connected in series between the trimming machine and the thin-arm cylinder 24): To ensure stable and controllable operation of the thin-arm cylinder 24, the following standard pneumatic components need to be connected in series / parallel in the air circuit. All components are integrated and installed on a small air circuit manifold next to the cylinder bracket 27 for easy debugging and maintenance: Pneumatic quick connector: Connects to the external air circuit of the trimming machine and the air circuit hose of the mold end respectively, realizing quick disassembly and assembly of the mold air circuit, adapting to the mold changing operation requirements; Pressure regulating valve: Precisely regulates the air pressure input to the thin-arm cylinder 24, controls the extension thrust of the piston rod, and avoids excessive thrust causing blank deformation or insufficient thrust preventing bending; Throttling valve: Divided into inlet throttling and exhaust throttling, adjusting the air pressure of the thin-arm cylinder 24. The piston rod's extension / retraction speed ensures smooth bending without impact; the electromagnetic reversing valve: a core control element, controlled by the die-closing position electrical signal of the trimming machine, realizes the switching of the air circuit of the thin-arm cylinder 24 (when the die-closing signal is triggered, the reversing valve reverses, compressed air enters the rodless chamber of the thin-arm cylinder 24, and the piston rod extends; when the upper die returns, the reversing valve resets, compressed air enters the rod chamber, and the piston rod retracts); the muffler: installed at the exhaust port of the thin-arm cylinder 24, reduces exhaust noise and meets the environmental protection requirements of the workshop; the air circuit manifold: integrates the air circuits of the two thin-arm cylinders 24, realizes the synchronous drive of the two thin-arm cylinders 24 by a single control signal, and ensures that the pressure and flow of the parallel air circuits are consistent.

[0032] 4. Air duct routing and fixing method: To prevent the air hose from being squeezed or pulled during the reciprocating motion of the trimming machine and the mold operation, the air duct adopts a concealed routing and segmented fixing method. Specific requirements are as follows: Pipe selection: Polyurethane pneumatic hoses are used, with the pipe diameter matched to the cylinder diameter of the thin-arm cylinder 24 (commonly 4mm / 6mm), possessing wear-resistant, bending-resistant, and high-pressure-resistant characteristics, suitable for the workshop industrial environment; Pipe routing path: After being led out from the external interface of the trimming machine, the hose runs along the pre-set wire groove / pipe groove on the side / bottom of the lower mold base 10, to the air duct manifold next to the cylinder bracket 27, and then from the manifold... The flow plate is connected to the air ports of the two thin-arm cylinders 24 via two short flexible hoses. The hose length at the thin-arm cylinder 24 end is minimized to reduce swaying during operation. Segmented fixing: Plastic pipe clamps / metal pipe clips are used to fix the air hoses to the lower mold base 10 or cylinder bracket 27 every 100-150mm to prevent the hoses from swaying with the vibration of the trimming machine and the movement of the upper mold. At the same time, a small amount of hose slack is reserved to meet the needs of mold fine adjustment and disassembly. Protective treatment: For hose sections exposed in the working area, plastic corrugated pipes are used for protection to prevent aluminum shavings and burrs generated by the trimming machine from scratching the hoses and causing air leakage.

[0033] The air circuit linkage control logic is as follows: the air circuit of the thin-arm cylinder 24 is deeply linked with the mechanical action and electrical signal of the trimming machine to ensure that the bending action is triggered at the correct operation node. Its core control logic is as follows: 1. Upper die descent stage: the trimming machine drives the upper die assembly to move downward, the ejector block 21 presses the blank, the cutter plate 13 cuts off the horizontal slag bag / sprue, and the pressure column 25 completes one downward bend. During this process, the mold closing position sensor of the trimming machine is not triggered, the electromagnetic reversing valve is in the initial position, the air circuit of the thin-arm cylinder 24 is disconnected, and the piston rod remains in the retracted state without action; 2. Mold closing trigger stage: the upper die assembly continues to descend to the mold closing limit position, the sliding guide sleeve 16 is in contact with the lower die limit sleeve 2, 1. The stroke proximity switch / position sensor of the trimming machine is triggered, sending a mold closing position signal to the electrical control system of the trimming machine; 2. Cylinder extension bending: After receiving the mold closing signal, the electrical control system supplies power to the solenoid reversing valve coil, the reversing valve reverses, and compressed air enters the rodless chamber of the two thin-arm cylinders 24 through the air path, pushing the piston rod to extend upward synchronously, driving the riser ejector 26 to complete the second upward bending of the vertical runner; 3. Upper mold return stage: After trimming is completed, the trimming machine drives the upper mold assembly to return upward, the mold closing position sensor is reset, the electrical control system cuts off the power supply to the reversing valve coil, the reversing valve is reset, compressed air enters the rod chamber of the thin-arm cylinder 24, the piston rod drives the riser ejector 26 to retract downward to the initial position, waiting for the next work cycle; 4. Emergency protection: If the trimming machine stops suddenly, or the upper mold is not closed in place, the mold closing position signal is not triggered, the solenoid reversing valve is always in the open state, and the thin-arm cylinder 24 does not move, to avoid product displacement and damage caused by bending when the blank is not pressed tightly.

[0034] It should be added that the side-cutting module of the present invention requires modification of the equipment and addition of air circuits to link the air circuits of the module with the equipment to control the sequence of each action. That is, the air circuits of the module are connected to the air circuits of the edge-cutting machine, so that the thin-arm cylinder 24 can be opened and closed.

[0035] Optionally, the ejector block 21 has three evenly arranged ejector pin 18 mounting holes. The ejector pin 18 passes through the mounting holes and connects to the ejector block 21. The ejector pin 18 is installed in the ejector pin 18 mounting limit hole opened in the upper mold base 17. The end face of the ejector block 21 is flush with or 2-3mm higher than the end face of the cutter plate 13. The purpose is that when cutting the blank, the ejector block 21 can quickly press the blank, so that the blank will not move when the cutter plate 13 is cutting, thereby making the cutting efficiency higher and the cutting position more accurate.

[0036] Optionally, the upper mold assembly is also provided with a sliding guide sleeve 16, which is inserted into the upper mold base 17 by an interference fit. The lower mold assembly is also provided with a sliding guide post 12, which is fixed to the lower mold base 10 by an interference fit. There are three sets of sliding guide sleeves 16 and sliding guide posts 12 with clearance fit.

[0037] Optionally, the upper mold assembly also includes punches, including punch A32 and punch B33. The fixing plate 15 has two punch mounting holes, and punches A32 and B33 are installed in the punch mounting holes to remove the diaphragm inside the hole of the product during the edge trimming process.

[0038] In addition, punches A32 and B33 are used to effectively remove the internal partitions (small gaps between die-casting mold parts formed by the filling of the inner cavity with molten aluminum during die-casting) in the blank forming process during the trimming process. Meanwhile, the punch assembly 11 and the lower die base 10, fixed to the lower die assembly, are designed with blanking holes of the same diameter to facilitate smooth blanking after the partitions are punched down during the trimming process. Furthermore, the ejector block 21 is designed with holes through which punches A32 and B33 can pass, ensuring that punches A32 and B33 do not interfere with the ejector block 21 and move independently and orderly during its up-and-down movement.

[0039] Design Principle: Main Trimming Module Principle: The blank is installed on the punch assembly 11 and positioned on the punch assembly 11 by two positioning mandrels 3 on one side. The ejector block 21 is installed on the upper die assembly. The upper die assembly drives the ejector block 21 to move downwards, pressing the blank assembly. Under the pressing state of the ejector block 21, the blank is trimmed. The upper die assembly resets, and the ejector block 21 is simultaneously pushed forward by the spring return, pushing the blank out of the cutting edge of the cutter plate 13, completing the blank ejection. After the device is installed, the ejector block 21 is flush with or 2-3mm higher than the end face of the cutter plate 13. Side-cutting module principle: Side-cutting is a coupling effect that facilitates material stress concentration and metal fatigue to remove the side stalk and slag. When the blank is pressed by the ejector block 21, the upper die's pressure post 25 simultaneously presses the stalk downwards, achieving a first downward bend. In the closed die state, the cylinder riser ejector rod 26 bends the stalk upwards, a second bend removing the stalk. The downward movement of the upper die assembly consists of five actions: 1. Initial position: The upper die assembly is in the initial position, the rectangular spring 22 is in a pre-compression state with a compression of 9KN, and the total force of the rectangular spring 22 is 5-6KN, ensuring sufficient clamping and ejection force; 2. Ejector block 21 contacts the blank: As the upper die assembly continues to move downwards, the ejector block 21 (in the initial state, the ejector block 21 is flush with or 2-3mm higher than the end face of the cutter plate 13) first contacts the blank surface. 1. From the initial position, the ejector block 21 begins to contact the blank surface, and the rectangular spring 22 is in a pre-compressed state; 2. The cutter plate 13 begins to trim the edge: the upper mold assembly continues to move downward, the ejector block 21 presses against the blank surface, and the rectangular spring 22 is compressed at the same time. With the blank surface pressed, the lower mold assembly moves downward by 2-3mm, and the cutter plate 13 contacts the end face of the slag bag. During the downward movement, the cutter plate 13 cuts off the slag bag; at the same time, during the trimming process, the pressure column 25 assembly contacts the blank sprue, and during the downward movement, it bends the sprue downward for the first time. 4. Upper mold assembly closing: The upper mold base 17 assembly continues to move downwards, and the cutting blade 13 cuts to the lower end face of the lowest slag bag by 3-5mm. The sliding guide sleeve 16 in the upper mold assembly contacts and is mechanically limited by the adjusting block 1 in the lower mold assembly, which is called mold closing; 5. Side cutting start: The upper mold remains in the closed state, and the blank is in the state of being pressed by the ejector block 21. The side cutting cylinder is connected to the equipment. The piston rod of the thin arm cylinder 24 drives the riser ejector rod 26 to bend the sprue upwards for a second time. The sprue is removed under the action of the first downward bending of the pressure column 25 assembly and the second upward bending of the riser ejector rod 26.

[0040] Technical benefits: The development of the side-cutting and edge-cutting mold has completely eliminated the need for manual grinding of blank edges, effectively reducing the labor intensity of edge cutting and significantly improving edge cutting efficiency.

[0041] In addition, the following points need to be noted during the design: 1. The working parts of the punch assembly 11, the ejector block 21, the cutter plate 13, and the die 14 are the same as the blank shape and are irregularly shaped parts. Machining requires the use of machining center equipment to ensure machining accuracy and shape, resulting in higher machining costs. At the same time, these four parts need to withstand high impact and strong friction during operation, and the material selection needs to meet the requirements of high strength, high wear resistance, and good toughness. Cr12MoV is used in this device. To ensure the hardness and accuracy of each component, the machining process adopts heat treatment followed by wire cutting to reduce deformation and also helps to ensure the machining accuracy of individual parts. 2. Spring selection: The clamping force and ejection force need to be calculated according to the number of blank mold cavities to accurately select the springs, ensuring sufficient force during clamping and ejection to smoothly complete the entire edge cutting action of the device. The clamping force (removal force) of a single mold cavity is set at 4-6KN; the spring model and quantity can be reasonably selected according to the magnitude of the clamping force and the removal force, and the spring force can be appropriately selected according to the complexity coefficient of the product's outer contour; 3. The spring is externally placed on the upper mold base 17, which facilitates the observation of the spring compression state and abnormal conditions in various working states of the device, making it easy to observe spring jamming and facilitating later maintenance; 4. The spring guide post is designed and installed on the spring plate 23. The spring guide post plays a shock absorption and buffering role when the device is subjected to impact or vibration. During the spring movement, the guide rod always stays in the center position, thereby achieving precise guidance and facilitating smooth spring compression; 5. The upper and lower mold guide and limit modules, the upper mold part is designed with guide sleeves, and the lower mold part is designed with guide posts. The cooperation design of the guide sleeves and guide posts (3 sets) plays a guiding role in the relative movement of the upper and lower molds. During the downward movement of the upper mold, the upper guide sleeve and the lower guide post first come into contact (three sets of guide sleeves and guide posts are designed around the upper and lower molds for coordinated use), effectively guiding the relative position of the upper and lower molds; when the upper and lower molds are closed, the end face of the upper guide sleeve contacts the upper end face of the limiting sleeve on the outer side of the lower mold guide post, forming a mechanical limit, and the upper mold moves downward to the limit position; 6. Pressure column 25 module: The pressure column 25 module is designed to be installed on the upper mold base 17. After the upper mold moves downward and the ejector block 21 presses the blank, the pressure column 25 component bends the sprue downward for the first time. The downward bending effect of the pressure column 25 component on the sprue continues until the upper and lower molds are closed; 7. Side cutting component: The air circuit is controlled by equipment linkage; when the blank is pressed by the ejector block 21, the pressure column 25 presses the material handle downward to achieve a downward bend; after the mold is closed, the cylinder is used to bend the material handle upward, and the second bend removes the material handle. The cylinder is the main power for side cutting.

[0042] Example 2, a method for side trimming of a water pump die-casting part, includes the following steps: Step 1: After assembling the upper mold assembly according to the connection relationship, fix it to the upper template of the edge cutting machine. After assembling the lower mold assembly according to the connection relationship, fix it to the lower template of the edge cutting machine. Correct the relative coaxial position of the upper mold assembly and the lower mold assembly and lock it in place. Connect the air circuit of the thin arm cylinder 24 of the side cutting module to the control air circuit of the edge cutting machine through the air pipe and complete the air circuit debugging. Step 2: Place the blank on the positioning mandrel 3 of the lower die assembly, so that the blank is in contact with the upper surface of the punch assembly 11, and the upper die assembly is in the initial position. Step 3: Start the trimming machine. The upper mold assembly moves downward. The sliding guide sleeve 16 and the sliding guide post 12 are guided by clearance fit. The lower end face of the ejector block 21 is in contact with the upper surface of the blank. The upper mold continues to move downward. The rectangular spring 22 is compressed. The ejector block 21 remains in contact with the blank. The cutting edge of the cutting plate 13 contacts the slag bag and the horizontal runner of the blank and cuts it off. At the same time, the pressure column 25 contacts the upper end face of the vertical runner and bends it downward. Step 4: The upper mold continues to move downward until the sliding guide sleeve 16 contacts the limiting sleeve to form a mold closing state. At this time, the cutting edge of the cutter plate 13 extends 3-5mm beyond the lower end face of the bottom slag bag. Step 5: The thin-arm cylinder 24 is activated, and its piston rod drives the riser push rod 26 to move upward, causing the vertical runner to bend upward; Step Six: The upper mold assembly returns upwards, the blank is removed and placed in the designated position.

[0043] When necessary, assemble and install the various components of the device onto the equipment. After aligning the positions of the upper and lower dies, fix them to the upper and lower dies of the trimming machine. The air circuit of the side cutting component is connected to the equipment for joint operation control. The blank is installed on the positioning mandrel 3 of the punch assembly 11 in the lower die assembly. Check that the bottom of the blank is in contact with the top of the punch assembly 11. At this time, the upper die assembly is in the initial position. Start the equipment, and the upper die assembly moves downward. The upper die guide sleeve contacts and cooperates with the lower die guide post. Under the guidance of the guide post and guide sleeve, the lower end face of the ejector block 21 contacts the top of the blank. The upper die assembly continues to move downward, the rectangular spring 22 is compressed, and the ejector block 21 moves downward in the lower die. When the rectangular spring 22 is compressed, it presses the blank, and the cutting edge of the cutter plate 13 contacts the blank shank and begins to cut the edge. At the same time, the pressure post 25 contacts the upper end face of the shank. During the downward movement of the lower mold assembly, the pressure post 25 of the upper mold assembly presses the shank downward, realizing the downward bending of the sprue. The upper mold assembly continues to move downward, and the lower end face of the upper mold guide sleeve contacts the upper end face of the outer limit sleeve of the lower mold guide post. The lower mold assembly reaches the limit position, and the upper and lower molds maintain this position, that is, the molds are closed. At this time, the cutting edge of the cutter plate 13 passes 3-5mm below the bottom slag bag, the side cutting assembly is activated, and the cylinder drives the riser rod 26 to bend upward. The second bending removes the shank, completing the side cutting process. The aluminum alloy blank, with its vertical shank under pressure, is bent downwards once and upwards twice. This process introduces fatigue and stress concentration into the material. The side-cutting process utilizes these fatigue and stress concentration phenomena. Firstly, repeated bending leads to material fatigue. Secondly, the stress concentration is severe during the first downward bend, easily causing cracks or fractures. The material already contains internal stress and micro-cracks; the second upward bend further concentrates these stresses and cracks, making fracture even more likely. After the upper die assembly returns, the blank is removed and trimmed to the designated point.

[0044] This device can cut edges in both horizontal and vertical directions on die-cast blanks, effectively reducing the labor intensity of edge cutting, saving manual edge cutting formulas, effectively ensuring product quality, and solving the risk of product damage caused by manual removal of edge material; at the same time, it is easy to promote to similar edge cutting molds.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solutions of the present invention, as long as they do not depart from the spirit and scope of the technical solutions of the present invention, should be covered within the scope of the claims of the present invention.

Claims

1. A design device for a side trimming mold for aluminum alloy castings, comprising a trimming machine, an upper mold assembly, and a lower mold assembly, wherein the trimming machine has an upper template, the upper mold assembly is mounted on the upper template and is used to reciprocate toward the lower mold assembly, and the lower mold assembly is used to place the component to be trimmed, characterized in that: It also includes a main cutting edge module and a side cutting module; the main cutting edge module includes a cutting blade (13), which is disposed on the upper mold assembly and is used to move with the upper mold assembly to squeeze the horizontal scrap of the component to be cut; the side cutting module includes a pressure post (25) and a riser rod (26), the pressure post (25) is disposed on the upper mold assembly and is spaced apart from the cutting blade (13), the pressure post (25) is used to move with the upper mold assembly to squeeze the vertical scrap of the component to be cut downwards and bend it, the riser rod (26) is disposed on the lower mold assembly and is used to move up and down to squeeze the downwardly bent vertical scrap upwards.

2. The design device for the aluminum alloy casting side-cutting mold as described in claim 1, characterized in that: The upper mold assembly also includes an upper mold base (17), a die (14), a fixing plate (15), and an ejector rod (18); the upper mold base (17) is fixedly connected to the upper mold plate, the fixing plate (15) is fixed to the lower part of the upper mold base (17) by fasteners, the cutter plate (13) is embedded in the bottom of the die (14) and fixedly connected to the die (14), one end of the ejector rod (18) is threadedly connected to the ejector block (21), and the other end is movably inserted into the ejector rod (18) mounting limit hole opened in the upper mold base (17), and the pressure column (25) is fixed to the lower part of the upper mold base (17) by threaded connection and located on one side of the ejector block (21).

3. The design device for the aluminum alloy casting side-cutting mold as described in claim 1, characterized in that: The upper mold assembly also includes a material ejection mechanism, which includes an ejection block (21), a spring plate (23), a rectangular spring (22), a spring guide post, and an upper cover plate (19). The ejection block (21) is disposed inside the cavity mold (14). The spring plate (23) is fixed to the upper side of the upper mold base (17) by fasteners. The two ends of the spring guide post (30) are fixedly connected to the spring plate (23) and the upper mold base (17) respectively. The rectangular spring (22) is sleeved on the outside of the spring guide post. The upper cover plate (19) is fixed to the upper side of the spring plate (23) by fasteners and abuts against the upper end of the rectangular spring (22).

4. The design device for the aluminum alloy casting side-cutting mold as described in claim 1, characterized in that: The lower mold assembly also includes a positioning support mechanism and a guide limiting mechanism; the positioning support mechanism includes a lower mold base (10), a lower pad (9), a punch assembly (11) and a positioning mandrel (3). The lower mold base (10) is fixedly installed on the lower mold plate. The lower pad (9) is fixed above the lower mold base (10) by fasteners. The punch assembly (11) is positioned and engaged with the positioning mandrel (3) by a cylindrical pin. The punch assembly (11) is fixed above the lower pad (9) by fasteners. The positioning mandrel (3) is located on the punch assembly (11) and is used for positioning the component to be cut.

5. The design device for the aluminum alloy casting side-cutting mold as described in claim 4, characterized in that: The guide limiting mechanism includes an adjusting block (1), a limiting sleeve (2) and a sliding guide post (12). The adjusting block (1) and the limiting sleeve (2) are both sleeved on the outside of the sliding guide post (12). The lower end of the sliding guide post (12) is fixedly connected to the lower mold base (10).

6. The design device for the aluminum alloy casting side-cutting mold as described in claim 1, characterized in that: The lower mold assembly also includes a cylinder bracket (27) and a thin-arm cylinder (24). The cylinder bracket (27) is fixed to one side of the lower mold base (10) by fasteners. The thin-arm cylinder (24) is fixed to the cylinder bracket (27) by an internal hexagonal head screw (28). The riser rod (26) is threaded and fixedly connected to the piston rod of the thin-arm cylinder (24). The air passage of the thin-arm cylinder (24) is connected to the air passage of the trimming machine through an air pipe.

7. The design device for the aluminum alloy casting side-cutting mold as described in claim 3, characterized in that: The ejector block (21) has three evenly arranged ejector rod (18) mounting holes. The ejector rod (18) passes through the mounting holes and connects to the ejector block (21). The ejector rod (18) is installed in the ejector rod (18) mounting limit hole opened in the upper mold base (17). The end face of the ejector block (21) is flush with the end face of the cutter plate (13) or 2-3mm higher than the cutter plate.

8. The design device for the aluminum alloy casting side-cutting mold as described in claim 5, characterized in that: The upper mold assembly is also provided with a sliding guide sleeve (16), which is fitted into the upper mold base (17) by an interference fit. The lower mold assembly is also provided with a sliding guide post (12), which is fixed to the lower mold base (10) by an interference fit. There are three sets of sliding guide sleeves (16) and sliding guide posts (12) with clearance fit.

9. The design device for the aluminum alloy casting side-cutting mold as described in claim 2, characterized in that: The upper mold assembly also includes punches, which include punch A (32) and punch B (33). The fixing plate (15) has two punch mounting holes. Punch A (32) and punch B (33) are both installed in the punch mounting holes to remove the diaphragm inside the hole of the product during the edge trimming process.

10. A method for side-cutting of aluminum alloy castings, using the apparatus described in any one of claims 1-9, characterized in that: Includes the following steps: Step 1: After assembling the upper mold assembly according to the connection relationship, fix it to the upper template of the edge cutting machine. After assembling the lower mold assembly according to the connection relationship, fix it to the lower template of the edge cutting machine. Correct the relative coaxial position of the upper mold assembly and the lower mold assembly and lock it in place. Connect the air circuit of the thin arm cylinder (24) of the side cutting module to the control air circuit of the edge cutting machine through the air pipe and complete the air circuit debugging. Step 2: Place the blank on the positioning mandrel (3) of the lower die assembly, so that the blank is in contact with the upper surface of the punch assembly (11), and the upper die assembly is in the initial position; Step 3: Start the trimming machine. The upper mold assembly moves downward. The sliding guide sleeve (16) and the sliding guide post (12) are guided with clearance. The lower end face of the ejector block (21) is in contact with the upper surface of the blank. The upper mold continues to move downward. The rectangular spring (22) is compressed. The ejector block (21) remains in contact with the blank. The blade of the cutter plate (13) contacts and cuts off the slag bag and the horizontal runner of the blank. At the same time, the pressure column (25) contacts the upper end face of the vertical runner and bends it downward. Step 4: The upper mold continues to move downward until the sliding guide sleeve (16) contacts the limiting sleeve to form a mold closing state. At this time, the cutting edge of the cutter plate (13) extends 3-5mm beyond the lower end face of the lowest slag bag. Step 5: The thin-arm cylinder (24) is started, and its piston rod drives the riser rod (26) to move upward, so that the vertical runner bends upward; Step 6: The upper mold assembly returns upwards, removes the blank, and places it in the designated position.

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