Light alloy die core life comprehensive evaluation structure and method
By setting feature units on the mold core and conducting full life cycle experiments, the problem of the disconnect between mold core material life assessment and real-time working conditions was solved, achieving efficient and accurate mold life assessment and material selection, reducing costs and improving production efficiency and quality stability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- CHUANGZHIREN TECHNOLOGY (SUZHOU) CO LTD
- Filing Date
- 2026-04-13
- Publication Date
- 2026-07-21
AI Technical Summary
Existing technologies cannot achieve accurate detection under real-time working conditions in the life assessment of mold core materials, resulting in inaccurate assessment of mold core material failure modes, high mold design and development costs, low production efficiency, and unstable quality.
A comprehensive evaluation structure for the life of lightweight alloy mold cores is designed. By setting structural feature units, such as stepped surfaces, grid-shaped ribs, round ribs, and concave platforms, on basic planar units, and combining mold life cycle experiments and microscopic observation, a quantitative evaluation method is established to simulate material failure modes under high temperature and high pressure conditions.
It enables real-time working condition matching for mold core material life assessment, reduces mold design and R&D costs, improves production efficiency and quality stability, and provides a unified failure evaluation standard.
Smart Images
Figure CN122433293A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of mold core steel life evaluation and testing, specifically to a structure and method for comprehensive evaluation of the life of lightweight alloy mold cores. Background Technology
[0002] In modern manufacturing, molds, as core equipment in die casting and injection molding, essentially depend on the matching degree between the strength of the mold core material (including fatigue strength, high-temperature strength, impact strength, etc.) and the working load, directly affecting product quality stability, production efficiency, and operating costs. With the increasing demand for precision castings in the automotive, 3C electronics, and aerospace industries, die casting processes are evolving towards higher temperatures (>700℃), higher pressures (100-200MPa), and higher cycle frequencies (1800-5000 times / day), placing higher technical demands on the failure modes of mold core materials. However, the industry currently faces significant technical bottlenecks in the assessment and application of failure modes for mold core materials. Traditional detection methods cannot accurately match the failure mode requirements under real-time working conditions, making innovative detection technologies focusing on the failure modes of mold core materials urgently needed.
[0003] From a technological perspective, the core pain points in mold core material failure mode assessment are concentrated in three aspects: First, during the mold design stage, companies rely on engineers' experience to judge the suitability of mold core materials for failure, without establishing quantitative testing standards for material strength under dynamic injection pressure impact and instantaneous temperature fluctuations. This leads to significant deviations between the actual fatigue strength and high-temperature strength of the selected materials and the design expectations, resulting in frequent early cracking (due to stress concentration caused by insufficient strength) and wear (due to substandard surface strength), increasing mold replacement costs and causing production interruptions. Second, in the mold core steel selection stage, the industry lacks unified evaluation technical standards. Mold core material strength testing is limited to static laboratory environments (such as room temperature tensile strength and bending strength tests), which cannot simulate the material strength decay law under the combined conditions of "high temperature-high pressure-cyclic load" in die casting. This results in a serious lack of accuracy in predicting mold core material failure risks, often leading to the problem of "testing strength in the laboratory but failing in actual application." Third, in the mold core steel R&D stage, companies adopt the approach of "producing materials first and then testing static strength." The current model cannot monitor the strength changes of materials under simulated working conditions in real time. It also has high initial investment costs (over 500,000 yuan per batch of R&D) and long trial and error cycles (3-6 months), which seriously restricts the R&D efficiency of high-strength mold core steel.
[0004] In terms of die casting process optimization, the technical pain points related to the strength of mold core steel are also prominent: In the development of new product processes, due to the lack of dynamic testing data on material strength under actual production conditions, it is impossible to accurately match the coupling relationship between injection parameters and material strength. The process needs to be determined through repeated manual adjustments, resulting in a significant extension of the cycle. The core function of mold coating is to improve the surface strength of the material, but the current coating performance testing relies on laboratory static friction experiments, which cannot simulate the attenuation of coating-substrate bonding strength under high-speed scouring of molten metal. The testing data is seriously insufficient to support the optimization of coating strength, resulting in coating peeling and substrate strength exposure failure. As key components that directly withstand high temperature and high pressure, the high temperature strength and adaptability of the material of hot working parts (punches, pressure chambers) directly determine their service life. However, the industry lacks real-time material strength assessment technology for hot working parts under working conditions, making it impossible to determine the optimal strength matching scenario. This leads to frequent replacement of hot working parts due to insufficient strength, resulting in a significant increase in usage costs.
[0005] In summary, the core challenges facing the lightweight alloy mold core material industry in terms of lifespan testing, material selection, and process optimization all stem from the disconnect between lifespan assessment and real-time production conditions. Non-quantitative testing methods, lack of supporting strength data, significant discrepancies between laboratory and operational strength data, and inconsistent industry strength assessment standards directly lead to a mismatch between the lifespan of mold core materials and actual production conditions. This results in shortened lifespan, low production efficiency, high costs, and large quality fluctuations, hindering technological upgrades in the industry. Summary of the Invention
[0006] To address the shortcomings of existing technologies, this invention provides a comprehensive evaluation structure and method for the lifespan of lightweight alloy mold cores. It resolves the core contradictions in the existing lightweight alloy mold core material industry regarding lifespan testing, material selection, and process optimization. These issues primarily focus on the disconnect between lifespan assessment and real-time production conditions—non-quantitative testing methods, lack of supporting strength data, large discrepancies between laboratory and operational strength data, and inconsistent industry strength assessment standards. This directly leads to a mismatch between the lifespan of mold core materials and actual production conditions, resulting in problems such as shortened lifespan, low production efficiency, high costs, and significant quality fluctuations.
[0007] To achieve the above objectives, the present invention is implemented through the following technical solution: a comprehensive evaluation structure for the life of a lightweight alloy mold core, characterized in that it includes a basic planar unit, on which a plurality of structural feature units are provided, the structural feature units including: a stepped surface, a grid-shaped rib, a circular rib, and a recessed platform; The thickness of the structural feature unit – the stepped surface – is 2–6 mm. The structural feature unit - the grid-shaped ribs - has a wall thickness of 2-8mm and a height of 20-35mm; The structural feature unit – the circular rib – has a wall thickness of 2.5–4 mm and a height of 2.5–3 mm. The structural feature unit - the recessed platform - has a depth of 20-35 mm and a diameter of 11-21 mm; The evaluation structure is composed of one or more of the following structural feature units: stepped surface, grid-shaped rib, circular rib, and concave platform.
[0008] In some embodiments, the number of basic planar units is several, and the several basic planar units can be interconnected to form a molten metal flow channel. The several basic planar units can be parallel to the same plane of the mold parting surface, or one basic planar unit can be parallel to the parting surface, and another basic planar unit can form a stepped shape with the parting surface, and so on, extending alternately.
[0009] In some embodiments, the stepped thickness difference between the planes of the basic planar unit can be flexibly designed to facilitate the design of other structural features. At the same time, the remaining structural features can be designed on the same parting surface as the planar structure, reducing the projected area of the mold and lowering the requirements for the tonnage of the die-casting machine. When the faces of the basic planar unit form an angle, they are connected by an arc surface. Meanwhile, the impact of changes in flow direction on performance can be evaluated.
[0010] In some embodiments, an evaluation structure may include multiple planar structures, and different planar structures may have different basic planar unit thicknesses to simultaneously evaluate thermal fatigue resistance and melt loss resistance under different filling thicknesses.
[0011] In some embodiments, one or more structural feature units are vertically placed on a basic planar unit parallel to the parting surface. A chamfer is provided at the connection between the structural feature unit and the basic planar unit. The structural feature unit itself is provided with a draft angle. Related features between structural features can also be connected, and a chamfer is provided at the connection.
[0012] In some embodiments: the structural feature unit - recess can be connected to both the basic planar unit and the structural feature unit - rib; the structural feature unit - rib can be connected to another rib, the basic planar unit, and the structural feature unit - recess at the same time; ribs of different thicknesses can be provided at the same time and connected to each other; the structural feature unit - groove can be placed on the basic planar unit and / or the structural feature unit - rib; the shock wave and thermal strain force of units with different thicknesses and diameters are different, and this difference is used to form internal stress to evaluate the thermal cracking tendency of the mold steel.
[0013] In some embodiments, structural feature units are combined to form structural feature unit groups. Multiple structural feature unit groups are placed at various flow distances of planar structural features of different thicknesses. By flexibly connecting the units to each other, an evaluation structure that is closer to the actual part features can be formed.
[0014] A method for comprehensively evaluating the lifespan of lightweight alloy mold cores includes the following steps: S1. By sampling 600-1000mm inward from the end face of the mold steel, and then making the sampled steel parts into characteristic molds, a full life cycle test of the mold is carried out. Through appearance observation and evaluation every 5000 mold cycles, the data of the entire mold life cycle and the full life cycle of each failure feature are recorded in detail. Orthogonal coupling simulation prediction is used to comprehensively evaluate the thermal fatigue resistance and melting resistance of the target mold steel material. S2. After obtaining the sample mold, the basic planar units are numbered. The number includes the thickness and flow distance information of the basic planar unit. The thickness and flow channel information are marked with the uppercase letter T and the thickness number, and the flow distance information of the unit is marked with the uppercase letter F and the sequential number. For structural feature units, the concave platform is marked as S, the circular rib as R, and the grid-shaped rib as N, followed by a number and combined with the number of the basic planar unit. If multiple test samples are prepared in one basic planar unit, they are marked with # followed by a number. S3. Visual crack observation and evaluation includes: observation of the failure status of flow channels on each plane; failure status of structural feature units at each flow distance of each flow channel; crack status at each flow distance of each planar feature structure: crack length, crack depth, etc.; crack propagation status at different locations; and graded and scored the visual crack status at each flow distance of each flow channel to achieve quantitative evaluation and comparison. The cracking tendency of lightweight alloy mold core material can be evaluated based on the crack status near each structural feature unit - grid-shaped ribs, bosses, round ribs, and near the connection of different units, and the influence of flow distance and thickness on crack propagation can be analyzed. S4. Microscopic observation (precision camera) includes: using a precision camera to collect data on the failure characteristics of the mold under different mold cycles, in order to understand the structural failure of the mold surface, including R-corner cracking / chipping; rib erosion, grid-shaped rib cracking / chipping, concave erosion and cracking, etc., and further, to study the influence of flow distance and thickness on the characteristic structure. S5. The evaluation of processing methods covers the following aspects: under different planar structures and flow distances, the concave platform structure is observed and data is collected throughout its entire life cycle. The effects of electrical discharge machining and tool cutting on the connection performance are compared. The evaluation process can sample the connection area between basic planar units to meet experimental requirements, and the influence of flow distance and material thickness on the processing method is systematically studied. S6. By conducting experiments on the above-mentioned evaluation structures using different die-casting processes, the influence mechanism of process parameters on various material properties can be further evaluated, providing a theoretical basis for the design and optimization of die-casting processes; by analyzing the distribution patterns of performance indicators, data support can be provided for the structural optimization design of actual engineering parts. S7. By conducting experimental research on the aforementioned evaluation structure using different lightweight alloy mold core materials, failure performance indicators of various materials can be further obtained, thereby providing data support for the mold core material industry to build a systematic and standardized failure evaluation standard; S8. By conducting experimental verification of the above-mentioned evaluation structure on the same lightweight alloy mold core material that has undergone different heat treatments or surface coatings, the applicability and reliability of the heat treatment process and coating process of the mold core material are systematically evaluated. S9. By modularly decomposing the feature structure of the mold core, the feature structure is transformed into a block form; if a feature block fails during the experiment, the overall experiment can be avoided due to the failure of a single feature; by adopting a block replacement mechanism, the failure block can be replaced with a planar block, which can ensure the continuity of the experimental process, improve experimental efficiency, and reduce the influence of other interference factors.
[0015] Beneficial effects: The evaluation structure proposed in this technical solution is designed with the characteristics of actual die casting in mind, more closely resembling the failure characteristics and process features of molds in actual die casting. This facilitates strength testing of structural features, and the detection of heat treatment and coating processes. Simultaneously, it has a minimal volume and projected area, reducing mold size, saving costs, and lowering the tonnage requirements of the die casting machine. Based on this evaluation structure, the proposed method can evaluate the thermal fatigue resistance of lightweight alloy mold core materials, including erosion tendency, cracking tendency, and resistance to melting (corrosion). Furthermore, all performance evaluations are conducted at different flow distances and thicknesses, allowing for multi-dimensional analysis and meeting the comprehensive performance evaluation needs under different flow distances and thicknesses. This method can be applied to material selection, structural optimization design, and process design of mold core materials, helping to solve key scientific and technological problems in this field. Attached Figure Description
[0016] Figure 1 This is a schematic diagram of the external structure of the present invention; Figure 2 This is a three-dimensional schematic diagram of the present invention. Detailed Implementation
[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0018] Please see Figure 1-2 The present invention provides a technical solution: a comprehensive evaluation structure for the life of a lightweight alloy mold core, characterized in that it includes a basic planar unit, on which a number of structural feature units are provided, the structural feature units including: structural feature unit - stepped surface, structural feature unit - grid-shaped rib, structural feature unit - round rib, and structural feature unit - concave platform; The thickness of the structural feature unit – stepped surface – is 2–6 mm; Structural feature unit - the wall thickness of the grid-shaped ribs is 2-8mm, and the height is 20-35mm; Structural feature unit - the wall thickness of the round rib is 2.5-4mm, and the height is 2.5-3mm; The structural feature unit - the depth of the recessed platform is 20-35 mm, and the diameter is 11-21 mm; The evaluation structure is composed of one or more structural feature units, such as stepped surfaces, grid-shaped ribs, circular ribs, and concave platforms.
[0019] Combine multiple basic planar elements, structural feature elements - ribs, structural feature elements - concave platforms, and structural feature elements - grooves according to the method described in the instructions. Five flow channels are set up, with basic planar unit thicknesses of 2, 3, 4, 5, and 6 mm, and side lengths of 112*24.6 mm. The basic planar units are connected by radius (R) angles of R2, R1.5, R1, and R0.5. Four structural feature units (ribs) with thicknesses of 2, 4, 6, and 8 mm and heights of 20, 25, 30, and 35 mm are connected to form a grid with a side length of 25 mm. Four structural feature units (recesses) with diameters of 11, 14, 16, and 21 mm, heights of 20, 25, 30, and 35 mm, and chamfers of R2, R3, R4, and R5 mm are intersected to form a cross shape. Two structural feature units (round ribs) with widths of 2.5 and 4 mm, heights of 2.5 and 3 mm, and chamfers of R0.5 mm are placed side by side. All the above structural feature units and their combinations are arranged in a row to form a structural feature unit group, and this structural feature unit group is repeated on the entire basic planar unit.
[0020] In some embodiments, the number of basic planar units is several, and the several basic planar units can be interconnected to form a molten metal flow channel. The several basic planar units can be parallel to the same plane of the mold parting surface, or one basic planar unit can be parallel to the parting surface, and one basic planar unit can form a stepped shape with the parting surface, and so on, extending alternately.
[0021] In some embodiments, the stepped thickness difference between the planes of the basic planar unit can be flexibly designed to facilitate the design of other structural features. At the same time, the remaining structural features can be designed on the same parting surface as the planar structure, reducing the projected area of the mold and lowering the requirements for the tonnage of the die-casting machine. When the faces of the basic planar unit form an angle, they are connected by an arc surface. Meanwhile, the impact of changes in flow direction on performance can be evaluated.
[0022] In some embodiments, an evaluation structure may include multiple planar structures, and different planar structures may have different basic planar unit thicknesses to simultaneously evaluate thermal fatigue resistance and melt loss resistance under different filling thicknesses.
[0023] In some embodiments, one or more structural feature units are vertically placed on a basic planar unit parallel to the parting surface. A chamfer is provided at the connection between the structural feature unit and the basic planar unit. The structural feature unit itself is provided with a draft angle. Related features between structural features can also be connected, and a chamfer is provided at the connection.
[0024] In some embodiments: the structural feature unit - recess can be connected to both the basic planar unit and the structural feature unit - rib; the structural feature unit - rib can be connected to another rib, the basic planar unit, and the structural feature unit - recess at the same time; ribs of different thicknesses can be provided at the same time and connected to each other; the structural feature unit - groove can be placed on the basic planar unit and / or the structural feature unit - rib; the shock wave and thermal strain force of units with different thicknesses and diameters are different, and this difference is used to form internal stress to evaluate the thermal cracking tendency of the mold steel.
[0025] In some embodiments, structural feature units are combined to form structural feature unit groups. Multiple structural feature unit groups are placed at various flow distances of planar structural features of different thicknesses. By flexibly connecting the units to each other, an evaluation structure that is closer to the actual part features can be formed.
[0026] First, sample the mold core material, then design and manufacture the characteristic structure die-casting mold core, and use a suitable die-casting machine and die-casting process to die-cast the target mold to obtain observation data.
[0027] Each basic planar unit is numbered, designated T2, T3, T4, T5, and T6 to indicate that it belongs to a flow channel with a thickness of 2, 3, 4, 5, and 6 mm, respectively. Along the flow direction, the basic planar units within the entire flow channel are sequentially assigned labels, denoted as F1, F2, F3, F4, and F5. The thickness label is combined with the sequence label to form the number of each basic planar unit. For example, T2F1 refers to the first basic planar unit in a flow channel with a thickness of 2 mm, and T4F3 refers to the third basic planar unit in a flow channel with a thickness of 4 mm. The thickness and flow distance of the basic planar unit can be determined by its number. For structural feature units, the concave platform is denoted as S, the circular rib as R, and the grid-shaped rib as N. The numbers are added after the numbers and combined with the basic plane unit number to mark them. For example, T3F2S1 represents the first structural feature unit - the concave platform - on the second basic plane unit in the flow channel with a thickness of 3mm. T4F3N2 represents the second structural feature unit - the groove - on the third basic plane unit in the flow channel with a thickness of 4mm.
[0028] After numbering, the first step is to sample 600-1000mm inward from the end face of the mold core material, then fabricate the sampled mold core material into a characteristic mold core, and conduct a full life cycle experiment on the mold core material. Appearance observation and evaluation are performed every 5000 cycles, and detailed data on the entire life cycle of the mold core material and the full life cycle of each failure characteristic are recorded. All observation results are recorded according to different numbering. Orthogonal coupled simulation prediction is used to comprehensively evaluate the thermal fatigue resistance, melt loss (erosion) resistance, and bonding performance of the target mold steel material. Furthermore, the data under each numbering is analyzed to study the influence of flow distance and thickness on appearance.
[0029] The second step involves observing and evaluating the characteristic structures. A precision camera is used to collect data on the failure characteristics of the mold core material under different molding cycles. This data is used to understand the structural failure features of the mold core material surface, including corner cracking / chipping; rib erosion; cracking / chipping of the grid-shaped ribs; and erosion and cracking of recesses. All observation results are recorded according to different numbers. Further analysis of the data under each numbering is conducted to study the influence of flow distance and thickness on the microstructure.
[0030] The third step is to evaluate the processing method. Observe and collect data throughout the entire life cycle of the concave platform under various flow distances of each planar structure. Compare the connection performance of the concave platform under EDM and tool cutting processes. All test results are recorded according to different numbers. Further, analyze the data under each number to evaluate and study the influence of flow distance and thickness on the material connection performance.
[0031] The fourth step is to analyze and summarize the data obtained from the above evaluations to establish a comprehensive performance evaluation database for future use.
[0032] A method for comprehensively evaluating the lifespan of lightweight alloy mold cores includes the following steps: S1. By sampling 600-1000mm inward from the end face of the mold steel, and then making the sampled steel parts into characteristic molds, a full life cycle test of the mold is carried out. Through appearance observation and evaluation every 5000 mold cycles, the data of the entire mold life cycle and the full life cycle of each failure feature are recorded in detail. Orthogonal coupling simulation prediction is used to comprehensively evaluate the thermal fatigue resistance and melting resistance of the target mold steel material. S2. After obtaining the sample mold, the basic planar units are numbered. The number includes the thickness and flow distance information of the basic planar unit. The thickness and flow channel information are marked with the uppercase letter T and the thickness number, and the flow distance information of the unit is marked with the uppercase letter F and the sequential number. For structural feature units, the concave platform is marked as S, the circular rib as R, and the grid-shaped rib as N, followed by a number and combined with the number of the basic planar unit. If multiple test samples are prepared in one basic planar unit, they are marked with # followed by a number. S3. Visual crack observation and evaluation includes: observation of the failure status of flow channels on each plane; failure status of structural feature units at each flow distance of each flow channel; crack status at each flow distance of each planar feature structure: crack length, crack depth, etc.; crack propagation status at different locations; and graded and scored the visual crack status at each flow distance of each flow channel to achieve quantitative evaluation and comparison. The cracking tendency of lightweight alloy mold core material can be evaluated based on the crack status near each structural feature unit - grid-shaped ribs, bosses, round ribs, and near the connection of different units, and the influence of flow distance and thickness on crack propagation can be analyzed. S4. Microscopic observation (precision camera) includes: using a precision camera to collect data on the failure characteristics of the mold under different mold cycles, in order to understand the structural failure of the mold surface, including R-corner cracking / chipping; rib erosion, grid-shaped rib cracking / chipping, concave erosion and cracking, etc., and further, to study the influence of flow distance and thickness on the characteristic structure. S5. The evaluation of processing methods covers the following aspects: under different planar structures and flow distances, the concave platform structure is observed and data is collected throughout its entire life cycle. The effects of electrical discharge machining and tool cutting on the connection performance are compared. The evaluation process can sample the connection area between basic planar units to meet experimental requirements, and the influence of flow distance and material thickness on the processing method is systematically studied. S6. By conducting experiments on the above-mentioned evaluation structures using different die-casting processes, the influence mechanism of process parameters on various material properties can be further evaluated, providing a theoretical basis for the design and optimization of die-casting processes; by analyzing the distribution patterns of performance indicators, data support can be provided for the structural optimization design of actual engineering parts. S7. By conducting experimental research on the aforementioned evaluation structure using different lightweight alloy mold core materials, failure performance indicators of various materials can be further obtained, thereby providing data support for the mold core material industry to build a systematic and standardized failure evaluation standard; S8. By conducting experimental verification of the above-mentioned evaluation structure on the same lightweight alloy mold core material that has undergone different heat treatments or surface coatings, the applicability and reliability of the heat treatment process and coating process of the mold core material are systematically evaluated. S9. By modularly decomposing the feature structure of the mold core, the feature structure is transformed into a block form; if a feature block fails during the experiment, the overall experiment can be avoided due to the failure of a single feature; by adopting a block replacement mechanism, the failure block can be replaced with a planar block, which can ensure the continuity of the experimental process, improve experimental efficiency, and reduce the influence of other interference factors.
[0033] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, the phrase "comprising an element defined as..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0034] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A structure for comprehensively evaluating the lifespan of lightweight alloy mold cores, characterized in that, It includes a basic planar unit, on which a number of structural feature units are provided. The structural feature units include: structural feature unit - stepped surface, structural feature unit - grid-shaped rib, structural feature unit - circular rib, and structural feature unit - concave platform. The thickness of the structural feature unit – the stepped surface – is 2–6 mm. The structural feature unit - the grid-shaped ribs - has a wall thickness of 2-8mm and a height of 20-35mm; The structural feature unit – the circular rib – has a wall thickness of 2.5–4 mm and a height of 2.5–3 mm. The structural feature unit - the recessed platform - has a depth of 20-35 mm and a diameter of 11-21 mm; The evaluation structure is composed of one or more of the following structural feature units: stepped surface, grid-shaped rib, circular rib, and concave platform.
2. The lightweight alloy mold core life comprehensive evaluation structure according to claim 1, characterized in that, The number of basic planar units is several. Several basic planar units can be connected to each other to form a molten metal flow channel. Several basic planar units can be parallel to the same plane of the mold parting surface, or one basic planar unit can be parallel to the parting surface, and another basic planar unit can form a stepped shape with the parting surface, and so on, extending alternately.
3. The lightweight alloy mold core life comprehensive evaluation structure according to claim 2, characterized in that, The stepped thickness difference between the planes of the basic planar unit can be flexibly designed to facilitate the design of other structural features. At the same time, the remaining structural features can be designed on the same parting surface as the planar structure, reducing the projected area of the mold and lowering the requirements for the tonnage of the die-casting machine. When the faces of the basic planar unit form an angle, they are connected by an arc surface. Meanwhile, the impact of changes in flow direction on performance can be evaluated.
4. The lightweight alloy mold core life comprehensive evaluation structure according to claim 3, characterized in that, Multiple planar structures can be set in an evaluation structure. Different planar structures can be set with different basic planar unit thicknesses to simultaneously evaluate the thermal fatigue resistance and melting loss resistance under different filling thicknesses.
5. The lightweight alloy mold core life comprehensive evaluation structure according to claim 4, characterized in that, One or more structural feature units are placed vertically on the basic planar unit parallel to the parting surface. The connection between the structural feature unit and the basic planar unit is provided with a chamfer. The structural feature unit itself is provided with a draft angle. Related features between structural features can also be connected, and the connection is provided with a chamfer.
6. The lightweight alloy mold core life comprehensive evaluation structure according to claim 5, characterized in that: The structural feature unit - concave platform can be connected to both the basic planar unit and the structural feature unit - rib; the structural feature unit - rib can be connected to another rib, the basic planar unit, and the structural feature unit - concave platform. Ribs of different thicknesses can be set at the same time and connected to each other. The structural feature unit - groove can be placed on the basic planar unit or / and the structural feature unit - rib. Units of different thicknesses and diameters are subjected to different shock waves and thermal strain forces. This difference is used to form internal stress to evaluate the thermal cracking tendency of the mold steel.
7. The lightweight alloy mold core life comprehensive evaluation structure according to claim 6, characterized in that, After being combined, structural feature units form structural feature unit groups. Multiple structural feature unit groups are placed at various flow distances of planar structural features of different thicknesses. By flexibly connecting the units with each other, an evaluation structure that is closer to the actual part features can be formed.
8. A method for comprehensively evaluating the lifespan of lightweight alloy mold cores, characterized in that, Includes the following steps: S1. By sampling 600-1000mm inward from the end face of the mold steel, and then making the sampled steel parts into characteristic molds, a full life cycle test of the mold is carried out. Through appearance observation and evaluation every 5000 mold cycles, the data of the entire mold life cycle and the full life cycle of each failure feature are recorded in detail. Orthogonal coupling simulation prediction is used to comprehensively evaluate the thermal fatigue resistance and melting resistance of the target mold steel material. S2. After obtaining the sample mold, the basic planar units are numbered. The number includes the thickness and flow distance information of the basic planar unit. The thickness and flow channel information are marked with the uppercase letter T and the thickness number, and the flow distance information of the unit is marked with the uppercase letter F and the sequential number. For structural feature units, the concave platform is marked as S, the circular rib is marked as R, and the grid-shaped rib is marked as N. The numbers are added after the numbers and combined with the number of the basic planar unit in which it is located for marking. If multiple test samples are prepared within a basic planar unit, they are marked with # followed by a number. S3. Visual crack observation and evaluation includes: observation of the failure status of flow channels on each plane; failure status of structural feature units at each flow distance of each flow channel; crack status at each flow distance of each planar feature structure: crack length, crack depth, etc.; crack propagation status at different locations; and graded and scored the visual crack status at each flow distance of each flow channel to achieve quantitative evaluation and comparison. The cracking tendency of lightweight alloy mold core material can be evaluated based on the crack status near each structural feature unit - grid-shaped ribs, bosses, round ribs, and near the connection of different units, and the influence of flow distance and thickness on crack propagation can be analyzed. S4. Microscopic observation (precision camera) includes: using a precision camera to collect data on the failure characteristics of the mold under different mold cycles, in order to understand the structural failure of the mold surface, including R-corner cracking / chipping; rib erosion, grid-shaped rib cracking / chipping, concave erosion and cracking, etc., and further, to study the influence of flow distance and thickness on the characteristic structure. S5. The evaluation of processing methods covers the following aspects: under different planar structures and flow distances, the concave platform structure is observed and data is collected throughout its entire life cycle. The effects of electrical discharge machining and tool cutting on the connection performance are compared. The evaluation process can sample the connection area between basic planar units to meet experimental requirements, and the influence of flow distance and material thickness on the processing method is systematically studied. S6. By conducting experiments on the above-mentioned evaluation structures using different die-casting processes, the influence mechanism of process parameters on various material properties can be further evaluated, providing a theoretical basis for the design and optimization of die-casting processes; by analyzing the distribution patterns of performance indicators, data support can be provided for the structural optimization design of actual engineering parts. S7. By conducting experimental research on the aforementioned evaluation structure using different lightweight alloy mold core materials, failure performance indicators of various materials can be further obtained, thereby providing data support for the mold core material industry to build a systematic and standardized failure evaluation standard; S8. By conducting experimental verification of the above-mentioned evaluation structure on the same lightweight alloy mold core material that has undergone different heat treatments or surface coatings, the applicability and reliability of the heat treatment process and coating process of the mold core material are systematically evaluated. S9. By modularly decomposing the feature structure of the mold core, the feature structure is transformed into a block form; if a feature block fails during the experiment, the overall experiment can be avoided due to the failure of a single feature; by adopting a block replacement mechanism, the failure block can be replaced with a planar block, which can ensure the continuity of the experimental process, improve experimental efficiency, and reduce the influence of other interference factors.