Anti-air-hole die-casting die for die-casting automobile inverter support

Abstract

The utility model discloses an air hole preventing die-casting die for die-casting an automobile inverter support, which comprises a lower die core, a metal liquid flow channel and a lower forming cavity are arranged on the lower die core, a sprue spreader is further arranged on the lower die core, a first main flow channel guide port and a second main flow channel guide port are arranged on the sprue spreader, and the first main flow channel guide port is communicated with the second main flow channel guide port. The metal liquid flow channel comprises a first main flow channel and a second main flow channel, the first main flow channel guide port is communicated with the first main flow channel, the second main flow channel guide port is communicated with the second main flow channel, and the first main flow channel is communicated with the lower forming cavity through a plurality of first branch flow channels; a first cold material groove is formed in the intersection point of the first sub-runner farthest from the first main runner guide opening and the tail end of the first main runner, a second sub-runner is arranged at the tail end of the second main runner, the second sub-runner is communicated with the lower forming cavity, and the tail end of the second main runner extends and is provided with a second cold material groove; air holes in non-key areas of the automobile inverter support, such as support reinforcing ribs, can be eliminated to a great extent.

Description

Technical Field

[0001] The utility model relates to a die-casting technology for an automobile inverter bracket, in particular to an anti-air hole die-casting die for die-casting the automobile inverter bracket. Background Art

[0002] In the modern automotive industry, die-casting technology is widely used due to its ability to quickly and efficiently produce metal parts with complex shapes and precise dimensions. In particular, die-casting ensures high strength and excellent thermal conductivity in the manufacture of automotive inverters. However, traditional die-casting technology faces the challenge of porosity when producing parts such as automotive inverter brackets.

[0003] Porosity is a common defect in die-cast parts, significantly reducing their mechanical properties and durability. In the die-casting process of automotive inverter brackets, the formation of pores is often related to factors such as mold design, gate layout, metal filling speed, metal flow direction, and metal purity.

[0004] Researchers and engineers have previously focused on porosity issues in four key areas of automotive inverter brackets: the large bushing hole and the three long mounting corners (areas classified as Level 1 in the aluminum die-casting defect standard). These issues were minimized by modifying gate layout and molten metal flow. However, significant porosity has been found in non-critical areas (areas classified as Level 2 in the aluminum die-casting defect standard), such as the bracket reinforcement ribs, with a failure rate exceeding the standard of approximately 7%. Extensive mold flow analysis of the gate feed pattern and filling sequence in these non-critical areas revealed the presence of large cavities during the die-casting filling process. These cavities are caused by incomplete evacuation of air from the die core cavity or by entrapment of air by the molten metal during the filling process, resulting in large cavities in these non-critical areas. Porosity in the bracket reinforcement ribs not only reduces rib strength but can also lead to fracture, compromising the performance and reliability of the entire automotive inverter bracket.

[0005] In the prior art, some methods have been proposed to reduce or eliminate air holes, such as improving mold design, optimizing the pouring system, etc. However, these methods are often difficult to completely eliminate air holes in actual operation.

[0006] Therefore, it is necessary to develop a new type of die-casting mold, which can effectively prevent the formation of air holes and improve the quality and performance of key parts such as automotive inverter brackets. Summary of the Invention

[0007] The technical problem to be solved by the utility model is to provide an anti-pore die-casting die for die-casting an automobile inverter bracket, which can largely eliminate pores in non-key areas of the automobile inverter bracket.

[0008] The technical solution adopted by the utility model to solve the above technical problems is: a pore-proof die-casting mold for die-casting automobile inverter bracket, comprising a lower mold core, the lower mold core is provided with a metal liquid flow channel and a lower molding cavity, and is characterized in that: the lower mold core is also provided with a diverter cone, the diverter cone is provided with a first main flow channel guide port and a second main flow channel guide port, the metal liquid flow channel includes a first main flow channel and a second main flow channel, the first main flow channel guide port is connected to the first main flow channel, the second main flow channel guide port is connected to the second main flow channel, the first main flow channel is connected to the lower molding cavity through multiple first diverter channels, a first cold material trough is provided at the intersection of the first diverter channel farthest from the first main flow channel guide port and the end of the first main flow channel, a second diverter channel is provided at the end of the second main flow channel, the second diverter channel is connected to the lower molding cavity, and the end of the second main flow channel extends and is provided with a second cold material trough.

[0009] The angle formed by the first cold sluice and the first main channel is greater than or equal to 90 degrees and less than or equal to 120 degrees. In this structure, by limiting the specific design position of the first cold sluice, the flow of molten metal and the collection of cold sluice are facilitated, the formation of pores is further reduced, the flow path of the molten metal is optimized, and the filling efficiency is improved.

[0010] Three first branch runners are provided. The molten metal in the first main channel first flows through the middle first branch runner via the ingate to the lower molding cavity, then flows through the first branch runner closest to the first main channel outlet via the ingate to the lower molding cavity, and finally flows through the first branch runner farthest from the first main channel outlet via the ingate to the lower molding cavity. In this structure, the three first branch runners enable staged filling of the molten metal, helping to reduce air holes caused by rapid filling. This sequential filling mode facilitates gas discharge, thereby improving the internal quality of the die-cast part.

[0011] The angle formed by the second cold sluice and the second branch channel is equal to 90 degrees. In this structure, by limiting the specific design position of the second cold sluice, the flow of molten metal and the collection of cold sluice are facilitated, the formation of pores is further reduced, the flow path of molten metal is optimized, and the filling efficiency is improved.

[0012] The lower mold core is also equipped with multiple slag ladles, one of which is connected to each of the locations in the lower molding cavity corresponding to the large bushing hole and the three mounting corners of the automotive inverter bracket. In this structure, the multiple slag ladles on the lower mold core connect to key locations on the automotive inverter bracket, helping to collect and remove impurities and gases from the molten metal. This design improves the purity and quality of the die-cast part, reduces porosity and inclusions, and thus enhances the mechanical properties and durability of the die-cast part.

[0013] The first branch runner gradually widens from its intersection with the first main runner to its ingate; the second branch runner gradually widens from its intersection with the second main runner to its ingate. In this structure, the gradually increasing widths of the first and second branch runners facilitate smooth transition and deceleration of the molten metal, reducing gas introduced by rapid flow. It also facilitates uniform filling of the molten metal and reduces the formation of pores and inclusions.

[0014] Compared with the prior art, the advantages of the present invention are:

[0015] By providing a diverter cone, two main channels, and multiple diverter channels, uniform distribution and sequential filling of the molten metal are achieved. This design helps reduce air holes within the die-casting mold cavity, as the molten metal can smoothly and sequentially fill the cavity, reducing gas entrapment. The diverter cone also helps disperse the impact force of the molten metal, reducing wear on the die-casting mold. The provision of a first cold slug trough changes the order of ingate feeding of multiple first diverter channels, and the provision of a second cold slug trough fills pre-existing cavities during the die-casting filling process, preventing gas entrapment and eliminating air holes in non-critical areas of the automotive inverter bracket, such as the bracket reinforcement ribs. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic diagram of the front structure of the automobile inverter bracket;

[0017] Figure 2 This is a schematic diagram of the back structure of the automobile inverter bracket;

[0018] Figure 3 This is a schematic diagram of the three-dimensional structure of the lower mold core in the anti-air hole die-casting mold of the present invention;

[0019] Figure 4 This is a front view of the lower mold core in the anti-air hole die-casting mold of the utility model;

[0020] Figure 5 This is a schematic diagram of the automobile inverter bracket on the lower mold core;

[0021] Figure 6 This is a front view of the automobile inverter bracket after demoulding;

[0022] Figure 7 This is a schematic diagram of the back of the automobile inverter bracket after demoulding;

[0023] Figure 8 This is the result of X-ray flaw detector inspection of the automobile inverter bracket obtained by die-casting using the existing die-casting mold;

[0024] Figure 9 This is a diagram showing the results of an automobile inverter bracket die-cast using the die-casting mold of the present invention and detected by an X-ray flaw detector. DETAILED DESCRIPTION

[0025] The present invention will be described in further detail below with reference to the accompanying drawings and embodiments.

[0026] Figure 1 and Figure 2 A structural schematic diagram of an automobile inverter bracket A is given. The automobile inverter bracket A includes a large bushing hole a1 and three longer installation angles a2, a3, and a4.

[0027] The utility model proposes a die-casting mold for die-casting automobile inverter bracket, such as Figure 3 and Figure 4 As shown, it includes a lower mold core 1, which is provided with a molten metal flow channel 2 and a lower molding cavity 3. The lower mold core 1 is also provided with a diverter cone 4, which is provided with a first main flow channel guide 51 and a second main flow channel guide 52. The molten metal flow channel 2 includes a first main flow channel 21 and a second main flow channel 22. The first main flow channel guide 51 is connected to the first main flow channel 21, and the second main flow channel guide 52 is connected to the second main flow channel 22. The first main flow channel 21 is connected to the lower molding cavity 3 through multiple first diverter channels 23. A first cold material trough 61 is provided at the intersection of the first diverter channel 23 farthest from the first main flow channel guide 51 and the end of the first main flow channel 21. A second diverter channel 24 is provided at the end of the second main flow channel 22, which is connected to the lower molding cavity 3. The end of the second main flow channel 22 extends and is provided with a second cold material trough 62. The provision of the diverter cone 4 and the two main flow channels, as well as multiple diverter channels, achieves uniform distribution and sequential filling of the molten metal. This design helps to reduce air holes in the die-casting mold cavity, because the molten metal can fill the cavity smoothly and sequentially, reducing the entrapment of gas; at the same time, the design of the diverter cone 4 helps to disperse the impact force of the molten metal and reduce the wear of the die-casting mold; by setting the first cold material trough 61, the feeding order of the inner gates of multiple first diversion channels 23 can be changed, and by setting the second cold material trough 62, the originally existing cavity area is filled during the die-casting filling process, avoiding the entrapment of gas, thereby eliminating the air holes in non-key areas of the automobile inverter bracket, such as the bracket reinforcement ribs.

[0028] Furthermore, the angle α formed between the first cold sluice 61 and the first main channel 21 is greater than or equal to 90 degrees and less than or equal to 120 degrees. For example, the angle α is designed to be 110 degrees. In this structure, by defining the specific design position of the first cold sluice 61, the flow of molten metal and the collection of cold sluice are facilitated, the formation of pores is further reduced, the flow path of the molten metal is optimized, and the filling efficiency is improved.

[0029] Further specified, three first branch runners 23 are provided. The molten metal in the first main channel 21 first flows through the middle first branch runner 23 through the ingate to the lower molding cavity 3, then flows through the first branch runner 23 closest to the first main channel guide 51 through the ingate to the lower molding cavity 3, and finally flows through the first branch runner 23 farthest from the first main channel guide 51 through the ingate to the lower molding cavity 3. In this structure, the provision of three first branch runners 23 enables staged filling of the molten metal, helping to reduce air holes caused by rapid filling. This sequential filling mode facilitates gas discharge, thereby improving the internal quality of the die-casting.

[0030] Furthermore, the angle β formed by the second cold material trough 62 and the second branch channel 24 is defined to be 90 degrees. In this structure, by defining the specific design position of the second cold material trough 62, the flow of molten metal and the collection of cold material are facilitated, the formation of pores is further reduced, the flow path of the molten metal is optimized, and the filling efficiency is improved.

[0031] Further defined, the lower mold core 1 is also provided with a plurality of slag bags 7, and the lower molding cavity 3 is provided with a plurality of slag bags 7. Figure 1 and Figure 2 The large bushing hole a1 and the three mounting angles a2, a3, and a4 of the automotive inverter bracket A shown are each connected to a slag bag 7. In this structure, multiple slag bags 7, located on the lower mold core 1, connect to key locations of the automotive inverter bracket, helping to collect and remove impurities and gases from the molten metal. This design improves the purity and quality of the die-casting, reduces porosity and inclusions, and thus enhances the mechanical properties and durability of the die-casting.

[0032] The optimized solution is that the first branch runner 23 gradually increases in width from its intersection with the first main runner 21 to its ingate; the second branch runner 24 gradually increases in width from its intersection with the second main runner 22 to its ingate. In this structure, the gradually increasing widths of the first and second branch runners 23 and 24 facilitate smooth transition and deceleration of the molten metal, reducing gas introduced by rapid flow. It also facilitates uniform filling of the molten metal and reduces the formation of pores and inclusions.

[0033] The die-casting mold of the utility model is used to die-cast the automobile inverter bracket. Figure 5A schematic diagram of the automobile inverter bracket A still on the lower mold core 1 is given. Figure 6 and Figure 7 A schematic diagram of the automotive inverter bracket A after demolding is given.

[0034] An automobile inverter bracket was die-casted using the existing die-casting mold and the die-casting mold of the present invention. An X-ray flaw detector was used to detect the presence of pores in the bracket reinforcement ribs of the automobile inverter bracket die-cast using the existing die-casting mold (see Figure 8 , there are pores in the red circle), while there are no pores in the bracket reinforcement ribs of the automobile inverter bracket obtained by die-casting the die-casting mold of the utility model (see Figure 9 ).

[0035] The contents described in the embodiments of this specification are merely an enumeration of the implementation forms of the concept of the utility model. The scope of protection of the utility model should not be regarded as limited to the specific forms described in the embodiments. The scope of protection of the utility model also extends to equivalent technical means that can be thought of by those skilled in the art based on the concept of the utility model.

Claims

1. A porosity-proof die-casting mold for die-casting an automotive inverter bracket, comprising a lower mold core having a metal liquid flow channel and a lower molding cavity, characterized in that: The lower mold core is also provided with a diverter cone, and the diverter cone is provided with a first main flow channel guide port and a second main flow channel guide port. The metal liquid flow channel includes a first main flow channel and a second main flow channel. The first main flow channel guide port is connected to the first main flow channel, and the second main flow channel guide port is connected to the second main flow channel. The first main flow channel is connected to the lower molding cavity through multiple first diverter channels. A first cold material trough is provided at the intersection of the first diverter channel farthest from the first main flow channel guide port and the end of the first main flow channel. A second diverter channel is provided at the end of the second main flow channel. The second diverter channel is connected to the lower molding cavity, and the end of the second main flow channel extends and is provided with a second cold material trough.

2. The anti-porosity die-casting mold for die-casting an automobile inverter bracket according to claim 1, characterized in that: An included angle formed by the first cold material trough and the first main channel is greater than or equal to 90 degrees and less than or equal to 120 degrees.

3. The anti-porosity die-casting mold for die-casting an automobile inverter bracket according to claim 2, characterized in that: There are three first branch runners. The molten metal in the first main channel first flows through the first branch runner located in the middle through the inner gate to the lower molding cavity, then flows through the first branch runner closest to the first main channel guide opening through the inner gate to the lower molding cavity, and then flows through the first branch runner farthest from the first main channel guide opening through the inner gate to the lower molding cavity.

4. The anti-porosity die-casting mold for die-casting an automobile inverter bracket according to claim 1, characterized in that: An included angle formed by the second cold material trough and the second branch channel is equal to 90 degrees.

5. The anti-porosity die-casting mold for die-casting an automobile inverter bracket according to claim 1, characterized in that: The lower mold core is further provided with a plurality of slag bags, and the positions corresponding to the large bushing hole and three installation angles of the automobile inverter bracket in the lower molding cavity are respectively connected to one of the slag bags.

6. The anti-porosity die-casting mold for die-casting an automobile inverter bracket according to claim 1, characterized in that: The width of the first branch runner gradually increases from the intersection with the first main runner to the inner gate; the width of the second branch runner gradually increases from the intersection with the second main runner to the inner gate.

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