Ultrahigh-precision tooth-shaped insert structure for high-pressure casting of aluminum alloy
By embedding insert structures on the surface of the moving mold, the problem of difficulty in controlling the dimensional accuracy of the tooth profile in high-pressure casting is solved, and the tooth profile is directly formed during the die casting process, thereby improving product quality and production efficiency.
Patent Information
- Application Number
- CN202422942778.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-29
- Publication Date
- 2025-10-21
- Estimated Expiration
- 2034-11-29
AI Technical Summary
During the high-pressure casting process, the instability of aluminum liquid flow, mold temperature fluctuations and uneven pressure distribution make it difficult to control the tooth shape dimensional accuracy and cannot meet high-precision requirements.
A cavity is opened on the surface of the moving mold, and an insert structure is embedded therein. The insert is fixedly connected to the moving mold by screws. The insert is provided with tooth grooves corresponding to the tooth shape, and the standard surface is flush with the parting surface, so that the tooth shape can be directly formed during the die casting process.
It improves the dimensional accuracy and forming quality of the tooth profile, reduces subsequent machining time, lowers the risk of defects, increases production efficiency and product qualification rate, and enhances the versatility and flexibility of the mold.
Smart Images
Figure CN223455078U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to die casting processing technical field, concretely is high pressure casting aluminium alloy superhigh precision tooth shape insert structure. BACKGROUND
[0002] Die casting is a high-efficiency metal forming process, mainly used for producing metal parts with complex shape and high precision. In the die casting process, molten metal is injected into the mold cavity under high pressure, and the desired parts are formed after cooling and solidification. Among them, the mold is various molds of the required product, which is widely used in the forming process of die casting products. The mold generally includes two parts, the moving die and the fixed die, which can be separated and combined. When separated, the product is taken out, and when combined, the blank is injected into the mold cavity to form. The mold is a precision tool with complex shape, which bears the expansion force of the blank, and has high requirements on structural strength, rigidity, surface hardness, surface roughness and machining precision.
[0003] The products produced by the applicant are a gear box body (aluminum product) as shown in Figure 1 A plurality of teeth are formed in the box body, and each group of teeth includes circumferential teeth and vertical teeth arranged adjacent to each other. During high pressure casting, due to the instability of aluminum liquid flow, the fluctuation of mold temperature and the uneven distribution of pressure, etc., it is difficult to accurately control the size precision of the tooth shape, and deviation often occurs, which cannot meet the requirements of high precision size. INVENTION CONTENTS
[0004] The utility model provides high pressure casting aluminium alloy superhigh precision tooth shape insert structure, can promote the size precision of tooth shape in die casting product.
[0005] The present application provides the following technical solutions:
[0006] The high pressure casting aluminium alloy superhigh precision tooth shape insert structure comprises a moving die and an insert assembly, a cavity is formed on the surface of the moving die, the insert assembly comprises a plurality of inserts embedded in the cavity of the moving die, the inserts are fixedly connected with the moving die through mounting screws, the inserts comprise an integrally formed cylindrical part and a sector part, a tooth groove corresponding to the tooth shape on the die casting product is fixedly arranged on the sector part, one side of the sector part connected with the cylindrical part is a standard surface, and the standard surface is flush with the parting surface of the die casting product.
[0007] Technical principle: in the die casting process, the inserts are embedded in the mold cavity to form a specific part of the product. The inserts can be metal, plastic or other materials. By embedding the inserts in the mold, the size and shape precision of the parts at the specific position can be ensured, and the overall product quality can be improved.
[0008] Advantages:
[0009] 1. It is beneficial to shorten the time of processing the blank and improve production efficiency: The tooth groove corresponding to the tooth shape on the die is fixedly arranged on the insert, so that the size accuracy of the tooth shape of the molded die casting product can be guaranteed at the blank stage. This design allows the tooth structure to be directly formed on the part during the die casting process, reducing the time and process of subsequent machining. Traditional die casting products often require additional machining after molding to ensure the accuracy and surface quality of the tooth shape. By pre-setting the tooth groove on the insert, the tooth shape can be formed at the blank stage during the die casting process, greatly shortening the subsequent processing time of the blank and improving production efficiency. In addition, this method also reduces the cumulative error caused by multiple processing, ensuring the size and shape accuracy of the part.
[0010] 2. Ensure the forming quality of the tooth shape: The standard surface on the insert is flush with the parting surface of the die casting product, which can ensure the forming quality of the tooth shape. This precise alignment not only ensures the geometric shape and size accuracy of the tooth shape, but also avoids the problem of uneven or deformed tooth shape caused by positional deviation. The flush design with the parting surface also ensures uniform filling of molten metal during the die casting process, avoiding the generation of defects such as bubbles and cracks, reducing the risk of insert displacement, and further improving product pass rate and facilitating burr polishing. This design is particularly important in mass production, as it ensures that each batch of parts has highly consistent tooth shape quality. Further, as an improvement, the tooth groove includes one or a combination of a transverse tooth groove and a circumferential tooth groove.
[0011] Beneficial effects: This improved design allows the insert to adapt to various types of tooth structure on the die casting product, with the transverse tooth groove suitable for forming linear tooth shapes on the surface of the part, such as gears, racks, etc., and the circumferential tooth groove suitable for forming circular or circumferential tooth shapes on the surface of the part, such as worm gears, gear plates, etc. This design allows the insert to adapt to different shapes and types of tooth structure, improving the versatility and flexibility of the mold.
[0012] Further, as an improvement, a threaded hole is provided on the insert, and the end of the screw is threadedly connected with the threaded hole in the insert.
[0013] Beneficial effects: This improved design allows the insert to be fixedly installed on the moving die, and the threaded hole design allows the end of the screw to securely lock the insert, avoiding loosening or falling off due to vibration or impact during the die casting process. In addition, this design simplifies the installation of the insert, as the screw can be easily removed when replacing the insert, making the operation more convenient and efficient, and improving production efficiency.
[0014] Further, as an improvement, the installation position of the screw corresponds to the position of the tooth groove on the insert.
[0015] Beneficial effect: the installation position of the screw on the insert corresponds to the tooth groove position on the insert, so as to improve the locking force of the insert at the tooth groove part, further reduce the risk of loosening of the insert in the mold, and improve the forming quality of the tooth shape on the casting. BRIEF DESCRIPTION OF DRAWINGS
[0016] Figure 1 is a front view of the gear box body 1 in the utility model embodiment one;
[0017] Figure 2 is an axonometric view of the high-pressure cast aluminum alloy ultra-high-precision tooth-shaped insert structure and the gear box body 1 in the utility model embodiment one;
[0018] Figure 3 is Figure 2 is an exploded view of the movable mold 2 and the gear box body 1;
[0019] Figure 4 is Figure 3 is an axonometric view of the first insert 3a, the second insert 3b and the third insert 3c;
[0020] Figure 5 is a structural schematic view when the insert 3 contacts the gear box body 1;
[0021] Figure 6 is Figure 2 is a rear view. DETAILED DESCRIPTION
[0022] The following is further described in detail through specific embodiments:
[0023] The marks in the drawings of the specification include: the gear box body 1, the tooth shape 11, the circumferential tooth 11a, the vertical tooth 11b, the parting surface 12, the movable mold 2, the insert 3, the first insert 3a, the second insert 3b, the third insert 3c, the cylindrical part 31, the threaded hole 311, the sector part 32, the standard surface 321, the tooth groove 33, the transverse tooth groove 33a, the circumferential tooth groove 33b, the screw 4, the push plate 5, and the foot 6.
[0024] Embodiment one
[0025] The high-pressure cast aluminum alloy ultra-high-precision tooth-shaped insert structure in the embodiment is applied to a die casting processing process of a kind of gear box body 1 (aluminum product) blank as shown in Figure 1 After pressure casting forming, it still has to experience machining (that is, complete machining process from rough machining to finish machining) to make that size precision and surface quality satisfy design requirement. In the gear box body 1, there is set up as shown in Figure 1The 6 groups of tooth shapes 11 shown, the tooth shape 11 includes circumferential teeth 11a or vertical teeth 11b or circumferential teeth 11a and vertical teeth 11b, in the traditional process, the machining of circumferential teeth 11a and vertical teeth 11b is carried out in subsequent machining links, the structure of the insert 3 is improved in the present scheme, the dimensional accuracy of the tooth shape 11 is ensured at the stage of forming the blank, and the machining efficiency of the gear box body 1 is improved. The following is a specific description of the structure of the high-pressure cast aluminum alloy ultra-high-precision tooth-shaped insert:
[0026] Combined Figures 2-5 As shown, the high-pressure cast aluminum alloy ultra-high-precision tooth-shaped insert structure, including the movable die 2, the insert assembly, the foot 6 fixedly connected with the two ends of the movable die 2, the push plate 5 arranged between the two end feet 6, the cavity is opened on the surface of the movable die 2, and the insert assembly is installed on the mold core of the movable die 2.
[0027] In the present embodiment, the insert assembly includes, as shown in Figure 3 and Figure 4 6 inserts 3 embedded in the above-mentioned cavity, screws 4 for fixing the inserts 3. The insert 3 includes an integrally formed cylindrical part 31 and a fan-shaped part 32, a threaded hole 311 is formed on the cylindrical part 31, the screw 4 is selected as an internal hexagonal cylindrical head screw, and the end of the screw 4 is embedded into the threaded hole 311 so that the insert 3 is fixedly connected to the mold core of the movable die 2. The tooth groove 33 corresponding to the tooth shape 11 on the die casting product is fixedly arranged on the fan-shaped part 32, and the tooth groove 33 is divided into transverse tooth grooves 33a and circumferential tooth grooves 33b. There are three types of inserts 3 in the present embodiment, such as the first insert 3a which is only provided with transverse tooth grooves 33a, the second insert 3b which is only provided with circumferential tooth grooves 33b, and the third insert 3c which is provided with both transverse tooth grooves 33a and circumferential tooth grooves 33b. As shown in Figure 4 , the cylindrical part 31 of the third insert 3c is fixedly connected with two parallel screws 4, at least one of which needs to be opposite to the tooth groove 33 of the third insert 3c, i.e. the position where the transverse tooth groove 33a and the circumferential tooth groove 33b are arranged, so as to improve the locking force of the screw 4 on the corresponding tooth groove 33 part of the insert 3, thereby improving the forming quality of the tooth shape on the die casting product.
[0028] A through hole is provided on the push plate 5 for the screw 4 to pass through, so that when the insert 3 needs to be disassembled and replaced, the push plate 5 and the foot 6 do not need to be laboriously removed, and the screw 4 can be removed and the insert 3 can be removed through the through hole on the push plate 5.
[0029] One side of the fan-shaped part 32 connected with the cylindrical part 31 is a standard surface 321, which is flush with the parting surface 12 of the die casting product after the gear box body 1 is formed, and the parting surface 12 refers to the interface where the movable die 2 and the concave die of the die casting mold contact. If the height of the standard surface 321 is not flush with the parting surface 12 of the gear box body 1, it will bring inconvenience to the subsequent machining process.
[0030] The specific application process is as follows:
[0031] In use, first, the insert 3 is fixed in place on the mold core of the movable mold 2 by means of the screw 4, then a standard gear box body 1 is taken and placed on the movable mold 2 before first use, and whether the standard surface 321 of the insert 3 is flush with the parting surface 12 of the gear box body 1 is observed, if the inspection result is flush, then the movable mold 2 and the concave mold are used to perform the die casting process, and finally when the gear box body 1 is formed, the standard surface 321 of the insert 3 and the parting surface 12 of the gear box body 1 are checked again after demolding, if the inspection result is flush, it means that the part quality is qualified, and the subsequent machining steps can be continued.
[0032] Through experiments by the inventor, the depth error of the tooth shape on the gear box body 1 formed by using the above high-pressure cast aluminum alloy ultra-high precision tooth-shaped insert structure is within ±0.05mm, and the size error is within +0.05mm, which can ensure that the tooth shape is complete and meets the design requirements.
[0033] The above is only an embodiment of the present application, and the present application is not limited to this embodiment. The field involved in the embodiment, the specific structure and characteristics of the scheme, and other common knowledge are not described in detail here. It should be pointed out that for those skilled in the art, without departing from the structure of the present application, a number of modifications and improvements can be made, which should also be considered as the protection scope of the present application. These will not affect the effect and practicality of the present application. The protection scope of the present application should be subject to the content of its claims, and the specific implementation mode and the like in the specification can be used to explain the content of the claims.
Claims
1. A high pressure die cast aluminum alloy ultra-high precision tooth profile insert structure comprising a movable mold, characterized in that: The die set further comprises an insert assembly, a cavity is formed on the surface of the movable die, the insert assembly comprises a plurality of inserts embedded in the cavity of the movable die, the inserts are fixedly connected with the movable die through mounting screws, the inserts comprise an integrally formed cylindrical portion and a sector-shaped portion, a tooth groove corresponding to a tooth shape on the die casting product is fixedly arranged on the sector-shaped portion, one side of the sector-shaped portion connected with the cylindrical portion is a standard surface, and the standard surface is flush with a parting surface of the die casting product.
2. The high pressure die cast aluminum alloy ultra-high precision splined insert structure of claim 1, wherein: The tooth groove comprises one or both of a transverse tooth groove and a circumferential tooth groove.
3. The high pressure die cast aluminum alloy ultra-high precision splined insert structure of claim 2, wherein: Threaded holes are formed on the inserts, and end portions of the screws are threadedly connected with the threaded holes in the inserts.
4. The high pressure die cast aluminum alloy ultra-high precision splined insert structure of any one of claims 1-3, wherein: Mounting positions of the screws correspond to positions where the tooth grooves are arranged on the inserts.