Manufacturing method for single and dual injection die casting machines

Abstract

This invention provides a method for manufacturing single and dual injection die-casting machines. [Solution] The single / dual injection die-casting machine includes a head plate 200, a lower frame 300 for material injection, and an injection unit 400. The head plate and the lower frame for material injection are fixed with a gap between them. When there is one injection unit, the injection unit is mounted in the center of the lower frame for material injection so as to connect to a connection port in the center of the head plate. When there are two injection units, the injection units are mounted symmetrically on both sides of the lower frame for material injection so as to connect to connection ports on both sides of the head plate. [Effect] By simply changing the number of injection units, two modes, single injection and dual injection, can be realized, effectively expanding the scope of application of this invention and effectively reducing production costs.

Description

[Technical Field]

[0001] This application relates to the technical field of die-casting machines, and more particularly to a method for manufacturing single and dual injection die-casting machines. [Background technology]

[0002] With the development of die-casting technology for aluminum alloy materials, it has become possible to significantly improve their fluidity, strength, and toughness. As a result, the dimensions of metal products that can be produced by die-casting have gradually increased, with the one-piece die-casting of automobile bodies being one example.

[0003] As the dimensions of die-cast products increase, the distance to the mold cavity of the corresponding die-casting mold gradually increases. With conventional die-casting machines, when die-casting large products using a single injection method, the die-casting time for the product is relatively long, which consequently affects the processing accuracy of the product. Therefore, in conventional technology, dual injection die-casting machines have been proposed. That is, the die-casting machine has two injection mechanisms that can perform die-casting on the die-casting mold simultaneously in order to improve die-casting efficiency and die-casting accuracy.

[0004] However, conventional single-injection and dual-injection die-casting machines are typically used independently. Therefore, when companies produce products of different types and dimensions, they need to purchase both single-injection and dual-injection die-casting machines, which ultimately increases production costs. [Overview of the project] [Problems that the invention aims to solve]

[0005] One object of this invention is to provide a method for manufacturing single- and dual injection die-casting machines that can solve at least one of the drawbacks in the background art described above.

[0006] Another objective of this application is to provide a method for designing a head plate that can solve at least one of the drawbacks in the background art described above. [Means for solving the problem]

[0007] To achieve at least one of the above objectives, the technical solution employed in this application is a method for manufacturing a single-dual injection die-casting machine. The single-dual injection die-casting machine includes a head plate, a lower frame for material injection, and an injection unit, wherein the head plate and the lower frame for material injection are fixed with a gap between them, If there is one injection unit, the injection unit is mounted in the center of the lower material injection frame so as to be connected to the connection port in the center of the head plate. If there are two injection units, the injection units are mounted symmetrically on both sides of the lower material injection frame so that they are connected to the connection ports on both sides of the head plate.

[0008] Preferably, the area between the central connection port of the head plate and the connection ports on both sides is the main rib. The region between the connection port and the side edge on both sides of the head plate is a sub-rib. The thickness of the main rib is greater than the thickness of the sub-rib. The width of the main rib is smaller than the width of the sub-rib.

[0009] Preferably, the thickness of the main rib is 1.4 to 1.6 times the thickness of the sub-rib. The width of the main rib is 0.5 to 0.7 times the width of the sub-rib.

[0010] Preferably, the lower frame for material injection includes, in order, a connecting part, an oil tank and a mounting part, The aforementioned connection portion is fixedly connected to the lower clamping frame for attaching the head plate. The aforementioned mounting portion is used for mounting the injection unit. The oil tank has three oil inlets formed in the width direction. When one of the injection units is attached to the mounting portion, the injection unit is connected to the oil filler port in the central portion. When a pair of the injection units are attached to the mounting portion, the injection units are connected to the oil inlets on both sides.

[0011] Preferably, the oil tank is divided into multiple regions by multiple partition plates that intersect vertically and horizontally. Notches are formed in the upper part of at least some of the partition plates to allow air circulation between the divided adjacent areas. Notches are formed in the lower part of at least some of the partition plates to allow oil-liquid flow between the divided adjacent regions.

[0012] The design process for the head plate used in the manufacture of the above-mentioned single- and dual injection die-casting machines is as follows: Step S100 involves provisionally determining the outer dimensions of the head plate according to the structural dimensions of the injection unit, Step S200 calculates the total area on which the head plate is subjected to pressure based on the material injection impact force by the injection unit and the clamping force by the die-casting machine. Step S300: Based on the verification calculation of the strength of the head plate at the clamping force, determine the proportion of the area of ​​the head plate that is subjected to pressure that is occupied by the main ribs and sub-ribs formed between the plurality of connection ports, The method includes step S400, which involves analyzing the stress and strain of the head plate using finite element simulation software and obtaining the thickness dimensions of the main rib and sub-rib that have the minimum stress peak value and minimum deformation.

[0013] Preferably, step S200 is Based on the output pressure P of the clamping hydraulic cylinder of the die-casting machine and the piston rod diameter D of the clamping hydraulic cylinder, the clamping force F applied by the clamping hydraulic cylinder to the head plate S Step S210 of calculating The material injection impact force F applied by the injection unit to the head plate C is set to be kF S or less, and k represents the safety factor in step S220 Based on the formula F C = P0·S, calculate the total area S where the head plate receives pressure, and P0 represents the output pressure of the injection oil hydraulic cylinder of the injection unit in step S230, and includes

[0014] Preferably, the value of the safety factor k is 1.05 to 1.15

[0015] Preferably, step S300 includes Step S310 of obtaining the relational expression of the width dimension between the main rib and the sub-rib based on the outer contour dimension of the head plate Step S320 of identifying the dangerous cross-section for all cross-sections where the head plate receives pressure based on the structural distribution of the main rib and the sub-rib Set a criterion, and calculate the centroid based on the dimensions and positions of each of the dangerous cross-sections obtained in step S320 in step S330 Based on the formula of the centroid position calculated in step S330, calculate the second moment of area about the centroid axis of each of the dangerous cross-sections in step S340 Substitute the formula of the calculated second moment of area into the calculation formula of the bending moment, and derive the formula of the maximum bending stress in the dangerous cross-section in step S350 Based on the limited clamping force and the allowable stress of the material, perform iterative calculations on the formula of the maximum bending stress to obtain the optimal width dimensions of the main rib and the sub-rib in step S360, and include

[0016] Preferably, in step S330, with respect to the vertically positioned head plate, a horizontal line passing through the center of the connection port in the central part of the head plate is used as a reference, or a horizontal line passing through the center of the connection ports on both sides of the head plate is used as a reference.

[0017] Compared to the prior art, the beneficial effects of this invention are as follows:

[0018] Compared to the conventional two independent methods of single die casting and dual die casting, this invention enables the implementation of both single injection and dual injection modes simply by changing the number of injection units, and can be independently adjusted according to actual production demands. Therefore, the scope of application of this invention can be effectively expanded, and production costs can be effectively reduced. [Brief explanation of the drawing]

[0019] [Figure 1] This is a schematic diagram of the overall structure of the single / dual injection die-casting machine in the present invention, with two injection units attached. [Figure 2] This is a schematic diagram of the structure of the single / dual injection die-casting machine in the present invention with the injection unit removed. [Figure 3] This is a schematic diagram of the partial structure of the head plate in the present invention. [Figure 4] This is a schematic diagram of the lower frame for material injection in this application. [Figure 5] This is a schematic flowchart of the design method for the head plate in this application. [Figure 6] This is a stress cloud map obtained from a finite element method simulation of the head plate in this application. [Figure 7] Figure 6 shows a stress cloud map obtained from a finite element method simulation of Comparative Example 1 of the head plate in this application. [Figure 8] Figure 6 shows a stress cloud map obtained from a finite element method simulation of Comparative Example 2 of the head plate in this application. [Figure 9] This is a strain cloud map obtained from a finite element method simulation of the head plate in this application. [Figure 10] Figure 9 shows a strain cloud map obtained from a finite element method simulation of Comparative Example 1 of the head plate in this application. [Figure 11] Figure 9 shows a strain cloud map obtained from a finite element method simulation of Comparative Example 2 of the head plate in this application. [Modes for carrying out the invention]

[0020] The present application will be further described below in relation to specific embodiments. In this specification, any reference to terms such as “one embodiment,” “several embodiments,” “example,” “specific example,” or “several examples” means that the specific features, structures, materials, or properties described in conjunction with the embodiment or example are included in at least one embodiment or example of this application. In this specification, exemplary expressions for the above terms should not necessarily be construed as being limited to the same embodiment or example. Furthermore, the specific features, structures, materials, or properties described can be combined in an appropriate manner within any one or more embodiments or examples. Moreover, those skilled in the art can combine or link different embodiments or examples described herein.

[0021] Furthermore, in the description of this application, the directions or positional relationships indicated by directional terms such as "center," "horizontal," "vertical," "length," "width," "thickness," "top," "bottom," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," "clockwise," and "counterclockwise" are directions or positional relationships shown based on the drawings, and are solely for the convenience and simplification of the description of this application. They do not imply or suggest that the devices or elements shown must necessarily have a specific direction, or must be configured or operated in a specific direction, and should not be understood as limitations on the specific scope of protection of this application.

[0022] Furthermore, terms such as "First," "Second," etc., used in the specification and claims of this application are intended to distinguish similar subjects and are not necessarily intended to describe a specific order or sequence.

[0023] In this application, unless otherwise explicitly provided and limited, technical terms such as “attach,” “interconnect,” “connect,” and “fix” should be understood in a broad sense. For example, it may be a connection, a removable connection, or an integrated connection. It may be a mechanical connection or an electrical connection. It may be a direct connection or an indirect connection via an intermediate medium, or an internal communication between two elements or an interaction relationship between two elements. A person skilled in the art will be able to understand the specific meaning of the above terms in this invention, depending on the specific situation.

[0024] In this application, unless otherwise explicitly provided and limited, the phrase "above" or "below" the second feature of the first feature may include cases where the first and second features are in direct contact, or cases where they are in contact not by direct contact, but by other features interposed between them. The phrase "above," "above," or "upper side" of the second feature may include cases where the first feature is directly above or diagonally above the second feature, or simply means that the horizontal height of the first feature is greater than that of the second feature. The phrase "below," "below," or "lower side" of the second feature may include cases where the first feature is directly below or diagonally below the second feature, or simply means that the horizontal height of the first feature is less than that of the second feature.

[0025] The technical terms “including” and “having,” and all variations thereof, in the specification and claims of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus comprising a series of steps or units may include other steps or units that are not explicitly described or are specific to those processes, methods, products, or apparatus, without necessarily being limited to the steps or units explicitly described.

[0026] One aspect of the present invention provides a method for manufacturing a single- and dual injection die-casting machine, one preferred embodiment of which, as shown in Figures 1 and 2, includes a head plate 200, a lower material injection frame 300, and an injection unit 400. The head plate 200, used for mounting a die-casting mold (not shown), is fixed. The head plate 200 has three connection ports in the width direction, one of which is located in the central region of the head plate 200, and the other two connection ports are located on either side of the central connection port. The lower material injection frame 300, used for mounting the injection unit 400, is fixed with a gap between it and the head plate 200. When single injection die-casting is required, one injection unit 400 may be mounted in the center of the lower material injection frame 300 so as to be connected to the central connection port of the head plate 200. If dual injection die casting is required, two injection units 400 may be mounted symmetrically on either side of the lower material injection frame 300, so that they are connected to the connection ports on both sides of the head plate 200.

[0027] Furthermore, in the single / dual injection die-casting machines of this invention, the number of head plates 200 and lower frames 300 for material injection, as well as the overall connection relationships, remain unchanged in both single and dual injection die-casting. Only the number and mounting positions of the injection units 400 change. This means that companies can implement both single and dual injection die-casting with a maximum of three injection units 400. Compared to conventional methods that require two die-casting facilities, this invention effectively expands the scope of application and effectively reduces production costs.

[0028] The model numbers of the injection units 400 used in the single injection mode and dual injection mode of this application may be the same or different. With injection units 400 of the same model number, this application makes it possible to realize the single injection mode and dual injection mode of a die-casting machine by simply providing two injection units 400. With injection units 400 of different model numbers, this application makes it necessary to provide three injection units 400 to realize the single injection mode and dual injection mode of a die-casting machine. The specific model numbers of the injection units 400 can be independently selected according to the actual needs of those skilled in the art. The specific structure and operating principle of the injection units 400 are both well known to those skilled in the art, so a detailed explanation is omitted here.

[0029] In this embodiment, as shown in Figures 1 to 3, the area between the central connection port and the connection ports on both sides of the head plate 200 is the main rib 201, and the area between the connection ports on both sides of the head plate 200 and the side edges is the sub-rib 202. When designing the structure of the head plate 200, it is necessary to design the thickness of the main rib 201 to be greater than the thickness of the sub-rib 202, and to set the width of the main rib 201 to be smaller than the width of the sub-rib 202.

[0030] The connection ports formed in the head plate 200 are used to connect to the material injection plunger provided in the injection unit 400. To facilitate the installation of the material injection plunger, relief structures must be provided in the areas near the connection ports on the head plate 200. In single injection die casting, the material injection impact force applied by the injection unit 400 to the head plate 200 is mainly concentrated near the main rib 201. On the other hand, in dual injection die casting, the material injection impact force applied by the injection unit 400 to the head plate 200 is distributed to the main rib 201 and sub-rib 202 on both sides of the corresponding connection port. In both single and dual injection die casting, the main rib 201 is subjected to impact. That is, the main rib 201 operates under a harsher environment than the sub-rib 202. The material injection impact force applied by the injection unit 400 mainly causes bending deformation of the head plate 200. Therefore, when designing the main rib 201 and sub-rib 202, designing the thickness of the main rib 201 to be greater than the thickness of the sub-rib 202 ensures that the main rib 201 has a section modulus that is more resistant to bending, thereby ensuring the operational safety of the head plate 200. On the other hand, regarding the design of the width of the main rib 201 and sub-rib 202, the larger the dimensions of the head plate 200, the heavier the corresponding weight. Therefore, assuming that the structural strength is met, the width of the main rib 201 and sub-rib 202 must be made as small as possible. Considering the design dimensions of the thickness of the main rib 201 and sub-rib 202, in order for the sub-rib 202 to meet the structural strength requirements, the width of the sub-rib 202 must be designed to be greater than the width of the main rib 201.

[0031] Specifically, the dimensional design of the thickness and width of the main rib 201 and sub-rib 202 will be explained in detail below through a specific design method. The design dimensions that can guarantee that the head plate 200 has good performance are that the thickness of the main rib 201 is 1.4 to 1.6 times the thickness of the sub-rib 202, and the width of the main rib 201 is 0.5 to 0.7 times the width of the sub-rib 202.

[0032] In this embodiment, as shown in Figures 1 and 2, the lower frame 300 for material injection includes a connecting section 310, an oil tank 320, and a mounting section 330, which are provided in order. The connecting section 310 is fixedly connected to the lower clamping frame 100 for mounting the head plate 200. This ensures the structural stability of the entire die-casting machine and guarantees accuracy in the material injection process. The mounting section 330 is used to mount the injection unit 400, and the oil tank 320 has three oil inlets 321 in the width direction. When one injection unit 400 is mounted to the mounting section 330, the injection unit 400 is connected to the central oil inlet 321, and when a pair of injection units 400 are mounted to the mounting section 330, the injection units 400 are connected to the oil inlets 321 on both sides.

[0033] Specifically, as shown in Figure 4, the oil tank 320 is divided into multiple regions by a plurality of partition plates 322 that intersect vertically and horizontally. Notches 323 are formed in the upper part of at least some of the partition plates 322 to allow air to flow between adjacent divided regions. Notches 323 are also formed in the lower part of at least some of the partition plates 322 to allow oil to flow between adjacent divided regions.

[0034] The central region of the oil tank 320 is the main oil return region, which is the primary passage for oil return, while the sides of the oil tank 320 are sub-oil return regions. In dual injection mode, the partition plate 322 effectively reduces the impact caused by the flow of oil return, thereby making the oil flow more stable. As a result, noise and vibration can be reduced, improving the stability and reliability of material injection of the injection unit 400. Furthermore, the notch 323 formed at the bottom of the partition plate 322 ensures the flow of oil in each region of the oil tank 320 while simultaneously reducing the circulation speed, contributing to oil cooling and heat dissipation, bubble generation, and impurity sedimentation.

[0035] Another aspect of the present invention provides a method for designing a head plate used in the manufacture of the above-mentioned single-dual injection die-casting machine, one preferred embodiment thereof, as shown in Figure 5, includes the following design steps.

[0036] In step S100, the outer dimensions of the head plate 200 are provisionally determined according to the structural dimensions of the injection unit 400.

[0037] In step S200, the total area on which the head plate 200 is subjected to pressure is calculated based on the material injection impact force from the injection unit 400 and the clamping force from the die-casting machine.

[0038] In step S300, based on the verification calculation of the strength of the head plate 200 under clamping force, the proportion of the area of ​​pressure on the head plate 200 that is occupied by the main ribs 201 and sub-ribs 202 formed between the multiple connection ports is determined.

[0039] In step S400, stress and strain analysis of the head plate 200 is performed using finite element method simulation software, and the thickness dimensions of the main rib 201 and sub-rib 202 that have the minimum stress peak value and minimum deformation are obtained.

[0040] Regarding step S100, the outer dimensions of the head plate 200 depend mainly on the mounting dimensions of the injection unit 400 in dual injection mode. Specifically, A may be the width of a single injection unit 400, and B may be the minimum spacing that ensures the proper mounting of two injection units 400. Since the material injection plunger of the injection unit 400 is usually located in the center of the injection unit 400, the minimum spacing between the two connection ports for dual injection die casting on the head plate 200 is A + B. Next, based on the design dimensions of the connection ports, it is analyzed whether the width of the main rib 201 between adjacent connection ports meets the basic structural strength requirements. If the width of the main rib 201 meets the structural strength requirements, the profile dimension L in the width direction of the head plate 200 is at least A + B + 2C. Here, C represents the distance from the edge of the sub-rib 202 that meets the basic structural strength requirements to the center of the connection port on the same side. If the width of the main rib 201 does not meet the basic structural strength requirements, the profile dimension L in the width direction of the head plate 200 is at least A + B + 2C + D. Here, D represents the amount of increase in the width of the main rib 201 required for the widened main rib 201 to meet the basic structural strength requirements. Generally, the head plate 200 is made into a square structure such that the tie bars attached to the four corners of the head plate 200 are adjacent to each other at equal intervals in the horizontal and vertical directions.

[0041] The width of the main rib 201, which satisfies the basic structural strength requirements, may be calculated using a simple strength calculation formula or selected based on the experience of those skilled in the art. This dimension is only a provisional one and will be optimized later.

[0042] In this embodiment, step S100 merely determines the basic contour dimensions of the head plate 200. As can be seen from Figures 1 to 3, the connection port areas of the head plate 200 are all designed to have a relief structure, which facilitates the later installation of the material injection plunger at the connection port location and reduces the weight of the head plate 200. In designing the head plate 200, it is necessary to increase the space of the relief area as much as possible while satisfying the structural strength and facilitating the installation of the material injection plunger. This reduces the weight of the head plate 200 as much as possible and reduces costs. The size of the relief area at the connection port location may be determined based on the total pressure-receiving area S required for the head plate 200. That is, since the impact resistance of the head plate 200 is determined by the total pressure-receiving area S of the head plate 200, if the basic contour dimensions of the head plate 200 have already been determined, the total area of ​​the relief area can be obtained by calculating the total pressure-receiving area S, and then the specific structure can be determined. To facilitate understanding, the following section will explain in detail the specific calculation process for the total pressure-bearing area S in step S200.

[0043] Specifically, step S200 includes the following steps:

[0044] In step S210, the clamping force F applied by the clamping hydraulic cylinder to the head plate 200 is determined based on the output pressure P of the clamping hydraulic cylinder of the die-casting machine and the piston rod diameter D of the clamping hydraulic cylinder. S Calculate.

[0045] In step S220, the material injection impact force F applied by the injection unit 400 to the head plate 200. C to kF S The following settings are used, where k represents the safety factor.

[0046] In step S230, formula F CBased on =P0·S, the total area S on which the head plate 200 is subjected to pressure is calculated, where P0 represents the output pressure of the injection hydraulic cylinder of the injection unit.

[0047] Furthermore, when a die-casting machine performs die-casting, the die-casting mold on the head plate 200 must be securely clamped under the clamping force applied by the clamping mechanism (not shown). Therefore, the head plate 200 is supported by the clamping force of the clamping mechanism and resists the material injection impact force from the injection unit 400 during die-casting. However, in order to ensure the operational safety of the die-casting process, it is necessary to ensure that the material injection impact force applied by the injection unit 400 to the head plate 200 does not significantly exceed the clamping force. Otherwise, the clamping mechanism may fail. Accordingly, the value of the safety factor k in step S220 is generally 1.05 to 1.15, and preferably 1.1.

[0048] Furthermore, after calculating the total area S on which the head plate 200 is subjected to pressure using the steps S210 to S230 described above, the total area of ​​the relief region corresponding to the three connection ports can be obtained simply by subtracting the total area S on which the head plate 200 is subjected to pressure from the total cross-sectional area of ​​the head plate 200. Therefore, finally, by performing precise calculations based on strength verification on the structural dimensions of the main rib 201 and sub-rib 202, the proportion that the main rib 201 and sub-rib 202 occupy in the total area S on which the pressure is subjected can be obtained. In this way, the width dimensions of the main rib 201 and sub-rib 202 can be determined based on the position of the connection port, and the dimensions of the relief region at the position of the connection port can also be determined. For ease of understanding, the process of calculating the proportion that the main rib 201 and sub-rib 202 occupy in the total area on which the pressure is subjected will be explained below.

[0049] In this embodiment, step S300 includes the following steps.

[0050] In step S310, a relational expression for the width dimension between the main rib 201 and the sub-rib 202 is obtained based on the outer dimensions of the head plate 200.

[0051] In step S320, based on the structural distribution of the main ribs 201 and sub-ribs 202, critical sections are identified for all sections of the head plate 200 that are subjected to pressure.

[0052] In step S330, a reference is set, and the centroid is calculated based on the dimensions and location of each critical section obtained in step S320.

[0053] In step S340, the second moment of area of ​​each critical section with respect to the centroid axis is calculated based on the equation for the centroid position calculated in step S330.

[0054] In step S350, the calculated equation for the second moment of area is substituted into the equation for the bending moment to derive the equation for the maximum bending stress at the critical section.

[0055] In step S360, the optimal width dimensions of the main rib 201 and sub-rib 202 are obtained by performing iterative calculations on the formula for maximum bending stress based on the limited clamping force and the allowable stress of the material.

[0056] In step S330, when calculating the centroid, the reference point is determined according to the position where the head plate 200 is subjected to pressure. In single injection mode, the position where the head plate 200 is subjected to pressure is located at the central connection port, in which case the reference point may be a horizontal line passing through the center of the central connection port. In dual injection mode, the positions where the head plate 200 is subjected to pressure are located at the connection ports on both sides, in which case the reference point may be a horizontal line passing through the centers of the connection ports on both sides. In actual use, if the model numbers of the injection units 400 used in single injection mode and dual injection mode are the same, the heights of the three connection ports are the same, and the reference point is unified in this case. If the model numbers of the injection units 400 used in single injection mode and dual injection mode are different, the heights of the three connection ports are different, and there are two reference points. The selection of a specific reference point is determined by the worst operating conditions that the head plate 200 experiences in the two injection modes.

[0057] Below, we will describe step S300 in detail in relation to specific parameters to facilitate further understanding.

[0058] Specifically, as shown in Figure 3, if the reference point passes through the center of the central connection port and divides the head plate 200 into two equal parts vertically, the relief areas corresponding to the three connection ports will have the same height and be aligned with each other. The width of the relief areas corresponding to the connection ports on both sides may be X1, the width of the relief area corresponding to the central connection port may be X2, the width of the main rib 201 may be X4, the width of the sub-rib 202 may be X3, the height from the upper end of the relief area corresponding to the connection port to the upper edge of the head plate 200 may be H1, the height from the upper edge of the sub-rib 202 to the upper edge of the head plate 200 may be H2, and the height from the upper edge of the sub-rib 202 to the reference point may be H3.

[0059] According to the above analysis, the total area S that receives pressure is S = 4(X3×H2)+4(X1×H1)+4[X4×(H2 + H3)]+2(X2×H1), and the one-side width L of the head plate 200 is L = 2X1+X2+2X3+2X4. When L and S are known, the relational expression between the width X4 of the main rib 201 and the width X3 of the sub-rib 202 in step S310 can be obtained.

[0060] The identification of the dangerous cross-section in step S320 is mainly for facilitating the subsequent calculation of the centroid. Based on the structural distribution of the main rib 201 and the sub-rib 202, the areas of the identified dangerous cross-sections are the extended areas at both ends of the main rib 201, the extended areas at both ends of the sub-rib 202, and the corresponding areas above and below each connection port, respectively.

[0061] The centroid of the dangerous cross-section calculated in step S330 is the equivalent centroid y of all the dangerous cross-sections, and the specific calculation formula is

Equation

[0062] Here, S i represents the area corresponding to each dangerous cross-section, and h i represents the height of the center point with respect to the reference corresponding to each dangerous cross-section. For the sake of easy understanding, hereinafter, taking the dangerous cross-section corresponding to the upper region of the central connection port as an example, if the area of this dangerous cross-section is S1 and the height of the corresponding centroid is h1, then S1 = X2×H1, and h1 = H2 - 0.5H1 + H3.

[0063] In step S340, the formula for calculating the second moment of area J y of each dangerous cross-section with respect to the axis of the equivalent centroid y is

Equation

[0064] Here, J yiThis represents the second moment of area of ​​each hazardous section itself. As an example, the second moment of area J of the hazardous section corresponding to the upper region of the connection port in the central part is given. y1 =X² × H1 3 Let's divide by 12.

[0065] In step S350, the maximum bending moment M of the head plate 200 max Based on this, the maximum bending stress σ at the critical cross section b The formula for this calculation is: σ b =(M max ×y) / J y That is the case.

[0066] Note that the maximum bending moment M max This may be calculated according to 1.1 times the clamping force. Through all the steps described above, the maximum bending stress σ obtained is b The calculation formula is related to the widths of the main rib 201 and the sub-rib 202. Furthermore, the maximum bending stress σ b Based on a comparison with the safety stress [σ] specified in national or industry standards, an equation for the safety stress [σ] of the width of the main rib 201 and sub-rib 202 can be obtained. Furthermore, by iterative calculations on the equation, the width dimensions of the main rib 201 and sub-rib 202 corresponding to the head plate 200 with optimal structural strength and weight can be obtained. Conversely, based on the obtained width dimensions of the main rib 201 and sub-rib 202, the structural dimensions of the relief area corresponding to each connection port can also be determined.

[0067] Furthermore, the structural dimensions of the end face of the head plate 200 can be determined by the steps S310 to S360 described above. On the other hand, the thickness of the head plate 200 mainly reflects its deformation resistance when subjected to material injection impact. Therefore, it is difficult to obtain the optimal thickness dimension of the head plate 200 by numerical calculation. However, with the finite element method, the deformation state of the head plate 200 at microscopic angles can be obtained by the finite element method simulation method. Therefore, in this embodiment, the thickness dimensions of the main rib 201 and sub-rib 202 can be obtained by the finite element method simulation method. There are various general finite element analysis software programs, but for ease of understanding, the following will explain in detail the finite element analysis using ANSYS software as an example.

[0068] Specifically, a structural model of the head plate 200 described above is constructed using ANSYS software. Constraints are set on the constructed model and loads are applied to simulate the actual operating conditions. To verify the accuracy of the analysis results, finite element analysis is performed below using three head plates 200 with different thickness dimensions, defined as the first head plate, second head plate, and third head plate, respectively. In the first head plate, the thickness of the main rib 201 is 412 mm, and the thickness of the sub-rib 202 is 276 mm. In the second head plate, the thickness of the main rib 201 is 462 mm, and the thickness of the sub-rib 202 is 326 mm. In the third head plate, the thickness of the main rib 201 is 212 mm, and the thickness of the sub-rib 202 is 400 mm.

[0069] Figures 6 to 8 show the stress distribution cloud maps of the first to third head plates in order. As can be seen from the figures, during die casting, the head plate 200 is mainly subjected to impact forces from the injection unit 400. The area where the injection cylinder is attached is subjected to the direct action of the injection pressure and therefore has a relatively high stress level. The connection points of the connecting columns and reinforcing ribs are prone to generating large stresses due to the transmission and concentration of pressure. The maximum stresses experienced when the thickness of the main rib 201 is 412 mm and the thickness of the sub-rib 202 is 276 mm are 94 MPa and 91 MPa. When the thickness of the main rib 201 is 462 mm and the thickness of the sub-rib 202 is 326 mm, the stresses are 97 MPa and 104 MPa. When the thickness of the main rib 201 is 212 mm and the thickness of the sub-rib 202 is 400 mm, the stresses are 149 MPa and 114 MPa. As described above, in this embodiment, the stress experienced is minimal when the thickness of the main rib 201 is 1.5 times the thickness of the sub-rib 202. The stress experienced is slightly greater when the thickness of the main rib 201 is 1.4 times the thickness of the sub-rib 202. The stress experienced is clearly greater when the thickness of the main rib 201 is less than the thickness of the sub-rib 202.

[0070] Figures 9 to 11 show the strain distribution cloud maps of the first to third head plates in order. The maximum strain that occurs when the thickness of the main rib 201 is 412 mm and the thickness of the sub-rib 202 is 276 mm is 5.081 mm. The maximum strain that occurs when the thickness of the main rib 201 is 462 mm and the thickness of the sub-rib 202 is 326 mm is 5.8877 mm. The maximum strain that occurs when the thickness of the main rib 201 is 212 mm and the thickness of the sub-rib 202 is 400 mm is 6.0483 mm. In this embodiment, the deformation that occurs when the thickness of the main rib 201 is 1.5 times the thickness of the sub-rib 202 is minimal. The deformation that occurs when the thickness of the main rib 201 is 1.4 times the thickness of the sub-rib 202 is large. The deformation that occurs when the thickness of the main rib 201 is smaller than the thickness of the sub-rib 202 is even larger. Therefore, in this embodiment, it is preferable that the thickness of the main rib 201 is 1.5 times the thickness of the sub-rib 202.

[0071] The basic principles, main features, and advantages of this application have been described above. Those skilled in the art will understand that this application is not limited to the above embodiments, that the above embodiments and descriptions in the specification only represent the principles of this application, and that various modifications and improvements to this application are possible without departing from the gist and scope of this application, and that all such modifications and improvements fall within the scope for which protection is sought. The scope for which protection is sought is defined by the attached claims and equivalents. [Explanation of symbols]

[0072] Lower frame for clamping 100 type 200 Headplate 201 Main Rib 202 Subrib 300 Lower frame for material injection molding 310 Connection part 320 Oil Tank 321 Fuel filler cap 322 Partition Plate 323 Notch 330 Mounting part 400 injection units

Claims

1. A method for manufacturing a single or dual injection die-casting machine, including a head plate, a lower frame for material injection, and an injection unit, The head plate and the lower frame for material injection are fixed with a gap between them. If there is one injection unit, the injection unit is mounted in the center of the lower material injection frame so as to be connected to the connection port in the center of the head plate. If there are two injection units, the injection units are mounted symmetrically on both sides of the lower material injection frame so that they are connected to the connection ports on both sides of the head plate. The area between the connection port in the center of the head plate and the connection ports on both sides is the main rib. The region between the connection port and the side edge on both sides of the head plate is a sub-rib. The thickness of the main rib is greater than the thickness of the sub-rib. The width of the main rib is smaller than the width of the sub-rib. The design process for the head plate used in the manufacture of single and dual injection die-casting machines is as follows: Step S100 involves provisionally determining the outer dimensions of the head plate according to the structural dimensions of the injection unit, Step S200 involves calculating the total area on which the head plate is subjected to pressure based on the material injection impact force by the injection unit and the clamping force by the die-casting machine. Step S300: Based on the verification calculation of the strength of the head plate at the clamping force, the proportion of the area of ​​the head plate that is subjected to pressure is provisionally determined by the main ribs and sub-ribs. The process includes step S400, which involves analyzing the stress and strain of the head plate using finite element method simulation software and obtaining dimensional data of the main rib and sub-rib having the minimum stress peak value and minimum deformation. Manufacturing method for single and dual injection die-casting machines.

2. The thickness of the main rib is 1.4 to 1.6 times the thickness of the sub-rib. The width of the main rib is 0.5 to 0.7 times the width of the sub-rib. A method for manufacturing a single- or dual injection die-casting machine as described in claim 1.

3. The lower frame for material injection includes, in order, a connecting part, an oil tank, and a mounting part, The aforementioned connection portion is fixedly connected to the lower clamping frame for attaching the head plate. The aforementioned mounting portion is used for mounting the injection unit. The oil tank has three oil inlets formed in the width direction. When one of the injection units is attached to the mounting portion, the injection unit is connected to the oil filler port in the central portion. When a pair of the injection units are attached to the mounting portion, the injection units are connected to the oil inlets on both sides. A method for manufacturing a single- or dual injection die-casting machine as described in claim 1.

4. The oil tank is divided into multiple regions by multiple partition plates that intersect vertically and horizontally. Notches are formed in the upper part of at least some of the partition plates to allow air circulation between the divided adjacent areas. Notches are formed in the lower part of at least some of the partition plates to allow oil-liquid flow between the divided adjacent regions. A method for manufacturing a single- or dual injection die-casting machine as described in claim 3.

5. The aforementioned step S200 is, Based on the output pressure P of the clamping hydraulic cylinder of the die-casting machine and the piston rod diameter D of the clamping hydraulic cylinder, the clamping force F applied by the clamping hydraulic cylinder to the head plate is determined. Ｓ Step S210 for calculating, The material injection impact force F applied by the injection unit to the head plate Ｃ to kF Ｓ The settings are as follows, where k represents the safety factor in step S220, Formula F Ｃ = P ０ Based on S, the total area S on which the head plate is subjected to pressure is calculated, and P ０ This includes step S230, which represents the output pressure of the injection hydraulic cylinder of the injection unit, A method for manufacturing a single- or dual injection die-casting machine as described in claim 1.

6. The value of the safety factor k is 1.05 to 1.

15. A method for manufacturing a single- or dual injection die-casting machine according to claim 5.

7. The aforementioned step S300 is, Step S310 involves obtaining a relational expression for the width dimension between the main rib and the sub-rib based on the outer dimensions of the head plate, Step S320 involves identifying a critical cross-section for all cross-sections subjected to pressure from the head plate, based on the structural distribution of the main ribs and sub-ribs. Step S330 involves setting a standard and calculating the centroid based on the dimensions and position of each of the critical cross-sections obtained in step S320, Step S340 is to calculate the second moment of area of ​​each critical cross section with respect to the centroid axis based on the formula for the centroid position calculated in step S330, Step S350 involves substituting the calculated equation for the second moment of area into the equation for calculating the bending moment to derive the equation for the maximum bending stress at the critical cross section. The process includes step S360, which involves iteratively calculating the maximum bending stress formula based on a limited clamping force and the allowable stress of the material to obtain the optimal width dimensions of the main rib and the sub-rib, A method for manufacturing a single- or dual injection die-casting machine as described in claim 1.

8. In step S330, with respect to the vertically positioned head plate, a horizontal line passing through the center of the connection port in the central part of the head plate is used as a reference, or a horizontal line passing through the center of the connection ports on both sides of the head plate is used as a reference. A method for manufacturing a single- or dual injection die-casting machine according to claim 7.

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