Manufacturing method for single and dual injection die casting machines

Abstract

This application discloses a method for manufacturing a single-dual injection die casting machine, which includes a head plate, a lower material injection frame, and an injection unit. The head plate and the lower material injection frame are fixed at a distance from each other. When there is one injection unit, the injection unit is attached to the center of the lower material injection frame so that it connects to the connection port in the center of the head plate. When there are two injection units, the injection units are symmetrically attached to both sides of the lower material injection frame so that they connect to the connection ports on both sides of the head plate. The head plate design method can be used to design head plates used in manufacturing the above-mentioned single-dual injection die casting machine. A beneficial effect of this application is that, compared to the conventional two independent methods of single die casting and dual die casting, this application can achieve two modes, single injection and dual injection, by simply changing the number of injection units, which can be independently adjusted according to actual production needs. This effectively broadens the application scope of this application and effectively reduces production costs.

Description

[Technical Field]

[0001] The present application relates to the technical field of die casting machines, and in particular to a manufacturing method for a single-dual injection die casting machine. [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, and as a result, the dimensions of metal products that can be produced by die casting have gradually become larger, such as the integral molding of automobile bodies by die casting.

[0003] As the size of die-cast products increases, the distance to the corresponding mold cavity of the die-casting mold becomes increasingly longer. When using a conventional die-casting machine to cast large products, the single-injection method requires a relatively long die-casting time, which ultimately affects the processing accuracy of the product. Therefore, the prior art proposed a dual-injection die-casting machine. That is, the die-casting machine has two injection mechanisms that can simultaneously cast into the die-casting mold to improve die-casting efficiency and die-casting accuracy.

[0004] However, conventional single injection die casting machines and dual injection die casting machines are usually used independently, so when a company produces products of different types and sizes, it needs to purchase both a single injection die casting machine and a dual injection die casting machine, which results in an increase in the production costs of the products. Summary of the Invention [Problem to be solved by the invention]

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

[0006] Another object of the present 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-mentioned objectives, the technical solution adopted in this application is a manufacturing method for a single-dual injection die-casting machine, which includes 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 at a distance from each other, When the number of the injection unit is one, the injection unit is attached to the center of the lower frame for material injection so as to be connected to the connection port in the center of the head plate; When the number of the injection units is two, the injection units are symmetrically mounted on both sides of the material injection lower frame so as to be connected to the connection ports on both sides of the head plate, respectively.

[0008] Preferably, the area between the connection port in the center of the head plate and the connection ports on both sides is a main rib, The areas between the connection ports and the side edges on both sides of the head plate are sub-ribs, 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 material injection lower frame includes a connection part, an oil tank and a mounting part, which are arranged in this order; The connection portion is fixedly connected to a lower mold clamping frame for mounting the head plate, the mounting portion is used to mount the injection unit, The oil tank is formed with three oil filler openings in the width direction, When one injection unit is attached to the attachment portion, the injection unit is connected to the fuel filler port in the center portion, When a pair of the injection units are attached to the attachment portion, the injection units are connected to the fuel filler ports on both sides.

[0011] Preferably, the oil tank is divided into a plurality of regions by a plurality of partition plates intersecting vertically and horizontally, A notch is formed in the upper portion of at least some of the partition plates so as to allow air circulation between adjacent divided areas, At least some of the partition plates have notches formed in the lower portions thereof so as to allow oil and liquid to flow between adjacent divided regions.

[0012] The design process of the head plate used in the manufacture of the above single-dual injection die-casting machine is as follows: Step S100: provisionally determining the outer dimensions of the head plate according to the structural dimensions of the injection unit; Step S200: calculating a total area of ​​the head plate subjected to pressure based on the material injection impact force of the injection unit and the mold clamping force of the die-casting machine; Step S300: determining a ratio of the area of ​​the head plate subjected to pressure, which is occupied by the main rib and the sub-rib formed between the plurality of connection ports, based on a verification calculation of the strength of the head plate under the mold clamping force; and step S400: performing stress and strain analysis on the head plate using finite element simulation software to obtain the thickness dimensions of the main rib and the sub-rib with the minimum stress peak value and minimum deformation.

[0013] Preferably, step S200 includes: The clamping force F applied to the head plate by the clamping hydraulic cylinder 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 Step S210 of calculating The material injection impact force F applied by the injection unit to the head plate C kF S Step S220: Set as follows, where k represents a safety coefficient: formula F C and step S230: calculating the total area S of the head plate subjected to pressure based on =P0·S, where P0 represents the output pressure of the injection hydraulic cylinder of the injection unit.

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

[0015] Preferably, step S300 includes: Step S310: 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: identifying critical sections for all sections subjected to pressure of the head plate based on the structural distribution of the main ribs and the sub-ribs; Step S330: setting a reference and calculating a centroid based on the dimensions and positions of each of the critical cross sections obtained in step S320; Step S340: calculating the moment of inertia of each of the critical cross sections with respect to the centroid axis based on the equation for the position of the centroid calculated in step S330; Step S350: Substituting the calculated equation for the moment of inertia into a bending moment calculation equation to derive an equation for the maximum bending stress at the critical section; and step S360 of performing iterative calculations on the formula for the maximum bending stress based on the limited clamping force and allowable stress of the material to obtain the optimal width dimensions of the main rib and the sub-rib.

[0016] Preferably, in step S330, for a head plate positioned vertically, the reference is a horizontal line passing through the center of the connection port in the center of the head plate, or a horizontal line passing through the centers of the connection ports on both sides of the head plate.

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

[0018] Compared with the conventional two independent methods of single die casting and dual die casting, the present invention can realize two modes of single injection and dual injection by simply changing the number of injection units, which can be independently adjusted according to actual production demands, thereby effectively expanding the application scope of the present invention and effectively reducing production costs. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 is a schematic diagram of the overall structure of a single-dual injection die-casting machine in accordance with the present invention, in which two injection units are installed. [Figure 2] FIG. 1 is a structural schematic diagram of the single-dual injection die-casting machine of the present application with the injection unit removed. [Figure 3] FIG. 2 is a schematic diagram of a partial structure of a head plate in the present application. [Figure 4] FIG. 2 is a structural schematic diagram of the lower frame for material injection in the present application. [Figure 5] 1 is a schematic flowchart of a method for designing a head plate according to the present application. [Figure 6] 1 is a stress cloud map from a finite element simulation of the head plate in the present application. [Figure 7] 7 is a stress cloud map obtained by finite element method simulation of Comparative Example 1 of the head plate shown in FIG. 6 in the present application. [Figure 8] 7 is a stress cloud map obtained by finite element method simulation of Comparative Example 2 of the head plate shown in FIG. 6 in the present application. [Figure 9] 1 is a strain cloud map from a finite element simulation of the head plate in the present application. [Figure 10] 10 is a strain cloud map obtained by finite element method simulation of Comparative Example 1 of the head plate shown in FIG. 9 in the present application. [Figure 11] 10 is a strain cloud map obtained by finite element method simulation of Comparative Example 2 of the head plate shown in FIG. 9 in the present application. DETAILED DESCRIPTION OF THE INVENTION

[0020] The present application will be further described below in connection with specific embodiments. In this specification, references to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "several examples" mean that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In this specification, exemplary expressions for the above terms should not be construed as necessarily being limited to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any appropriate manner in any one or more embodiments or examples. Furthermore, those skilled in the art may combine or combine different embodiments or examples described herein.

[0021] In the description of this application, the orientations or positional relationships indicated by directional terms, such as the terms "center," "lateral," "longitudinal," "length," "width," "thickness," "up," "down," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," "clockwise," and "counterclockwise," are orientations or positional relationships shown based on the drawings, and are intended solely for the convenience and simplification of the description of this application. They do not state or imply that the devices or elements shown therein must necessarily have a specific orientation or be configured or operated in a specific orientation, and should not be understood as limiting the specific scope of protection of this application.

[0022] In addition, the terms "first," "second," etc. in the specification and claims of this application are used to distinguish between similar objects and are not necessarily used to describe a specific order or chronology.

[0023] In this application, unless otherwise clearly specified or limited, technical terms such as "attach," "interconnect," "connect," and "fix" should be understood in a broad sense. For example, they may be connected, detachably connected, or integral. They may be mechanically connected or electrically connected. They may be directly connected, indirectly connected through an intermediate medium, or may be internal communication between two elements or an interactive relationship between two elements. Those skilled in the art can understand the specific meanings of the above terms in the present invention according to specific circumstances.

[0024] In this application, unless otherwise clearly specified or limited, a first feature being "above" or "below" a second feature may include a case where the first feature and the second feature are in direct contact with each other, or a case where the first feature and the second feature are not in direct contact but are in contact with each other through another feature interposed therebetween. A first feature being "above," "above," or "upper side" of a second feature may include a case where the first feature is directly above or diagonally above the second feature, or may simply mean that the horizontal height of the first feature is greater than that of the second feature. A first feature being "below," "below," or "below" a second feature may include a case where the first feature is directly below or diagonally below the second feature, or may simply mean that the horizontal height of the first feature is smaller than that of the second feature.

[0025] The technical terms "comprise" and "have" and all variations thereof in the present specification and claims are intended to cover a non-exclusive inclusion. For example, a process, method, system, product, or apparatus comprising a series of steps or units is not necessarily limited to the explicitly stated steps or units, but may include other steps or units not explicitly stated or inherent to the process, method, product, or apparatus.

[0026] One aspect of the present application provides a method for manufacturing a single-dual injection die-casting machine. As shown in FIGS. 1 and 2, a preferred embodiment of the method includes a head plate 200, a material injection lower frame 300, and an injection unit 400. The head plate 200, which is used to attach a die-casting mold (not shown), is fixed. Three connection ports are formed in the head plate 200 in the width direction, one of which is located in the central region of the head plate 200, and the remaining two connection ports are located on either side of the central connection port. The material injection lower frame 300, which is used to attach 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 attached to the center of the material injection lower frame 300 so that it is connected to the central connection port of the head plate 200. If dual injection die casting is required, two injection units 400 may be symmetrically mounted on both sides of the lower material injection frame 300 so as to be connected to the connection ports on both sides of the head plate 200, respectively.

[0027] Furthermore, in the case of the single / dual injection die casting machine of the present application, the number and overall connection relationship of the head plates 200 and material injection lower frames 300 do not change in either single injection die casting or dual injection die casting; only the number and installation positions of the injection units 400 change. This means that companies can achieve single injection die casting and dual injection die casting with a maximum of three injection units 400. Compared to the conventional method requiring two die casting facilities, this application effectively expands the scope of application and reduces production costs.

[0028] The model numbers of the injection units 400 employed in the single injection mode and dual injection mode of the present application may be the same or different. For injection units 400 of the same model number, the present application requires only two injection units 400 to realize the single injection mode and dual injection mode of the die casting machine. For injection units 400 of different model numbers, the present application requires three injection units 400 to realize the single injection mode and dual injection mode of the 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 principles of the injection unit 400 are well known to those skilled in the art, and therefore will not be described in detail here.

[0029] 1 to 3, in this embodiment, the area between the connection port in the center of the head plate 200 and the connection ports on both sides 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 on the head plate 200 are used to connect to the material injection plungers provided on the injection unit 400. To facilitate the attachment of the material injection plungers, the areas near the connection ports on the head plate 200 must each have a relief structure. In single-injection die casting, the material injection impact force applied by the injection unit 400 to the head plate 200 is concentrated mainly near the main rib 201. 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-injection die casting and dual-injection die casting, the main rib 201 receives the impact. That is, the main rib 201 experiences a harsher operating environment than the sub-rib 202. The material injection impact force applied by the injection unit 400 primarily causes bending deformation of the head plate 200. Therefore, when designing the main ribs 201 and the sub-ribs 202, the thickness of the main ribs 201 is designed to be greater than the thickness of the sub-ribs 202, thereby ensuring that the position of the main rib 201 has a stronger bending section modulus and ensuring the operational safety of the head plate 200. Meanwhile, when designing the width of the main ribs 201 and the sub-ribs 202, the larger the dimension of the head plate 200, the heavier the corresponding weight becomes, so the width of the main ribs 201 and the sub-ribs 202 needs to be as small as possible on the premise that the structural strength is satisfied. Considering the design dimensions of the thickness of the main ribs 201 and the sub-ribs 202, the width of the sub-ribs 202 needs to be designed to be greater than the width of the main rib 201 in order for the sub-ribs 202 to meet the structural strength requirements.

[0031] Specifically, the dimensional design of the thickness and width of the main rib 201 and the sub-rib 202 will be described in detail below through a specific design method. The design dimensions that can ensure good performance of the head plate 200 are such 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 FIGS. 1 and 2, the material injection lower frame 300 includes a connection portion 310, an oil tank 320, and a mounting portion 330, which are arranged in this order. The connection portion 310 is fixedly connected to the lower clamping frame 100, which mounts the head plate 200. This ensures the structural stability of the entire die casting machine and the accuracy of the material injection process. The mounting portion 330 is used to mount the injection unit 400, and the oil tank 320 has three oil filler ports 321 formed in the width direction. When one injection unit 400 is mounted on the mounting portion 330, the injection unit 400 is connected to the central oil filler port 321. When a pair of injection units 400 are mounted on the mounting portion 330, the injection units 400 are connected to the oil filler ports 321 on both sides.

[0033] 4, the oil tank 320 is divided into multiple regions by multiple partition plates 322 that intersect vertically and horizontally. To allow air to circulate between adjacent divided regions, at least some of the partition plates 322 have cutouts 323 formed in the upper part. To allow oil to circulate between adjacent divided regions, at least some of the partition plates 322 have cutouts 323 formed in the lower part.

[0034] The central region of the oil tank 320 is the main oil return region, which is the main oil return passage, and the two sides of the oil tank 320 are sub-oil return regions. In dual injection mode, the partition plate 322 effectively reduces the impact of the oil return flow, thereby stabilizing the oil flow. As a result, noise and vibration are reduced, improving the stability and reliability of material injection from the injection unit 400. Furthermore, the notch 323 formed at the bottom of the partition plate 322 ensures the oil flow in each region of the oil tank 320 while also reducing the circulation speed, contributing to the cooling and heat dissipation of the oil, the generation of bubbles, and the precipitation of impurities.

[0035] Another aspect of the present application provides a method for designing a head plate used in manufacturing the above-mentioned single-dual injection die casting machine. As shown in Figure 5, one preferred embodiment of the method 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 of ​​the head plate 200 subjected to pressure is calculated based on the material injection impact force of the injection unit 400 and the mold clamping force of the die-casting machine.

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

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

[0040] In step S100, the outer dimensions of the head plate 200 depend primarily on the mounting dimensions of the injection units 400 in dual injection mode. Specifically, the width of a single injection unit 400 may be A, and the minimum distance required to ensure proper mounting of two injection units 400 may be B. Because the material injection plunger of each injection unit 400 is typically located in the center of the injection unit 400, the minimum distance between the two connection ports on the head plate 200 for dual injection die casting is A+B. Next, based on the design dimensions of the connection ports, analyze 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 widthwise contour dimension L of the head plate 200 is at least A+B+2C. Here, C represents the distance from the edge of the sub-rib 202 to the center of the connection port on the same side, which satisfies the basic structural strength requirements. If the width of the main rib 201 does not satisfy the basic structural strength requirement, the contour dimension L in the width direction of the head plate 200 is at least A+B+2C+D, where D represents the increase in width of the main rib 201 required for the widened main rib 201 to satisfy the basic structural strength requirement. Generally, the head plate 200 has a square structure so 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 that satisfies the basic structural strength may be calculated using a simple strength calculation formula or may be selected based on the experience of a person skilled in the art. This dimension is merely a tentatively determined dimension 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 FIGS. 1 to 3 , the connection port areas of the head plate 200 are all designed with a relief structure, which facilitates the later installation of the material injection plungers at the connection port locations and reduces the weight of the head plate 200. The design of the head plate 200 requires as much space as possible for the relief area, while ensuring sufficient structural strength and facilitating the installation of the material injection plungers. 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 pressure-receiving area S can be calculated to obtain the total area of ​​the relief area, and then the specific structure can be determined. For ease of understanding, the specific calculation process of the total area S subjected to pressure in step S200 will be described in detail below.

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

[0044] In step S210, the clamping force F applied to the head plate 200 by the clamping hydraulic cylinder is calculated 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 is C kF S It is set as follows, where k represents a safety coefficient.

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

[0047] When the 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 to resist the material injection impact force of the injection unit 400 during die casting. However, to ensure operational safety during the die-casting process, it is necessary to ensure that the material injection impact force applied to the head plate 200 by the injection unit 400 does not significantly exceed the clamping force. Failure to do so may result in failure of the clamping mechanism. Therefore, the value of the safety factor k in step S220 is generally 1.05 to 1.15, preferably 1.1.

[0048] After calculating the total area S of the head plate 200 subjected to pressure through steps S210 to S230 described above, the total area of ​​the relief regions corresponding to the three connection ports can be obtained simply by subtracting the total area S subjected to pressure from the total cross-sectional area of ​​the head plate 200. Therefore, by performing an accurate calculation based on strength verification on the structural dimensions of the main rib 201 and the sub-ribs 202, the proportions of the total area S subjected to pressure that the main rib 201 and the sub-ribs 202 account for can be obtained. In this way, the width dimensions of the main rib 201 and the sub-rib 202 can be determined based on the positions of the connection ports, and the dimensions of the relief regions at the positions of the connection ports can also be determined. For ease of understanding, the process of calculating the proportions of the total area subjected to pressure that the main rib 201 and the sub-rib 202 account for can be described 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 the sub-ribs 202, a critical section is identified from among all sections that receive pressure from the head plate 200.

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

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

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

[0055] In step S360, based on the limited clamping force and the allowable stress of the material, an iterative calculation is performed on the formula for the maximum bending stress to obtain the optimal width dimensions of the main rib 201 and the sub-rib 202.

[0056] When calculating the centroid in step S330, the reference is determined according to the position where the head plate 200 receives pressure. In single injection mode, the position where the head plate 200 receives pressure is located at the central connection port. In this case, the reference 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 receives pressure are located at the connection ports on both sides. In this case, the reference may be a horizontal line passing through the centers of the connection ports on both sides. In actual use, if the model number of the injection unit 400 used in the single injection mode and the dual injection mode is the same, the heights of the three connection ports are the same, and in this case, the reference is unified. If the model number of the injection unit 400 used in the single injection mode and the dual injection mode is different, the heights of the three connection ports are different, and two references are used. The specific reference is determined according to the worst-case operating conditions experienced by the head plate 200 in the two injection modes.

[0057] In the following, step S300 will be described in detail with respect to specific parameters for ease of understanding.

[0058] 3, if the reference passes through the center of the central connection port and bisects the head plate 200 vertically, the relief areas corresponding to the three connection ports have the same height and are aligned with one another. 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 may be H3.

[0059] From the above analysis, we can obtain the total area subjected to pressure S = 4(X3 × H2) + 4(X1 × H1) + 4[X4 × (H2 + H3)] + 2(X2 × H1), and the width of one side of the head plate 200 L = 2X1 + X2 + 2X3 + 2X4. When L and S are known, we can obtain the relationship between the width X4 of the main rib 201 and the width X3 of the sub-rib 202 in step S310.

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

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

number

[0062] where S i represents the area corresponding to each dangerous cross section, and h i represents the height of the center point relative to the reference point for each dangerous section. For ease of understanding, the dangerous section corresponding to the upper region of the central connection port will be taken as an example below, and if the area of ​​this dangerous 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 moment of inertia J of each critical cross section relative to the axis of the equivalent centroid y is calculated. y The formula for this is:

number

[0064] Here, J yirepresents the moment of inertia of each dangerous section itself. Taking the dangerous section corresponding to the upper region of the central connection port as an example, the moment of inertia of this dangerous section J y1 =X2×H1 3 / 12.

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

[0066] In addition, the maximum bending moment M max may be calculated according to 1.1 times the mold clamping force. b The formula for calculating the maximum bending stress σ is related to the width of the main rib 201 and the sub-rib 202. b and the safe stress [σ] specified in national or industry standards, an equation for the safe stress [σ] for the width of the main rib 201 and the sub-rib 202 can be obtained. Furthermore, by performing iterative calculations on the equation, the width dimensions of the main rib 201 and the sub-rib 202 corresponding to the head plate 200 having optimal structural strength and weight can be obtained. Conversely, based on the obtained width dimensions of the main rib 201 and the sub-rib 202, the structural dimensions of the relief areas corresponding to each connection port can also be determined.

[0067] The structural dimensions of the end face of the head plate 200 can be determined by steps S310 to S360 described above. Meanwhile, the thickness of the head plate 200 is primarily determined by its ability to withstand deformation during material injection impact. Therefore, it is difficult to obtain the optimal thickness of the head plate 200 using numerical calculations. Meanwhile, the finite element method (FEM) can obtain the deformation status of the head plate 200 at microscopic angles using FEM simulations. Therefore, in this embodiment, the thickness dimensions of the main rib 201 and the sub-rib 202 can be obtained using FEM simulations. While there are various common FEM analysis software programs available, for ease of understanding, the following detailed description will be given using ANSYS software as an example of FEM analysis.

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

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

[0070] 9 to 11 show strain distribution cloud maps of the first to third head plates, respectively. The maximum strain generated when the main rib 201 is 412 mm thick and the sub-rib 202 is 276 mm thick is 5.081 mm. The maximum strain generated when the main rib 201 is 462 mm thick and the sub-rib 202 is 326 mm thick is 5.8877 mm. The maximum strain generated when the main rib 201 is 212 mm thick and the sub-rib 202 is 400 mm thick is 6.0483 mm. In this example, the deformation generated when the main rib 201 is 1.5 times thicker than the sub-rib 202 is minimal. The deformation generated when the main rib 201 is 1.4 times thicker than the sub-rib 202 is large. The deformation generated when the main rib 201 is thinner than the sub-rib 202 is even larger. Therefore, in this embodiment, the thickness of the main rib 201 is preferably 1.5 times the thickness of the sub-rib 202 .

[0071] The above has described the basic principles, main features, and advantages of the present application. Those skilled in the art will understand that the present application is not limited to the above embodiments, and that the above embodiments and descriptions in the specification are merely the principles of the present application. Various modifications and improvements to the present application are possible without departing from the spirit and scope of the present application, and all such modifications and improvements are included within the scope of the present application, which is sought to be protected. The scope of protection sought to be protected by the present application is defined by the appended claims and their equivalents. [Explanation of symbols]

[0072] 100 Lower clamping frame 200 Head Plate 201 Main Rib 202 Sublib 300 Lower frame for material injection 310 Connection 320 Oil Tank 321 Fuel filler 322 Partition 323 Notch 330 Mounting part 400 Injection Unit

Claims

1. A manufacturing method for a single-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 therebetween, When the number of the injection unit is one, the injection unit is attached to the center of the lower frame for material injection so as to be connected to the connection port in the center of the head plate; When the number of the injection units is two, the injection units are symmetrically mounted on both sides of the lower frame for material injection so as to be connected to the connection ports on both sides of the head plate, respectively; The area between the connection port in the center of the head plate and the connection ports on both sides is a main rib, The areas between the connection ports and the side edges on both sides of the head plate are sub-ribs, 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 of the head plate used in the manufacture of single and dual injection die casting machines is as follows: Step S100: provisionally determining the outer dimensions of the head plate according to the structural dimensions of the injection unit; Step S200: calculating a total area of ​​the head plate subjected to pressure based on the material injection impact force of the injection unit and the mold clamping force of the die-casting machine; Step S300: provisionally determining the ratio of the main rib and the sub-rib to the area of ​​the head plate subjected to pressure based on a verification calculation of the strength of the head plate under the clamping force; and step S400 of performing stress and strain analysis on the head plate using finite element method simulation software to obtain dimensional data of the main rib and the sub-rib having the minimum stress peak value and the 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.

2. A method for manufacturing a single-dual injection die casting machine according to claim 1.

3. the lower frame for material injection includes a connection part, an oil tank and a mounting part, which are arranged in this order; The connection portion is fixedly connected to a lower mold clamping frame for mounting the head plate, the mounting portion is used to mount the injection unit, The oil tank is formed with three oil filler openings in the width direction, When one injection unit is attached to the attachment portion, the injection unit is connected to the fuel filler port in the center portion, When a pair of the injection units are attached to the attachment portion, the injection units are connected to the fuel filler ports on both sides.

2. A method for manufacturing a single-dual injection die casting machine according to claim 1.

4. The oil tank is divided into a plurality of regions by a plurality of partition plates that intersect vertically and horizontally, A notch is formed in the upper portion of at least some of the partition plates so as to allow air circulation between adjacent divided areas, A notch is formed in the lower portion of at least a part of the partition plate so that oil can flow between adjacent divided regions.

4. The method for manufacturing a single / dual injection die casting machine according to claim 3.

5. Step S200 The clamping force F applied to the head plate by the clamping hydraulic cylinder 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 Step S210 of calculating The material injection impact force F applied by the injection unit to the head plate Ｃ kF Ｓ Step S220: Formula F Ｃ =P ０ Calculate the total area S on which the head plate is subjected to pressure based on S, and P ０ and step S230 representing the output pressure of the injection hydraulic cylinder of the injection unit.

2. A method for manufacturing a single-dual injection die casting machine according to claim 1.

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

15.

6. A method for manufacturing a single / dual injection die casting machine according to claim 5.

7. Step S300 Step S310: 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: identifying critical sections for all sections subjected to pressure of the head plate based on the structural distribution of the main ribs and the sub-ribs; Step S330: setting a reference and calculating a centroid based on the dimensions and positions of each of the critical cross sections obtained in step S320; Step S340: calculating the moment of inertia of each of the critical cross sections with respect to the centroid axis based on the equation for the position of the centroid calculated in step S330; Step S350: Substituting the calculated equation for the moment of inertia into a calculation equation for the bending moment to derive an equation for the maximum bending stress at the critical section; and step S360 of performing an iterative calculation on the formula of the maximum bending stress based on the limited clamping force and the allowable stress of the material to obtain the optimum width dimensions of the main rib and the sub-rib.

2. A method for manufacturing a single-dual injection die casting machine according to claim 1.

8. In step S330, for the head plate arranged vertically, 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 centers of the connection ports on both sides of the head plate is used as a reference.

8. The method for manufacturing a single / dual injection die casting machine according to claim 7.

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