Conformal Cooling Insert for Faster Die Casting Cycles
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Solution Overview
Problem
Existing high-pressure die casting processes face inefficiencies in heat removal due to expensive and time-consuming additive manufacturing of cooling inserts with complex channels, leading to prolonged solidification times and potential hot spots.
Innovation Solution
A cooling insert formed of H13 tool steel, manufactured via investment casting, with complex cooling channels located close to the surface, reducing solidification time and cycle duration through conformal cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If additive manufacturing is used to form cooling inserts with complex cooling channels, then cooling channel complexity is improved, but manufacturing cost and time consumption increase
Solution Approach 1:
The patent changes the manufacturing method from additive manufacturing to investment casting, and optimizes the cooling channel parameters (diameter, spacing, depth) to achieve conformal cooling. This resolves the contradiction by providing complex cooling channels through a more cost-effective and time-efficient investment casting process while maintaining the desired channel complexity for effective heat removal.
2Temperature
If cooling channels are located closer to the surface, then heat removal efficiency is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent specifies optimal parameters for cooling channel location (distance from surface equal to 1.5 to 2.0 times the channel diameter) and combines this with investment casting technology. This resolves the contradiction by enabling precise placement of cooling channels close to the surface through the investment casting process, achieving superior heat removal efficiency while managing manufacturing complexity through parameter optimization.
Solution Approach 2:
The patent uses investment casting as an intermediary manufacturing process that enables the creation of complex cooling channel geometries close to the surface. This intermediary process bridges the gap between the desired cooling channel configuration for heat removal and the practical manufacturing capabilities, avoiding the need for more difficult additive manufacturing.
3Ease of manufacture
If conventional cooling inserts are used, then manufacturing simplicity is maintained, but hot spots and prolonged solidification time occur
Solution Approach 1:
The patent implements conformal cooling by positioning cooling channels at specific locations and distances from the die surface, creating localized optimal cooling zones. This resolves the contradiction by using investment casting to achieve precise local cooling quality that eliminates hot spots and reduces solidification time, while maintaining relative manufacturing simplicity compared to additive manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The investment casting process enables efficient, cost-effective, and durable cooling inserts with uniform cooling, reducing solidification time and energy consumption while avoiding hot spots.
Implementation Method 1
water or another cooling fluid flows through the cooling channels to cool the metal
Implementation Method 2
conveying cooling fluid through the at least one cooling channel of the cooling insert while molten metal is disposed in the cavity
Data Source
AI summary
A cooling insert for a die, such as a distributor for a high pressure die casting assembly, and a method of manufacturing the cooling insert, is provided. The cooling insert can be formed of H13 tool steel and is manufactured using an investment casting process, for example, a process which uses a printed investment casting shell. The cooling insert includes complex cooling channels to improve cooling and reduce the duration of the casting process.