Mould Cooled Core with Planar Flow Cavity for Die-Casting
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Solution Overview
Problem
Current die-casting tools face limitations in heat exchange due to small surface area channels, leading to inefficient temperature control, potential thermal shock, and increased cycle times, as well as high water consumption and risk of tool damage from external cooling methods.
Innovation Solution
A molded part for a die-casting tool featuring a contour insert and core with a flat flow cavity supported by elements, allowing for controlled temperature regulation and even heat distribution, minimizing external cooling needs and enhancing pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If drilled channels are used for cooling the molded part, then temperature control is achieved, but the heat exchange surface area is limited and temperature distribution is uneven
Solution Approach 1:
The invention transitions from one-dimensional drilled channels to a two-dimensional planar cooling channel arranged parallel to the molded part surface. This dimensional change dramatically increases the heat exchange surface area while maintaining close proximity to the molded part, enabling more effective and uniform temperature control.
Solution Approach 2:
The cooling system is segmented into multiple planar cooling channels that can be independently arranged and configured. Each cooling channel segment can be optimized for specific regions of the molded part, allowing for localized temperature control and improved overall temperature distribution uniformity.
2Temperature
If water spraying is used for additional cooling, then cooling effectiveness is improved, but thermal shock and tool damage occur
Solution Approach 1:
The planar cooling channels are integrated into the molded part structure during manufacturing, establishing a controlled cooling pathway before the casting process begins. This preliminary integration ensures that cooling occurs through a designed, gradual heat extraction mechanism rather than sudden external water application, preventing thermal shock.
Solution Approach 2:
The planar cooling channel acts as an intermediary between the molded part and the external cooling medium. Instead of direct water contact with the molded part surface, the cooling medium flows through the intermediate channel structure, providing controlled and distributed cooling that eliminates thermal shock while maintaining cooling effectiveness.
3Temperature
If external water cooling is applied, then cooling capacity is increased, but water consumption increases
Solution Approach 1:
The cooling function is merged directly into the molded part structure by integrating planar cooling channels within the tool body. This integration eliminates the need for separate external cooling systems and water spraying mechanisms, reducing water consumption while maintaining or improving cooling capacity through the optimized channel design.
4Temperature
If conventional cooling methods are used, then cooling is achieved, but cycle times are lengthened
Solution Approach 1:
The transition to two-dimensional planar cooling channels provides substantially increased heat exchange surface area in close proximity to the molded part. This dimensional improvement accelerates heat extraction during the cooling phase, reducing the time required to solidify the casting and thereby shortening the overall cycle time while maintaining effective cooling.
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
This solution achieves uniform temperature control, reduces thermal stress, and shortens cycle times by optimizing heat exchange and pressure resistance within the tool, while minimizing external cooling and potential tool damage.
Implementation Method 1
a flat flow cavity for a fluid medium, through which a medium at a defined temperature can be conducted
Implementation Method 2
Temperature of the cavity can be changed by the medium, which can flow through the at least one flow cavity
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a mold part (2) for a tool for casting a component, wherein the mold part (2) comprises at least one contour insert (4) and at least one core (6) as components, wherein the at least one contour insert (4) has an outer wall (10) which at least partially forms a cavity for the component to be cast, and an inner wall designed as a boundary wall, wherein the at least one core (6) has an outer wall designed as a boundary wall, wherein at least one support element (14) is arranged on a boundary wall of at least one of the two components, and wherein boundary walls of two immediately adjacent components enclose at least one flow cavity (20) for a fluid medium.