Split Mold Thermal Deformation Compensation

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Solution Overview

Problem

The split-type water-cooling side die in aluminum alloy wheel casting experiences significant thermal deformation issues, leading to dimensional inaccuracies, mold damage, and increased costs due to flashing, aluminum-sticking, and reduced mold lifetime, making it difficult to maintain precise matching and extend mold service life.

Innovation Solution

A split-type mold design with thermal deformation arc compensation surfaces on the lower die and V-gaps on the upper die matching surfaces, allowing for precise matching and stress reduction, thereby addressing thermal expansion and contraction challenges.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If water-cooling is applied to the split-type side die, then cooling effect is improved, but thermal deformation and temperature difference between areas increase

Engineering Contradiction:

Improvecooling effectVSAvoiddimensional accuracy

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The side die is divided into multiple segments (first side die segment, second side die segment, third side die segment, fourth side die segment) arranged circumferentially. Each segment can be independently cooled and adjusted, allowing localized temperature control to reduce thermal deformation while maintaining overall cooling effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different cooling strategies are applied to different regions of the side die. Water-cooling channels are strategically positioned, and compensation surfaces are selectively applied to specific matching surfaces based on their thermal deformation characteristics, optimizing both cooling efficiency and dimensional stability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If split-type structure is used for side die, then assembly simplicity and repair cost are improved, but thermal deformation difference between segments increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidmatching accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Thermal deformation compensation surfaces are pre-machined on the matching surfaces of the side die segments during manufacturing. These compensation surfaces account for expected thermal expansion and contraction, ensuring accurate matching even when temperature changes occur during operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The geometry of the matching surfaces is modified by introducing thermal deformation compensation. The compensation surfaces have specific arc radii and dimensional relationships that compensate for thermal effects, transforming the static geometry into a thermally adaptive configuration.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If thermal deformation compensation surfaces are added, then matching precision is improved, but device complexity increases

Engineering Contradiction:

Improvematching precisionVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Thermal deformation compensation surfaces with specific arc radii are introduced on the matching surfaces. These curved surfaces naturally accommodate thermal expansion and contraction patterns, achieving compensation through geometric form rather than complex mechanical adjustment mechanisms.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 solution enhances arc matching precision, reduces stress and mold damage, decreases flashing and aluminum-sticking, and significantly extends mold service life, improving casting accuracy and reducing production costs.

Implementation Method 1

the temperature of the water-cooling portion is lower, the shrinkage of the mold at this portion is more serious

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Implementation Method 2

thermal expansion and cold contraction of the split-type mold

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS9616491B2Split-type mold for wheel casting

Publication Date: 2017.04.11 CITIC DICASTAL CO LTD

AI summary

The invention provides a split-type mold for wheel casting, the mold having an upper die, a split-type water-cooling side die and a lower die, and the split-type water-cooling side die is divided into four pieces along a circumferential direction of the wheel mold. A thermal deformation arc compensation surface is machined on ¼ arc portion of each split-type water-cooling lower side die, and a compensation surface is machined on key portions of 45-degree matching surfaces of adjacent split-type water-cooling upper side dies. The side die can effectively solve the problems such as untight matching between the matching surfaces, flashes of the matching surfaces and aluminum sticking and the like due to the thermal deformation and non-homogeneous expansion and shrinkage of the two portions of the split-type water-cooling side die.