经典的流道与浇口设计系统教材(压铸).ppt

Click to edit Master title style,Click to edit Master text styles,Second Level,Third Level,Fourth Level,Fifth Level,Castec,AUSTRALIA,流道與澆口設計系統,Designing Runner and Gating Systems,T.H.Siauw,Castec Australia Pty.Ltd.,1,產品背景,Product background,經過,CSIRO,的15年研發,Over 15 years R&D by CSIRO,在,MS-WINDOWS,環境下操作,Operate under MS-WINDOWS,由,CASTEC,作全球性行銷,Marketed worldwide by Castec Australia,2,模具設計的特性,Die Design Features,機械特性:模具分佈&各部界面,Mechanical features:die layout&parting face,流動特性:流道&澆口,Fluid flow features:runner and gate,熱流特性:冷卻&加熱,Thermal features:cooling&heating,3,模具設計電腦輔助工具,Computer-Aided die design tools,機械性:,Autocad,Unigraphics,(,Mechanical features:Autocad,Unigraphics),流動特性:,CASTFLOW,Fluid flow features:CASTFLOW,熱流特性:,CASTHERM,Thermal features:CASTHERM,4,模具設計之整合,Integrated Die Design,模具設計,Die Design,流道設計:,CASTFLOW,Runner Design,冷卻&加熱,Cooling/Heating,CASTHERM,NC,加工,NC Machining,IGES,5,充填模式法,(,Fill Pattern based approach),1.,決定充填模式,Define fill pattern,2.設計流道&澆口,Design runner&gate,充填模式達到?,Fill pattern achieved?,3.分析,(,Analyze),OK?,No,No,Yes,6,“充填模式”,是什么,?,What is fill pattern?,7,怎樣才是好的充填模式?,What is a good fill pattern?,應避免鎂湯在模穴中旋轉形成旋渦而包夾空氣,Avoid metal swirling in cavity forming vortices,which trap air,8,9,?,應避免,两个金属流前面在摸穴中,會合,Avoids metal fronts meeting in cavity,怎樣才是好的充填模式?,What is a good fill pattern?,10,11,12,怎樣才是好的充填模式?,What is a good fill pattern?,避免兩道或多道金屬流在模穴中會合而包夾空氣,Avoid two or more metal fronts meeting in cavity,which trap air,包夾空氣,Air trap,13,14,哪一種流道形狀好?,Which runner geometry?,扇形開口,Fan/Chisel Gate,錐形流道,Tapered runner,15,常見的錯誤觀念,：,浇口速度是一致的,Common mistaken idea:Gate velocity is uniform,扇形流道,Fan/Chisel Gate,錐形流道,Tapered runner,16,扇形流道:,浇口速度,不一致,Fan gate speed:Not uniform,扇形流道,Fan/Chisel Gate,17,不一致的澆口速度的結果,Consequences of non uniform gate speed,扇形流道,Fan/Chisel Gate,高速會引起模具腐蝕或黏模,High speed causes Die erosion and/or,soldering,低速會引起澆口堵塞,或冷模瑕疵,Low speed causes gate blockage and/or,cold shut defects,18,扇形流是不被推薦的話!,Fan gating system is not recommendable!,扇形流道,Fan/Chisel Gate,高速會引起模具腐蝕或黏模,High speed causes Die erosion and/or,soldering,低速會引起澆口堵塞,或冷模瑕疵,Low speed causes,gate blockage and/or,cold shut defects,19,錐形流道:澆口速度一致,Tapered Runner:Gate speed is uniform,錐形流道,Tapered runner,20,常見的錯誤:金屬流動的方向是因為撞擊到模壁,Common mistaken idea:The change in flow direction is caused by metal impinging the core,錐形流道,Tapered runner,流動方向之改變,change in flow direction,21,例如,:,金屬流動的方向,没改变Example:metal jets out of gate do not change direction when they impinge the cavity walls,澆口速度,向量,金屬流,上与下，但方向大概一样,。,Metal flows up and down in an approximately the same direction as it first flows out of the gate,22,以模具設計者的角度而言錐形流道的重要性是:,1.)流角,The significance of tapered runner from die designers point of view are:1.Flow Angle,錐形流道,Tapered runner,流角,Flow angle,23,2.)流角將構成充填區:,2.,Flow angle leads to Zone of fill:,錐形流道,Tapered runner,非直接充填區,Ungated zone,直接充填區,Gated zone,24,雙錐形流道流道會有三個區,The twin tapered runner results in three zone of fills,left,zone,Right,zone,中區,Centre zone,三角洲區,Delta gate,右區,左區,25,流道&澆口的形狀大小影響充填區域的分佈,Runner&gate geometry affects zone of fills,left,zone,Right,zone,Centre,zone,直接充填區,Gated zone,非直接充填區,Ungated zone,26,充填區域=充填模式,Zone of fills=Cavity Fill Pattern,left,zone,Right,zone,Centre,zone,直接充填區,Gated zone,非直接充填區,Ungated zone,27,模穴之充填模式可以,定性的,Cavity fill pattern is qualitative,錐形流道,Tapered runner,28,充填區域是可以,定,量的,Zone of fill is Quantitative,锥形流道,Tapered runner,非直接充填區,Ungated zone,直接充填區,Gated zone,區域體積,Zone volume,與模面接觸之表面積,Surface area in contact with die,最大充填距離,Maximum flow distance,29,样板,30,31,左边区,右边区,中间区,32,Castflow,流道分析,33,CASTFLOW,流道是三位的,34,Bearing2.dmt,35,非直接充填區,36,steer.dmt,37,Handle.dmt,滑快,滑快,滑快,38,有问题做搞产品？,.,用,CASTFLOW,流道与浇口的设计就没有问题,流向是,CASTFLOW,预言的,box-casting.dmt,39,phone.dmt,40,DOOR-knob.DMT,流向是,CASTFLOW,预言的,41,door-handle.dmt,Castflow,流道,比较小,42,tap-handle.dmt,Castflow,流道,比较小,43,44,45,46,以前的,流道 比,CASTFLOW,流道,以前的流道,CASTFLOW,流道,47,很厚的产品,48,很小的产品,49設計冷卻與加熱系統,Designing cooling and heating system,T.H.Siauw,Castec Australia Pty.Ltd.,50,練習,請依下面指示做?,Exercise,Please do the following,畫出冷卻管,Draw the cooling circuit,標示出與分模面之距離,Show the distance from the parting face,51,問題在哪,?,The problem,?,?,?,?,需要幾個迴路,在哪裡?,How many and circuit layout?,距模面多遠?,Cooling distance from die surface?,冷卻劑種類:水/油?,Coolant type oil or Water?,冷卻劑流動條件?,Coolant flow condition?,52,分什麼要分析?模溫的影響,Why analyse?Die temperature affects,鑄件品質,Casting Quality,模具壽命,Die life,生產效率,Production rate,53,實驗:利用,CASTHERM,研究對下面兩項的影響:,An experiment:,use CASTHERM to study the effect of,水流率,water flow rate and,冷卻距離對模面溫度,cooling distance on die surface temperature,距离,distance,54,水流率&冷卻距離的效益,Effect of water flow rate&cooling distance,distance,溫度,Temperature,水流率,Flow rate,55,模具冷卻&加熱設計的方法,Die Cooling/Heating Design Procedures,大姆指法(經驗法),Rule of thumb-experience based,Castherm,法,CASTHERM procedure,56CASTHERM,方法,CASTHERM Procedure,水管定位,(,Locate channel),計算溫度,Calculate,temperature,可接受,(,Acceptable?),修改,(,Modify),開模,(,Build die),57,2,D,分析-,CASTHERM,2,D analysis-CASTHERM,58,為何不是3,D?,Why not 3D?,模具圖仍未做到3,D,3,D die drawings are not readily available,只能鑽直的孔,Drilled holes are straight,導熱區的概念引入已考慮3,D:,體積&表面積,Thermal zone concept takes into account 3D entities-volume&surface area,根據經驗:五個剖面就足夠,Experience suggests up to 5 die sections are sufficient,59,樣品1:,2,D,已足夠,Sample 1:2D sections are sufficient,60,樣品1:,2,D,已足夠,Sample 2:2D sections are sufficient,61,樣品1:,2,D,已足夠,Sample 3:Three 2D sections are sufficient,62,