经典的流道与浇口设计系统教材(压铸)

CastecAUSTRALIA流道與澆口設計系統DesigningRunnerandGatingSystemsT.H.SiauwCastecAustraliaPty.Ltd.CastecAUSTRALIA產品背景Productbackground經過CSIRO的15年研發Over15yearsR&DbyCSIRO在MS-WINDOWS環境下操作OperateunderMS-WINDOWS由CASTEC作全球性行銷MarketedworldwidebyCastecAustraliaCastecAUSTRALIA模具設計的特性DieDesignFeatures機械特性:模具分佈&各部界面Mechanicalfeatures:dielayout&partingface流動特性:流道&澆口Fluidflowfeatures:runnerandgate熱流特性:冷卻&加熱Thermalfeatures:cooling&heatingCastecAUSTRALIA模具設計電腦輔助工具Computer-Aideddiedesigntools機械性:Autocad,Unigraphics(Mechanicalfeatures:Autocad,Unigraphics)流動特性:CASTFLOWFluidflowfeatures:CASTFLOW熱流特性:CASTHERMThermalfeatures:CASTHERMCastecAUSTRALIA模具設計之整合IntegratedDieDesign模具設計DieDesign流道設計:CASTFLOWRunnerDesign冷卻&加熱Cooling/HeatingCASTHERMNC加工NCMachiningIGESCastecAUSTRALIA充填模式法(FillPatternbasedapproach)1.決定充填模式Definefillpattern2.設計流道&澆口Designrunner&gate充填模式達到?Fillpatternachieved?3.分析(Analyze)OK?NoNoYesCastecAUSTRALIA“充填模式”是什么?Whatisfillpattern?CastecAUSTRALIA怎樣才是好的充填模式?Whatisagoodfillpattern?應避免鎂湯在模穴中旋轉形成旋渦而包夾空氣AvoidmetalswirlingincavityformingvorticeswhichtrapairCastecAUSTRALIACastecAUSTRALIA?應避免两个金属流前面在摸穴中會合Avoidsmetalfrontsmeetingincavity怎樣才是好的充填模式?Whatisagoodfillpattern?CastecAUSTRALIACastecAUSTRALIACastecAUSTRALIA怎樣才是好的充填模式?Whatisagoodfillpattern?避免兩道或多道金屬流在模穴中會合而包夾空氣Avoidtwoormoremetalfrontsmeetingincavitywhichtrapair包夾空氣AirtrapCastecAUSTRALIACastecAUSTRALIA哪一種流道形狀好?Whichrunnergeometry?扇形開口Fan/ChiselGate錐形流道TaperedrunnerCastecAUSTRALIA常見的錯誤觀念：浇口速度是一致的Commonmistakenidea:Gatevelocityisuniform扇形流道Fan/ChiselGate錐形流道TaperedrunnerCastecAUSTRALIA扇形流道:浇口速度不一致Fangatespeed:Notuniform扇形流道Fan/ChiselGateCastecAUSTRALIA不一致的澆口速度的結果Consequencesofnonuniformgatespeed扇形流道Fan/ChiselGate高速會引起模具腐蝕或黏模HighspeedcausesDieerosionand/orsoldering低速會引起澆口堵塞或冷模瑕疵Lowspeedcausesgateblockageand/orcoldshutdefectsCastecAUSTRALIA扇形流是不被推薦的話!Fangatingsystemisnotrecommendable!!!!扇形流道Fan/ChiselGate高速會引起模具腐蝕或黏模HighspeedcausesDieerosionand/orsoldering低速會引起澆口堵塞或冷模瑕疵Lowspeedcausesgateblockageand/orcoldshutdefectsCastecAUSTRALIA錐形流道:澆口速度一致TaperedRunner:Gatespeedisuniform錐形流道TaperedrunnerCastecAUSTRALIA常見的錯誤:金屬流動的方向是因為撞擊到模壁Commonmistakenidea:Thechangeinflowdirectioniscausedbymetalimpingingthecore錐形流道Taperedrunner流動方向之改變changeinflowdirectionCastecAUSTRALIA例如:金屬流動的方向没改变Example:metaljetsoutofgatedonotchangedirectionwhentheyimpingethecavitywalls澆口速度向量金屬流上与下，但方向大概一样。MetalflowsupanddowninanapproximatelythesamedirectionasitfirstflowsoutofthegateCastecAUSTRALIA以模具設計者的角度而言錐形流道的重要性是:1.)流角Thesignificanceoftaperedrunnerfromdiedesigner’spointofvieware:1.FlowAngle錐形流道Taperedrunner流角FlowangleCastecAUSTRALIA2.)流角將構成充填區:2.FlowangleleadstoZoneoffill:錐形流道Taperedrunner非直接充填區Ungatedzone直接充填區GatedzoneCastecAUSTRALIA雙錐形流道流道會有三個區ThetwintaperedrunnerresultsinthreezoneoffillsleftzoneRightzone中區Centrezone三角洲區Deltagate右區左區CastecAUSTRALIA流道&澆口的形狀大小影響充填區域的分佈Runner&gategeometryaffectszoneoffillsleftzoneRightzoneCentrezone直接充填區Gatedzone非直接充填區UngatedzoneCastecAUSTRALIA充填區域=充填模式Zoneoffills=CavityFillPatternleftzoneRightzoneCentrezone直接充填區Gatedzone非直接充填區UngatedzoneCastecAUSTRALIA模穴之充填模式可以定性的Cavityfillpatternisqualitative錐形流道TaperedrunnerCastecAUSTRALIA充填區域是可以定量的ZoneoffillisQuantitative锥形流道Taperedrunner非直接充填區Ungatedzone直接充填區Gatedzone•區域體積Zonevolume•與模面接觸之表面積Surfaceareaincontactwithdie•最大充填距離MaximumflowdistanceCastecAUSTRALIA样板CastecAUSTRALIACastecAUSTRALIA左边区右边区中间区CastecAUSTRALIACastflow流道分析CastecAUSTRALIACASTFLOW流道是三位的CastecAUSTRALIABearing2.dmtCastecAUSTRALIA非直接充填區CastecAUSTRALIAsteer.dmtCastecAUSTRALIAHandle.dmt滑快滑快滑快CastecAUSTRALIA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.dmtCastecAUSTRALIAphone.dmtCastecAUSTRALIADOOR-knob.DMT流向是CASTFLOW预言的CastecAUSTRALIAdoor-handle.dmtCastflow流道比较小CastecAUSTRALIAtap-handle.dmtCastflow流道比较小CastecAUSTRALIACastecAUSTRALIACastecAUSTRALIACastecAUSTRALIA以前的流道比CASTFLOW流道以前的流道CASTFLOW流道CastecAUSTRALIA很厚的产品CastecAUSTRALIA很小的产品CastecAUSTRALIA設計冷卻與加熱系統DesigningcoolingandheatingsystemT.H.SiauwCastecAustraliaPty.Ltd.CastecAUSTRALIA練習,請依下面指示做?Exercise,Pleasedothefollowing畫出冷卻管Drawthecoolingcircuit標示出與分模面之距離ShowthedistancefromthepartingfaceCastecAUSTRALIA問題在哪?Theproblem????需要幾個迴路,在哪裡?Howmanyandcircuitlayout?距模面多遠?Coolingdistancefromdiesurface?冷卻劑種類:水/油?CoolanttypeoilorWater?冷卻劑流動條件?Coolantflowcondition?CastecAUSTRALIA分什麼要分析?模溫的影響Whyanalyse?Dietemperatureaffects鑄件品質CastingQuality模具壽命Dielife生產效率ProductionrateCastecAUSTRALIA實驗:利用CASTHERM研究對下面兩項的影響:Anexperiment:useCASTHERMtostudytheeffectof水流率waterflowrateand冷卻距離對模面溫度coolingdistanceondiesurfacetemperature距离distanceCastecAUSTRALIA水流率&冷卻距離的效益Effectofwaterflowrate&coolingdistancedistance溫度Temperature水流率FlowrateCastecAUSTRALIA模具冷卻&加熱設計的方法DieCooling/HeatingDesignProcedures大姆指法(經驗法)Ruleofthumb-experiencebasedCastherm法CASTHERMprocedureCastecAUSTRALIACASTHERM方法CASTHERMProcedure水管定位(Locatechannel)計算溫度Calculatetemperature可接受(Acceptable?)修改(Modify)開模(Builddie)CastecAUSTRALIA2D分析-CASTHERM2Danalysis-CASTHERMCastecAUSTRALIA為何不是3D?Whynot3D?模具圖仍未做到3D3Ddiedrawingsarenotreadilyavailable只能鑽直的孔Drilledholesarestraight導熱區的概念引入已