经典的流道与浇口设计系统教材(压铸)
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from the parting face
AUSTRALIA
問題在哪?
The problem ?
?
?
需要幾個迴路, 在哪裡?How many and circuit layout?
Castec
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?
T.H. Siauw
Castec
Castec Australia Pty. Ltd.
AUSTRALIA
練習, 請依下面指示做?
Exercise, Please do the following
畫出冷卻管 Draw the cooling circuit
Castec
標示出與分模面之距離 Show the distance
features: die layout & parting face
熱流特性:
heating
Castec
AUSTRALIA
模具設計電腦輔助工具
Computer-Aided die design tools
機械性:
(Mechanical features: Autocad, Unigraphics)
2. Flow angle leads to Zone of fill:
非直接充填區
Ungated zone
直接充填區 Gated zone
Castec
錐形流道Tapered runner
AUSTRALIA
雙錐形流道流道會有三個區
The twin tapered runner results in three zone of fills
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
澆口速度向 量
Castec
AUSTRALIA
以模具設計者的角度而言錐形流道的重要性是:
MS-WINDOWS 環境下操作 Operate under
Marketed worldwide by
由CASTEC作全球性行銷
Castec Australia
Castec
AUSTRALIA
模具設計的特性
Die Design Features 機械特性: 流動特性:
gate
模具分佈&各部界面 Mechanical 流道&澆口 Fluid flow features: runner and 冷卻&加熱 Thermal features: cooling &
流動方向之改變
change in flow direction
Castec
錐形流道 Tapered runner
AUSTRALIA
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
?
AUSTRALIA
分什麼要分析? 模溫的影響
Why analyse? Die temperature affects
鑄件品質
模具壽命 生產效率
Casting Quality Die life Production rate
Castec
AUSTRALIA
實驗:利用CASTHERM研究對 下面兩項的影響:
中區 Centre zone
左區
left zone
Right zone
右區
三角洲區 Delta gate
Castec
AUSTRALIA
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
非直接充填區 Ungated zone Centre zone
Castec
AUSTRALIA
左边区
中间 区
右边 区
Castec
AUSTRALIA
Castflow
流道分析
Castec
AUSTRALIA
CASTFLOW 流道是三位的
Castec
AUSTRALIA
Castec
Bearing2.dmt
AUSTRALIA
非直接充填區
Castec
AUSTRALIA
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
Castec
扇形流道
Fan/Chisel Gate
AUSTRALIA
錐形流道:澆口速度一致
Tapered Runner: Gate speed is uniform
Castec
錐形流道
Tapered runner
AUSTRALIA
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
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
Castec
锥形流道
Tapered runner
AUSTRALIA
样板
Castec
AUSTRALIA
What is a good fill pattern?
Castec
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
AUSTRALIA
Castec
AUSTRALIA
怎樣才是好的充填模式 ?
AUSTRALIA
Castec
DOOR-knob.DMT
AUSTRALIA
流向是 CASTFLOW预言的
Castflow 流道 比较小
Castec
AUSTRALIA
door-handle.dmt
Castflow流道 比较小
Castec
tap-handle.dmt
AUSTRALIA
Castec
Castec
AUSTRALIA
steer.dmt
滑快 滑快 滑快
Castec
Handle.dmt
AUSTRALIA
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
Castec
box-casting.dmt
AUSTRALIA
Castec
phone.dmt
流道與澆口設計系統
Designing Runner and Gating Systems
T.H. Siauw
Castec
Castec Australia Pty. Ltd.
AUSTRALIA
產品背景
Product background 經過CSIRO的15年研發 在
MS-WINDOWS
Over 15 years R&D by CSIRO
CastecΒιβλιοθήκη Baidu
AUSTRALIA
模穴之充填模式可以定性的
Cavity fill pattern is qualitative
Castec
錐形流道 Tapered runner
AUSTRALIA
充填區域是可以定量的
Zone of fill is Quantitative 非直接充填區
Ungated zone
AUSTRALIA
Castec
AUSTRALIA
Castec
AUSTRALIA
以前的流道 比 CASTFLOW 流 道
以前的流道
Castec
CASTFLOW 流道
AUSTRALIA
很厚的产品
Castec
AUSTRALIA
很小的产品
Castec
AUSTRALIA
設計冷卻與加熱系統
Designing cooling and heating system
Castec
扇形開口
Fan/Chisel Gate
錐形流道
Tapered runner
AUSTRALIA
常見的錯誤觀念： 浇口速度是一致的
Common mistaken idea: Gate velocity is uniform
Castec
扇形流道
Fan/Chisel Gate
錐形流道
Tapered runner
水流率&冷卻距離的效益
2. 設計流道&澆口
Design runner & gate
充填模式達到?
Fill pattern achieved?
No
3.分析 (Analyze)
No
Castec
OK?
Yes
AUSTRALIA
“充填模式” 是什么?
What is fill pattern?
Castec
AUSTRALIA
怎樣才是好的充填模式 ?
模具設計
Die Design
流道設計:
CASTFLOW
Runner Design
冷卻&加熱
IGES
Cooling/Heating CASTHERM
NC 加工
Castec
NC Machining
AUSTRALIA
充填模式法 (Fill Pattern based approach)
1.決定充填模式
Define fill pattern
包夾空氣
Air trap
避免兩道或多道金屬流在模穴中會合而包夾空氣
Castec
Avoid two or more metal fronts meeting in cavity which trap air
AUSTRALIA
Castec
AUSTRALIA
哪一種流道形狀好 ?
Which runner geometry?
1.) 流角
The significance of tapered runner from die designer’s point of view are: 1. Flow Angle
流角
Flow angle
Castec
錐形流道 Tapered runner
AUSTRALIA
2.) 流角將構成充填區:
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
Castec
AUSTRALIA
AUSTRALIA
扇形流道:浇口速度不一致
Fan gate speed: Not uniform
Castec
扇形流道
Fan/Chisel Gate
AUSTRALIA
不一致的澆口速度的結果
Consequences of non uniform gate speed
高速會引起模具腐蝕或黏模
High speed causes Die erosion and/or soldering
Autocad, Unigraphics
CASTFLOW Fluid flow CASTHERM Thermal features:
流動特性:
features: CASTFLOW
熱流特性:
CASTHERM
Castec
AUSTRALIA
模具設計之整合
Integrated Die Design
What is a good fill pattern?
?
Castec
應避免两个金属流前面在摸穴中會合
Avoids metal fronts meeting in cavity
AUSTRALIA
Castec
AUSTRALIA
Castec
AUSTRALIA
怎樣才是好的充填模式 ?
What is a good fill pattern?
left zone
Right zone
直接充填區
Gated zone
Castec
AUSTRALIA
充填區域 = 充填模式
Zone of fills = Cavity Fill Pattern
非直接充填區 Ungated zone Centre zone
left zone
Right zone
直接充填區 Gated zone
低速會引起澆口堵塞 或冷模瑕疵
Low speed causes gate blockage and/or cold shut defects
Castec
扇形流道 Fan/Chisel Gate
AUSTRALIA
扇形流是不被推薦的話!
Fan gating system is not recommendable !!!!
AUSTRALIA
問題在哪?
The problem ?
?
?
需要幾個迴路, 在哪裡?How many and circuit layout?
Castec
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?
T.H. Siauw
Castec
Castec Australia Pty. Ltd.
AUSTRALIA
練習, 請依下面指示做?
Exercise, Please do the following
畫出冷卻管 Draw the cooling circuit
Castec
標示出與分模面之距離 Show the distance
features: die layout & parting face
熱流特性:
heating
Castec
AUSTRALIA
模具設計電腦輔助工具
Computer-Aided die design tools
機械性:
(Mechanical features: Autocad, Unigraphics)
2. Flow angle leads to Zone of fill:
非直接充填區
Ungated zone
直接充填區 Gated zone
Castec
錐形流道Tapered runner
AUSTRALIA
雙錐形流道流道會有三個區
The twin tapered runner results in three zone of fills
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
澆口速度向 量
Castec
AUSTRALIA
以模具設計者的角度而言錐形流道的重要性是:
MS-WINDOWS 環境下操作 Operate under
Marketed worldwide by
由CASTEC作全球性行銷
Castec Australia
Castec
AUSTRALIA
模具設計的特性
Die Design Features 機械特性: 流動特性:
gate
模具分佈&各部界面 Mechanical 流道&澆口 Fluid flow features: runner and 冷卻&加熱 Thermal features: cooling &
流動方向之改變
change in flow direction
Castec
錐形流道 Tapered runner
AUSTRALIA
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
?
AUSTRALIA
分什麼要分析? 模溫的影響
Why analyse? Die temperature affects
鑄件品質
模具壽命 生產效率
Casting Quality Die life Production rate
Castec
AUSTRALIA
實驗:利用CASTHERM研究對 下面兩項的影響:
中區 Centre zone
左區
left zone
Right zone
右區
三角洲區 Delta gate
Castec
AUSTRALIA
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
非直接充填區 Ungated zone Centre zone
Castec
AUSTRALIA
左边区
中间 区
右边 区
Castec
AUSTRALIA
Castflow
流道分析
Castec
AUSTRALIA
CASTFLOW 流道是三位的
Castec
AUSTRALIA
Castec
Bearing2.dmt
AUSTRALIA
非直接充填區
Castec
AUSTRALIA
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
Castec
扇形流道
Fan/Chisel Gate
AUSTRALIA
錐形流道:澆口速度一致
Tapered Runner: Gate speed is uniform
Castec
錐形流道
Tapered runner
AUSTRALIA
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
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
Castec
锥形流道
Tapered runner
AUSTRALIA
样板
Castec
AUSTRALIA
What is a good fill pattern?
Castec
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
AUSTRALIA
Castec
AUSTRALIA
怎樣才是好的充填模式 ?
AUSTRALIA
Castec
DOOR-knob.DMT
AUSTRALIA
流向是 CASTFLOW预言的
Castflow 流道 比较小
Castec
AUSTRALIA
door-handle.dmt
Castflow流道 比较小
Castec
tap-handle.dmt
AUSTRALIA
Castec
Castec
AUSTRALIA
steer.dmt
滑快 滑快 滑快
Castec
Handle.dmt
AUSTRALIA
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
Castec
box-casting.dmt
AUSTRALIA
Castec
phone.dmt
流道與澆口設計系統
Designing Runner and Gating Systems
T.H. Siauw
Castec
Castec Australia Pty. Ltd.
AUSTRALIA
產品背景
Product background 經過CSIRO的15年研發 在
MS-WINDOWS
Over 15 years R&D by CSIRO
CastecΒιβλιοθήκη Baidu
AUSTRALIA
模穴之充填模式可以定性的
Cavity fill pattern is qualitative
Castec
錐形流道 Tapered runner
AUSTRALIA
充填區域是可以定量的
Zone of fill is Quantitative 非直接充填區
Ungated zone
AUSTRALIA
Castec
AUSTRALIA
Castec
AUSTRALIA
以前的流道 比 CASTFLOW 流 道
以前的流道
Castec
CASTFLOW 流道
AUSTRALIA
很厚的产品
Castec
AUSTRALIA
很小的产品
Castec
AUSTRALIA
設計冷卻與加熱系統
Designing cooling and heating system
Castec
扇形開口
Fan/Chisel Gate
錐形流道
Tapered runner
AUSTRALIA
常見的錯誤觀念： 浇口速度是一致的
Common mistaken idea: Gate velocity is uniform
Castec
扇形流道
Fan/Chisel Gate
錐形流道
Tapered runner
水流率&冷卻距離的效益
2. 設計流道&澆口
Design runner & gate
充填模式達到?
Fill pattern achieved?
No
3.分析 (Analyze)
No
Castec
OK?
Yes
AUSTRALIA
“充填模式” 是什么?
What is fill pattern?
Castec
AUSTRALIA
怎樣才是好的充填模式 ?
模具設計
Die Design
流道設計:
CASTFLOW
Runner Design
冷卻&加熱
IGES
Cooling/Heating CASTHERM
NC 加工
Castec
NC Machining
AUSTRALIA
充填模式法 (Fill Pattern based approach)
1.決定充填模式
Define fill pattern
包夾空氣
Air trap
避免兩道或多道金屬流在模穴中會合而包夾空氣
Castec
Avoid two or more metal fronts meeting in cavity which trap air
AUSTRALIA
Castec
AUSTRALIA
哪一種流道形狀好 ?
Which runner geometry?
1.) 流角
The significance of tapered runner from die designer’s point of view are: 1. Flow Angle
流角
Flow angle
Castec
錐形流道 Tapered runner
AUSTRALIA
2.) 流角將構成充填區:
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
Castec
AUSTRALIA
AUSTRALIA
扇形流道:浇口速度不一致
Fan gate speed: Not uniform
Castec
扇形流道
Fan/Chisel Gate
AUSTRALIA
不一致的澆口速度的結果
Consequences of non uniform gate speed
高速會引起模具腐蝕或黏模
High speed causes Die erosion and/or soldering
Autocad, Unigraphics
CASTFLOW Fluid flow CASTHERM Thermal features:
流動特性:
features: CASTFLOW
熱流特性:
CASTHERM
Castec
AUSTRALIA
模具設計之整合
Integrated Die Design
What is a good fill pattern?
?
Castec
應避免两个金属流前面在摸穴中會合
Avoids metal fronts meeting in cavity
AUSTRALIA
Castec
AUSTRALIA
Castec
AUSTRALIA
怎樣才是好的充填模式 ?
What is a good fill pattern?
left zone
Right zone
直接充填區
Gated zone
Castec
AUSTRALIA
充填區域 = 充填模式
Zone of fills = Cavity Fill Pattern
非直接充填區 Ungated zone Centre zone
left zone
Right zone
直接充填區 Gated zone
低速會引起澆口堵塞 或冷模瑕疵
Low speed causes gate blockage and/or cold shut defects
Castec
扇形流道 Fan/Chisel Gate
AUSTRALIA
扇形流是不被推薦的話!
Fan gating system is not recommendable !!!!