【作者】 董军刚；

【导师】 万里；

【作者基本信息】 华中科技大学 ， 材料加工工程， 2010， 硕士

【摘要】 压铸模温度对于金属液的填充、凝固过程以及压铸模使用寿命和铸件质量的稳定性有着非常大的影响,是必须要控制的参数之一。通常压铸模的温度控制包括预热和冷却两个方面,本文针对目前压铸模在预热时存在的速度慢、耗能大、污染环境;冷却时无法对模具细小型芯针部位进行有效控制、芯针温度高、寿命短等缺点,开发了基于高压过热水的压铸模预热控制装置和基于高压冷却循环水的压铸模型芯针温度控制装置,满足了现代大型复杂压铸模的生产要求,取得了良好的效果。本文设计并制作了一种多通道的压力为0.6MPa、最高加热温度为160℃、流量为50L/min的高压过热水模温控制装置(简称水式模温机)。该装置具有模具预热、模具冷却、自动补水、自动稳压和自动温控等功能。试验结果表明:在短时间内,该装置能迅速将模具温度预热到100℃以上,在同一加热时间内比传统的油式模温机提高约60℃;将模具预热到同一温度时,其加热时间比油式模温机减少约50%左右,节能约40%。水式模温机具有很好的模具预热效率和预热速度,使用方便、节能、不污染现场环境等优点。该装置现已成功地应用于某复杂通讯框体压铸件的生产上,效果良好,可取代油式模温机。本文设计并制作的压铸模型芯针冷却控制装置包括水温自动控制功能、制冷功能、循环水冷却功能和吹气冷却功能等。该装置设置了手动工作模式和自动工作模式,同时针对不同的工作模式设置了独立的控制系统,用户可以通过模式转换开关方便的进行选择。该装置的制冷量为18KW,冷却水流量为50L/min,最大工作压力为1Mpa。试验结果表明:在某国产自主品牌轿车的后副车架压铸技术开发中,不使用型芯针冷却装置时,芯针的温度高达200～260℃;而使用该装置的自动冷却功能时,芯针温度可降低到100～150℃;当使用手动冷却模式时,芯针温度可进一步降低至65～120℃。三种模式下的铸件X光照片对比显示,自动冷却功能下,芯针部位的缩松及裂纹缺陷最小。更多还原

【Abstract】 Temperature control has significant impact on filling and solidification of molten metal, die span-life and casting defects. It must be one of the parameters controlled by users. There are pre-heating and cooling two parts in temperature control. In order to solve these problems ,such as low speed, heavy energy cost, and pollution of the environment in pre-heating stage, temperture of the fine core needles hardly effective controlled, high temperature of core needles, short life in cooling stage, in this paper , the die temperature control equipment based on overheated water with high presuure and the die core needle temperature control equipment based on cycle cooling-water with high pressure have been developed, which will meet the present production need in large valume dies and have significant impacts.In this paper, a kind of temperature controller based on high pressure and overheated water (Water Temperature Controller for short) has been designed and producted, with the pressure of 0.6MPa, maximum heated temperature of 160℃and flow rate of 50L/min. It owns some functions such as pre-heating, automatic cooling, water charging automatically, keeping constant pressure and temperature control. The experimental results showed that die temperature had been preheated over 100℃by in the short time, higher approximately 60℃than that of oil temperature controller. Meanwhile, pre-heated time of die had been reduced 50%, compared to oil temperature controller under the same temperature. Consequently, the equipment has some advantages with higher heating efficiency, faster heating-velocity , energy saving and no pollution etc. The apparatus was successfully applied to a complicated communication frame casting instead of oil temperature controller.Core needle cooling controller which have been designed and manufacuted in this paper includes several functions such as water temperature controlling automatically, regrigeration, circulation water cooling and air blow cooling. The equipment sets up manual operation and automatically operation, meanwhile set up independent control system for respective mode. Consumer can choose modes conveniently by using change-over switch. Refrigerating capacity is 18KW, flow rate is 50L/min and the maximum work presure is 1 Mpa. The experimental results demonstrated that in the process of developing a complicated sub-frame casting in one domestic pcv, the temperature of core needle can be high to 200～260℃without using the cooling controller; it will be reduced to 100～150℃in the condition of using controller in automatically mode; it will further reduced to 65～120℃in the condition of using controller in manual mode.Meanwhile,compared with X ray pictures in three modes , we can conclude that porositys and cracks in core needle parts were ideal.更多还原