CN112108632A - Die casting control method and semi-solid die casting machine - Google Patents
Die casting control method and semi-solid die casting machine Download PDFInfo
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- CN112108632A CN112108632A CN201910533432.1A CN201910533432A CN112108632A CN 112108632 A CN112108632 A CN 112108632A CN 201910533432 A CN201910533432 A CN 201910533432A CN 112108632 A CN112108632 A CN 112108632A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/32—Controlling equipment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/007—Semi-solid pressure die casting
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Abstract
The invention discloses a die-casting control method and a semi-solid die-casting machine. The die-casting control method includes: accelerating the injection speed of the injection rod from 0 to a first speed, wherein the first speed is less than a critical speed; enabling the material injection rod to move at a first speed to enable a chamber of the material inlet cylinder to be filled with semi-solid metal liquid, and discharging gas in the chamber; accelerating the injection speed to a second speed; moving a material injection rod at a second speed to hydraulically inject the semi-solid metal in the material inlet cylinder into the die cavity; reducing the injection speed to a third speed, the third speed being less than the first speed; and injecting at a third speed when the die cavity is filled with the semi-solid molten metal. Through the staged control to the die-casting process and the accurate adjustment to the die-casting speed, effectively reduce the gas entrainment probability, avoid getting into stranded gas in the feed cylinder to avoid the foundry goods defect, improved product quality.
Description
Technical Field
The invention relates to a die casting control method and a die casting machine.
Background
With the development of the automobile industry, the lightweight of automobiles plays an important role in acceleration performance, stability and economy. Manufacturers have solved the light weight of automotive structural members by using wrought aluminum instead of cast iron or steel. However, because of high cost of aluminum forging, the price of the autonomous brand passenger cars in China is limited, and at present, almost no domestic car using the aluminum forging is available. In order to meet the requirement of lightening automobiles, products prepared by semi-solid metal die-casting are proposed in the industry to replace aluminum forging, the performance of the products is equivalent to that of the aluminum forging, the cost of the products is equivalent to that of cast aluminum with low price, and therefore the products can meet the requirement of high cost performance of the automobile industry and are the best method for achieving the light weight of target products. However, the semisolid aluminum alloy has the characteristics of high viscosity and low feeding efficiency, the existing die casting machine cannot adapt to the characteristics of high viscosity and low feeding efficiency, the die casting process is difficult to be effectively controlled, and the die-cast aluminum alloy is easy to have casting defects.
Disclosure of Invention
The invention aims to solve the technical problem that the control process of a die casting machine in the prior art is not accurate enough, and provides a die casting control method for semi-solid metal and a semi-solid die casting machine, which can realize accurate control on each die casting stage.
The invention solves the technical problems through the following technical scheme:
a die-casting control method is characterized by comprising the following steps:
step S1: accelerating the injection speed of the injection rod from 0 to a first speed, wherein the first speed is less than a critical speed;
step S2: enabling the material injection rod to move at a first speed to enable a chamber of the material inlet cylinder to be filled with semi-solid metal liquid, and discharging gas in the chamber;
step S3: accelerating the injection speed to a second speed;
step S4: moving a material injection rod at a second speed to hydraulically inject the semi-solid metal in the material inlet cylinder into the die cavity;
step S5: reducing the injection speed to a third speed, the third speed being less than the first speed;
step S6: and injecting at a third speed when the die cavity is filled with the semi-solid metal liquid, wherein the critical speed is a Garber critical speed.
Preferably, the step S3 is a step of uniform acceleration.
Preferably, the critical speed is calculated based on the degree of fullness, the advancing speed of the semi-solid metal liquid and the flow state.
Preferably, the first speed, the second speed and the third speed are calculated according to the pouring quality, the metal density and the punch diameter.
Preferably, the semi-solid metal liquid is semi-solid aluminum liquid or semi-solid aluminum alloy liquid.
The invention also provides a semi-solid die casting machine, which is characterized by comprising a starting control unit, a transition control unit, an acceleration control unit, a filling control unit, a deceleration control unit and a pressurization control unit, wherein,
the starting control unit is used for accelerating the injection speed of the injection rod from 0 to a first speed, and the first speed is less than a critical speed;
the transition control unit is used for enabling the material injection rod to move at a first speed so that a chamber of the material inlet cylinder is filled with semi-solid metal liquid, and gas in the chamber is exhausted;
the acceleration control unit is used for accelerating the injection speed to a second speed;
the filling control unit is used for enabling the material injection rod to move at a second speed so as to hydraulically inject the semi-solid metal in the material inlet cylinder into the die cavity;
the deceleration control unit is used for reducing the injection speed to a third speed, and the third speed is smaller than the first speed;
the pressurization control unit is used for injecting at a third speed when the die cavity is filled with semi-solid metal liquid, wherein the critical speed is Garber critical speed.
Preferably, it further comprises a calculation unit for calculating the critical speed based on the degree of fullness, the advancing speed of the semi-solid metal liquid and the flow pattern.
Preferably, the calculation unit is further configured to calculate the first speed, the second speed and the third speed according to the pouring quality, the metal density and the punch diameter.
Preferably, the semi-solid metal liquid is semi-solid aluminum liquid or semi-solid aluminum alloy liquid.
On the basis of the common knowledge in the field, the above preferred conditions can be combined randomly to obtain the preferred embodiments of the invention.
The positive progress effects of the invention are as follows: through the staged control to the die-casting process and the accurate adjustment to the die-casting speed, effectively reduce the gas entrainment probability, avoid getting into stranded gas in the feed cylinder to avoid the foundry goods defect, improved product quality.
Drawings
Fig. 1 is a schematic view of the partial components of a shot system according to one embodiment of the present invention.
Fig. 2 is a schematic diagram of a position sensor according to an embodiment of the present invention.
Fig. 3 is a schematic view of the arrangement of the charging barrel and the material injection rod according to an embodiment of the present invention.
Fig. 4 is a block diagram of a semi-solid die casting machine according to an embodiment of the present invention.
Fig. 5 is a flowchart of a die-casting control method according to an embodiment of the invention.
Fig. 6 is a schematic diagram of die casting speed and position relationship according to an embodiment of the present invention.
Fig. 7-9 are schematic diagrams of the semi-solid aluminum liquid when the die casting speed is equal to, greater than and less than the critical speed respectively according to the Garber slow-injection theory.
Detailed Description
The invention is further illustrated by the following examples, which are not intended to limit the scope of the invention.
Based on the characteristics of filling and solidification in the process of forming the aluminum alloy semi-solid die casting, the structural design of semi-solid die casting equipment and the modular control of real-time multi-section closed loop of pressure are developed, the technical requirements of semi-solid die casting such as ultra-low-speed injection, ultra-wide adjustable range, high dynamic pressurization, high repetition precision and the like are met, and a novel intelligent low-cost high-efficiency semi-solid die casting machine and a die casting control method are developed to avoid casting defects.
Referring to fig. 1-9, a semi-solid die casting machine includes the following major components: the injection system, the frame, the head plate, the middle plate, the tail plate, the hydraulic system and the control unit. Wherein the injection system comprises: the injection device comprises an injection piston 1, an injection oil cylinder 2, a booster cylinder piston 3, a booster cylinder barrel 4, a servo flow valve 5, a position sensor 6, an injection rod 8, a charging barrel 7 and the like, wherein the servo flow valve is arranged at an oil port of a rod cavity of the injection oil cylinder, and the position sensor 6 is arranged at the end part of the rod cavity oil and is connected with an injection piston rod of the injection oil cylinder.
Wherein the control unit comprises a start control unit 11, a transition control unit 12, an acceleration control unit 13, a filling control unit 14, a deceleration control unit 15 and a pressurization control unit 16, wherein,
the starting control unit 11 is used for accelerating the injection speed of the injection rod from 0 to a first speed, and the first speed is less than a critical speed;
the transition control unit 12 is used for enabling the material injection rod to move at a first speed to enable a chamber of the charging barrel to be filled with the semi-solid metal liquid, and gas in the chamber is discharged;
the acceleration control unit 13 is configured to accelerate the injection speed to a second speed;
the filling control unit 14 is used for moving the injection rod at a second speed to hydraulically inject the semi-solid metal in the charging barrel into the die cavity;
the deceleration control unit 15 is configured to decrease the injection speed to a third speed, which is smaller than the first speed;
the pressurization control unit 16 is adapted to inject at a third speed when the mold cavity is filled with the semi-solid molten metal,
wherein the critical speed is a Garber critical speed (critical speed according to Garber slow shot theory). Referring to fig. 7-9, which respectively show the case when the die casting speed is equal to, greater than, and less than the critical speed, when the die casting machine starts die casting, when the die casting speed is greater than or equal to the critical speed, the semi-solid molten aluminum 10 may trap gas in the feeding cylinder 7, causing casting defects; when the die casting speed is lower than the critical speed, the feeding barrel 7 is filled with semi-solid aluminum liquid 10, so that the defect of castings caused by trapped gas is avoided, and the product percent of pass is improved.
The semi-solid die casting machine further comprises a calculating unit 17, and the calculating unit is used for calculating the critical speed according to the filling degree, the advancing speed of the semi-solid metal liquid and the flow state. The calculation unit 17 is further configured to calculate the first speed, the second speed and the third speed based on the pouring quality, the metal density and the punch diameter.
The semi-solid metal liquid is semi-solid aluminum liquid or semi-solid aluminum alloy liquid, such as aluminum magnesium alloy liquid.
The intelligent injection process is controlled in multiple sections: the injection speed can be adjusted according to the state of the semisolid aluminum liquid in the feeding cylinder and the cavity in the die-casting process, so that the defect of a casting caused by trapped gas is avoided, and the die-casting process is more suitable for the requirement of a complex die-casting process.
Referring to fig. 5 and fig. 6, a die casting control method according to the present invention is described by taking a semi-solid aluminum liquid as an example.
Step 100: accelerating the injection speed of the injection rod from 0 to a first speed, wherein the first speed is less than a critical speed;
step 101: enabling the material injection rod to move at a first speed to enable a chamber of the material inlet cylinder to be filled with semi-solid metal liquid, and discharging gas in the chamber;
step 102: accelerating the injection speed to a second speed;
step 103: moving a material injection rod at a second speed to hydraulically inject the semi-solid metal in the material inlet cylinder into the die cavity;
step 104: reducing the injection speed to a third speed, the third speed being less than the first speed;
step 105: injecting at a third speed when the die cavity is filled with the semi-solid molten metal,
wherein the critical speed is a Garber critical speed.
Wherein step 102 is smooth acceleration.
Referring to fig. 6, at the time of shot, the shot speed is accelerated from 0 to a first speed smaller than the critical speed, and this process is a slow start section a. And then the material injection rod moves forwards at a first speed, so that the upper cavity in the material feeding barrel is filled with the semi-solid aluminum liquid exhaust gas, and the process is a transition section b. After the gas in the material feeding barrel is discharged, the injection speed is accelerated to the maximum injection speed (second speed), and the process is a uniform acceleration section c. And then the injection rod moves forwards at the maximum movement speed, and the semi-solid aluminum in the charging barrel is hydraulically injected into the die cavity, wherein the process is a filling section d. And (3) decelerating before the high-speed filling is finished, absorbing the mechanical inertia of the hammer head, and eliminating the impact of peak pressure on molten metal and a die, so that the appearance quality of the casting can be improved, and flash can be prevented, wherein the process is a deceleration section e. When the die cavity is filled with the semi-solid aluminum liquid, the injection system executes a pressurization command until the casting molding is finished, and the process is a pressurization section f.
And subdividing a plurality of position detection points in the full stroke of the injection oil cylinder. The oil port of the rod cavity of the oil cylinder is provided with a servo flow valve for controlling the movement speed of the piston rod of the oil cylinder, the oil end part of the rod cavity of the oil cylinder is provided with a magnetic induction position sensor, and the injection speed required by each position monitoring point is directly input into a control interface before the die casting machine performs the first injection and die casting. When the material is injected and die-cast, the controller controls the opening degree of the valve core of the servo flow valve through a 0-10V voltage control signal, so that the flow of hydraulic oil at the outlet of the injection oil cylinder is accurately controlled through the servo flow valve, and the accurate control of the movement speed of the injection material is realized. The magnetic induction position sensor feeds back a position signal during actual injection to the controller, the controller can calculate the speed passing through the position according to the time of the piston rod of the injection oil cylinder passing through the position and the passed displacement, the speed is calculated and compared with the set speed, and the opening degree of the valve core of the servo valve is controlled by the control signal in a real-time micro-adjustment mode according to the comparison result, so that the actual injection speed is accurately controlled.
For the intelligent calculation and automatic segmentation of the injection process parameters, a user only needs to input basic parameters such as pouring quality, alloy types (density), punch diameter and the like through a human-computer interface, and a system can simulate and calculate uniform acceleration, transition speed and equal speed values and speed switching positions. So as to facilitate the comparison and reference of the process adjustment. By using the functional relation of the Garber slow-injection theory on the fullness, the alloy advancing speed and the flow state (wave height during flowing), the critical speed of the flow state shown in figures 7-9 is simulated and calculated, so that the entrainment probability can be effectively reduced. A negative feedback closed loop control system: the repeated precision of the technological parameters can be ensured.
The instant pressure build-up is significant to the problem of compactness inside the die casting, and the real-time control system consisting of an industrial pc with high processing speed and a customized high-frequency response servo valve is used for controlling the time from data acquisition to response output within 5ms, and the action time of the servo valve and the one-way valve is totally within 15 ms.
In addition, semisolid and liquid die forging pressure forming has higher requirements on the working pressure of metal: for example not less than 65 MPa; sufficient shot force is provided and ensured by the following scheme. Designing a special injection mechanism for a specific product: 1) the inner diameter of the injection cylinder is properly increased, and the stress area of the injection oil cylinder is increased. 2) And the requirement of high-pressure injection force is realized by increasing the pressure of the hydraulic system.
While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that these are by way of example only, and that the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention, and these changes and modifications are within the scope of the invention.
Claims (9)
1. A die-casting control method characterized by comprising the steps of:
step S1: accelerating the injection speed of the injection rod from 0 to a first speed, wherein the first speed is less than a critical speed;
step S2: enabling the material injection rod to move at a first speed to enable a chamber of the material inlet cylinder to be filled with semi-solid metal liquid, and discharging gas in the chamber;
step S3: accelerating the injection speed to a second speed;
step S4: moving a material injection rod at a second speed to hydraulically inject the semi-solid metal in the material inlet cylinder into the die cavity;
step S5: reducing the injection speed to a third speed, the third speed being less than the first speed;
step S6: injecting at a third speed when the die cavity is filled with the semi-solid molten metal,
wherein the critical speed is a Garber critical speed.
2. The die-casting control method according to claim 1, wherein the step S3 is a step of uniform acceleration.
3. The die casting control method as claimed in claim 1 or 2, wherein the critical speed is calculated based on the degree of fullness, the advancing speed of the semi-solid molten metal, and the flow regime.
4. The die casting control method according to claim 1 or 2, wherein the first speed, the second speed, and the third speed are calculated from a pouring quality, a metal density, and a punch diameter.
5. The die casting control method according to claim 1 or 2, wherein the semi-solid metal liquid is a semi-solid aluminum liquid or a semi-solid aluminum alloy liquid.
6. A semi-solid die casting machine is characterized by comprising a starting control unit, a transition control unit, an acceleration control unit, a filling control unit, a deceleration control unit and a pressurization control unit, wherein,
the starting control unit is used for accelerating the injection speed of the injection rod from 0 to a first speed, and the first speed is less than a critical speed;
the transition control unit is used for enabling the material injection rod to move at a first speed so that a chamber of the material inlet cylinder is filled with semi-solid metal liquid, and gas in the chamber is exhausted;
the acceleration control unit is used for accelerating the injection speed to a second speed;
the filling control unit is used for enabling the material injection rod to move at a second speed so as to hydraulically inject the semi-solid metal in the material inlet cylinder into the die cavity;
the deceleration control unit is used for reducing the injection speed to a third speed, and the third speed is smaller than the first speed;
the pressurization control unit is used for injecting at a third speed when the die cavity is filled with the semi-solid metal liquid,
wherein the critical speed is a Garber critical speed.
7. The semi-solid die casting machine as claimed in claim 6, further comprising a calculation unit for calculating said critical speed based on the degree of fullness, the advancing speed of the semi-solid metal liquid, and the flow regime.
8. The semi-solid die casting machine of claim 7 wherein the calculation unit is further configured to calculate the first, second and third speeds based on the pour mass, the metal density and the punch diameter.
9. The semi-solid die casting machine as claimed in any one of claims 6 to 8, wherein the semi-solid metal liquid is a semi-solid aluminum liquid or a semi-solid aluminum alloy liquid.
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| CN201910533432.1A CN112108632A (en) | 2019-06-19 | 2019-06-19 | Die casting control method and semi-solid die casting machine |
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| CN201910533432.1A CN112108632A (en) | 2019-06-19 | 2019-06-19 | Die casting control method and semi-solid die casting machine |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113399642A (en) * | 2021-06-24 | 2021-09-17 | 厦门格耐尔科技有限公司 | Die-casting method for uniform acceleration pressure chamber inoculation semi-solid rheology |
| CN113649541A (en) * | 2021-07-19 | 2021-11-16 | 浙江华朔科技股份有限公司 | Multistage variable speed die-casting forming method for new energy automobile motor shell |
-
2019
- 2019-06-19 CN CN201910533432.1A patent/CN112108632A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113399642A (en) * | 2021-06-24 | 2021-09-17 | 厦门格耐尔科技有限公司 | Die-casting method for uniform acceleration pressure chamber inoculation semi-solid rheology |
| CN113399642B (en) * | 2021-06-24 | 2023-01-17 | 厦门格耐尔科技有限公司 | Die-casting method for uniform acceleration pressure chamber inoculation semi-solid rheology |
| CN113649541A (en) * | 2021-07-19 | 2021-11-16 | 浙江华朔科技股份有限公司 | Multistage variable speed die-casting forming method for new energy automobile motor shell |
| CN113649541B (en) * | 2021-07-19 | 2023-12-22 | 浙江华朔科技股份有限公司 | Multistage speed change die-casting molding method for motor shell of new energy automobile |
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