参考案例成果flow

1、流道與澆口設計系統Designing Runner and Gating SystemsT.H. SiauwCastec Australia Pty. Ltd.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

2、 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模具設計電腦輔助工具Computer-Aided die design tools機械性: Autocad, UnigraphicsMechanical features: Autocad, Unigraphics流動特性: CASTFLOWFluid flow features: CASTFLOW熱流特性: CASTHERMThermal features: CAS

3、THERM模具設計之整合Integrated Die Design 模具設計Die Design流道設計:CASTFLOWRunner Design冷卻&加熱Cooling/HeatingCASTHERMNC 加工NC MachiningIGES課程主題Topics流道&澆口設計之流程Runner and gating design procedures充填模式分析Fill pattern analysis電腦軟體CASTFLOWCASTFLOWCase studiesCase studies問題在哪?The problem?流道&澆口設計之流程Runner and Gating Design

4、 Procedures大姆指法則-經驗公式Rule of thumb - experience based充填時間法則Fill time based充填模式法則Fill pattern based充填時間法則之流程Fill time based procedure決定充填時間 (=t)Determine the cavity fill time (= t)計算鑄件體積 (=V)Calculate the casting volume (= V)計算金屬熔液湯流率 (F=V/t)Calculate metal flow rate (F=V/t)指定澆口速度 (u40m/s)Assign gate

5、 speed (u 40 m/s)澆口面積 (A=F/u)Gate area (A = F/u) 計算澆口面積Calculate the gate area1501001?充填時間法則之缺點Weaknesses of Fill Time based approach:最佳充填時間無法肯定Optimum cavity fill time is unknown 流道形狀的影響並未考慮The effect of runner geometry is not taken into account模穴充填距離並未考慮, 故澆口位置只能純憑經驗.The flow distance in cavity is

6、 not taken into account. Thus, gate position must be decided purely by experience鑄件形狀並未考慮Casting shape is not taken into account 充填模式法 (Fill Pattern based approach)決定充填模式Define fill pattern設計流道&澆口Design runner & gate充填模式達到?Fill pattern achieved?分析 (Analyze)OK?NoNoYes什麼是“充填模式”?What is fill pattern?怎樣

7、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 cavitywhich trap air包夾空氣Air trapGood Fill Pattern?Avoids metal fronts meetin

8、g in cavity怎樣才是好的充填模式 ? What is a good fill pattern?某些特殊形狀的鑄件會影響金屬流動與引起金屬在模穴中會合Some geometrical features in casting may interrupt flow and cause metal fronts meet in cavity包夾空氣air trap空洞Cutout決定充填模式後,下一步是.After defining fill pattern the next is .決定充填模式Define fill pattern設計流道&澆口Design runner & gate分析 AnalyzeOK?NoNoYes充填模式達到?Fill pattern achieved?哪一種流道形狀好 ? Which runner geometry?扇形開口Fan/Chisel Gate錐形流道Tapered runner請試描出下面兩種澆口的射出方向 ? Exercise show the likely