应用圆形断面流道于压铸模具设计之研究StudyofApplyingCircular.DOC

應用圓形斷面流道於壓鑄模具設計之研究 Study of Applying Circular Cross-Section Runners in the Design of Die Casting Molds 莊水旺1、范量景2 Shueiwan H. Juang1, Liang-Jing Fan2 1副教授、2研究生 1 Associate Professor, 2Graduate Student 先進製造工程研究中心 國立臺灣海洋大學 Engineering Research Center for Advanced Manufacturing Processes National Taiwan Ocean University 通訊作者：shjuang@mail.ntou.edu.tw 關鍵字：圓形斷面流道、捲氣量、鑄造壓力、壓鑄模具 摘要 傳統的壓鑄模具流道絕大多數採用梯形斷面的設計，以利於鑄件脫模及模具加工。流道的幾何形狀對熔湯的流動阻力影響甚鉅，進而影響熔湯能量傳遞的損失，使熔湯在模腔內的鑄造壓力降低。本研究將圓形斷面的流道設計概念，導入應用於一模六穴的汽車壓鑄件模具。利用數值模流分析，並配合實際壓鑄生產試驗，探討在相同鑄造方案配置及固定流道斷面積的情形下，比較圓形斷面流道及梯形斷面流道設計對壓鑄件品質之影響。模流分析結果顯示，圓形斷面流道在澆口的平均溫度高於梯形斷面流道約3℃，且澆口的熔湯鑄造壓力自56MPa提升至74MPa。同時發現熔湯在圓形斷面流道內流經轉彎處形成之空氣袋遠小於梯形斷面流道，此可有效減少氣體之捲入量。根據模流分析結果，建議壓鑄廠以圓形斷面流道取代原先之梯形斷面流道，再進一步分析實際生產的鑄件發現，原梯形斷面流道鑄件發生的冷接紋缺陷率為92%，改用圓形斷面流道設計則可降低至0%，同時孔隙亦獲得顯著地改善。 Keywords：ircular cross-section runner, gas entrapped, casting pressure, die casting mold Abstract The trapezoidal cross-section runner design is utilized in majority of traditional die-casting molds, in order to facilitate the casting releasing and mold processing. The influence of runner geometry on the flow resistance of melt is significant, thereby affecting the loss on energy transfer and reducing the casting pressure in mold cavities. In this study, the circular cross-section runner design concept was introduced into a six-cavity automotive die casting mold. The application of numerical flow analyses as well as real-world die-casting production tests was used to investigate the effect of both circular cross-section runners and trapezoidal cross-section runners on die casting quality under the same runner layout with the same cross-section areas in both types of runners. The results obtained from numerical flow analyses showed that the average temperature at gates for circular cross-section runners was higher about 3℃ as compared to the casting with trapezoidal cross-section runners; and the melt pressure at gates was increased from 56MPa to 74MPa as altering trapezoidal cross-section runners to ci