Flexible Adaptive High-Precision Mold

Description

TECHNICAL FIELD

The present invention relates to the technical field of forming molds, in particular to a flexible adaptive high-precision mold.

BACKGROUND

Attractive, safe, and light aluminum alloy wheels are loved by automobile manufacturers and terminal customers. Aluminum alloy wheels were manufactured on large scale in the 1980s. With the improvement of people's aesthetic idea and the development trend of energy conservation and consumption reduction, wheels with complex frontal shapes and small-angle window shapes have become increasingly popular. However, it is difficult to produce existing small draft angle wheel products continuously in batch under existing die-casting machines and mold structures. This technical problem has always constrained the diversity development of new products. Product scratches and aluminum adhesion defects are also common in the actual production process. Some require mass manpower and material resources for repair, while others can only be scrapped due to their serious impact. This seriously restricts production continuity, production efficiency, yield and on-line shifts, and greatly increases production and operation costs.

In continuous high-temperature production environments, thermal stress easily leads to thermal deformation and progressive wear of materials. These phenomena directly weaken the fit precision between components, resulting in precision reduction problems such as axis deviation of top and bottom molds and positional deviation of the top mold in the horizontal dimension. Such deviations are particularly obvious during the opening and closing process of molds, damage the coaxiality of mold systems, and further lead to quality problems such as scratches on product appearance and inconsistent dimensions, seriously affecting the final quality and yield of products.

In addition, conventional aluminum alloy wheel forming molds rely on an ejection rod to eject a formed workpiece. This structure often causes jamming during operation due to aluminum corrosion on the ejection rod, and the workpiece may deform due to uneven force or inconsistent length of the ejection rod. The mold needs to be replaced every time for off-line maintenance, resulting in high maintenance costs.

SUMMARY

In view of the above technical problems, the present invention provides a flexible adaptive high-precision mold, including a bottom mold, a top mold, a bottom plate, a die-casting machine table plate, and a mold release ring, where the die-casting machine table plate is arranged above the bottom plate and externally connected to a die-casting machine, a mold release plate is mounted at a middle portion of the die-casting machine table plate through a hydraulic mechanism, an adapter plate is mounted on each of two sides of a bottom surface of the die-casting machine table plate, the adapter plate has a Z-shaped structure, a connecting plate is suspended and connected to each adapter plate, the top mold is mounted on the connecting plate, the bottom mold is mounted on the bottom plate, a positioning column is mounted at each of four corners of the bottom plate, a side mold is provided between two adjacent positioning columns, an upper end of the positioning column is mated with a positioning sleeve on the top mold, an ejection rod plate is connected to the mold release ring through connecting columns, the connecting columns are slidably connected to the top mold, the side mold is mounted on the bottom plate, the mold release ring matches the side mold, a mold cavity for forming workpieces is formed through the bottom mold, the top mold and the side molds, and a return column is mounted on each of four sides of the ejection rod plate.

Further, the return column is arranged coaxially with the positioning column, the position of the ejection rod plate is restricted or adjusted by the mating of the positioning column and the return column, the top mold is provided with a clearance groove to ensure the smoothness of movement of the mold release ring, and the clearance groove is arranged at a mating position between the mold release ring and the top mold.

Further, each of the adapter plates is provided with a mating plane I, a mating plane II, a mating plane III, and four bolt holes I; each of the adapter plates is mounted on the bottom surface of the die-casting machine table plate through four bolts I and the four corresponding bolt holes I; the mating plane I is slidably connected to the connecting plate to adjust the gap between the adapter plate and the connecting plate in a front-back direction, the mating plane II is mated with the bottom surface of the die-casting machine table plate, a gap is provided between an upper end surface of the connecting plate and a lower end surface of the die-casting machine table plate to adjust a vertical direction position, and a gap is provided between the mating plane III and the connecting plate to adjust a horizontal direction.

Further, a lower end of the connecting plate is provided with bolt holes II, the bolt holes II are mounted at a top of the top mold through bolts II, and an upper end of the connecting plate is provided with a mating plane V for mating with the mating plane III and a mating plane IV for mating with the mating plane I.

Further, a plurality of exhaust grooves are circumferentially and uniformly provided at intervals on the mold release ring, the exhaust grooves penetrate the mold release ring to ensure smooth exhaust of the mold cavity, the mold release ring is provided with eight bolt holes V, and the eight bolt holes V are connected to the connecting columns through corresponding bolts V to ensure the stability of the mold release ring during operation.

Further, guide flat keys and two wear-resistant flat keys I are provided on four sides of the bottom plate, each guide flat key is distributed at middle positions of the four sides of the bottom plate, the two wear-resistant flat keys I are distributed on two sides of the guide flat keys, a bottom end of each side mold is provided with guide wear-resistant keys matching the guide flat keys, the guide wear-resistant keys are mounted in the middle of the bottom end of the side mold through four bolt holes IV and corresponding bolts IV, a lower portion of the guide wear-resistant key is provided with a positioning slot, the positioning slot is mated with the guide wear-resistant key, and two sides of the guide wear-resistant keys are provided with wear-resistant flat keys II mated with the wear-resistant flat keys I.

Further, the lower end of each positioning column is provided with a mounting seat, the upper end of each positioning column is provided with a guide column, each guide column is provided with a pin hole for lifting, and each mounting seat is provided with four bolt holes III circumferentially; the pin hole, the guide column, the positioning column, and the mounting seat are integrally formed to reduce assembly tolerances; the mounting seat is mounted in a corresponding groove on the bottom plate, and the mounting seat is mounted on the bottom plate through the four bolt holes III and bolts III.

Further, positioning key slots are provided at the middle positions of the four sides of the bottom plate, the positioning key slots are spaced apart from the guide flat keys, the positioning key slots are arranged between the center of the bottom plate and the guide flat keys, a wedge-shaped positioning key is mounted in each positioning key slot, and the bottom mold is assembled to the bottom plate through the four wedge-shaped positioning keys.

Compared to the prior art, the beneficial effects of the present invention are as follows: (1) through the flexible floating positioning between the adapter plates and the connecting plates, the present invention completely breaks conventional full rigid connection between the mold and the die-casting machine; the top mold can achieve adaptive high-precision fit positioning with the bottom mold by mating with the positioning columns when the mold is opened and closed; meanwhile, conventional small ejection rods are completely replaced by the hydraulic mechanism, the mold release plate, the ejection rod plate, the connecting columns, and the mold release ring, thereby significantly improving the force and deformation of workpieces, eliminating disassembly and replacement when the mold is maintained, greatly improving maintenance efficiency, and reducing maintenance costs; (2) the present invention optimizes and simplifies existing mold structures, making mold design, manufacturing, and assembly processes more convenient, reducing costs, and changing machine-mold connection methods; through flexible connections, the present invention has adaptive and adjustable functions, eliminates the influence of equipment on mold precision, improves the mating precision of mold components, reduces defects such as appearance scratches of products, and improves production continuity and efficiency; (3) at present, the structure and assembly method of the present invention have entered a mass production verification stage, where the mold and the die casting machine are assembled stably, and the appearance of workpieces is significantly improved during the production of the mold; the present invention not only achieves efficient and stable assembly of the mold and the die-casting machine, but also optimizes the mounting and production process of the mold, more importantly, significantly breaks through the appearance quality of workpieces, and now stably supports continuous production of 9° draft angle products, fully demonstrating the excellent performance and reliability of the structure of the present invention; and (4) the present invention is iteratively upgraded based on original mold structures, has no special requirements for casting equipment, supporting equipment, or supporting structural components, can be directly promoted and used on original mold frames and casting machines, and therefore, can be flexibly promoted to all production lines, with universality.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic structural diagram of a mold of the present invention.

FIG. 2 is a first schematic structural diagram of an adapter plate of the present invention.

FIG. 3 is a second schematic structural diagram of the adapter plate of the present invention.

FIG. 4 is a first schematic structural diagram of a connecting plate of the present invention.

FIG. 5 is a second schematic structural diagram of the connecting plate of the present invention.

FIG. 6 is a first schematic structural diagram of a positioning column of the present invention.

FIG. 7 is a second schematic structural diagram of the positioning column of the present invention.

FIG. 8 is a schematic diagram of a partial structure cut at the bottom of the present invention.

FIG. 9 is a first schematic structural diagram of guide wear-resistant keys of the present invention.

FIG. 10 is a second schematic structural diagram of the guide wear-resistant keys of the present invention.

FIG. 11 is a first schematic structural diagram of a mold release ring of the present invention.

FIG. 12 is a second schematic structural diagram of the mold release ring of the present invention.

FIG. 13 is a first schematic structural diagram of wedge-shaped positioning keys of the present invention.

FIG. 14 is a second schematic structural diagram of the wedge-shaped positioning keys of the present invention.

FIG. 15 is a third schematic structural diagram of the wedge-shaped positioning key of the present invention.

Reference numerals: 1—bottom mold; 2—top mold; 3—bottom plate; 4—positioning column; 5—connecting column; 6—return column; 7—mold release plate; 8—die-casting machine table plate; 9—adapter plate; 10—connecting plate; 11—ejection rod plate; 12—mold release ring; 13—side mold; 14—bolt hole I; 15—mating plane I; 16—mating plane II; 17—mating plane III; 18—mating plane IV; 19—bolt hole II; 20—mating plane V; 21—bolt hole III; 22—mounting seat; 23—guide column; 24—pin hole; 25—wear-resistant flat key I; 26—guide flat key; 27—guide wear-resistant key; 28—positioning slot; 29—exhaust groove; 30—clearance groove; 31—bolt hole V; 32—wedge-shaped positioning key.

DETAILED DESCRIPTION

The present invention will be further described below in conjunction with specific embodiments. The illustrative embodiments and explanations provided herein are intended to explain the present invention, but not to limit the present invention.

Embodiment: A flexible adaptive high-precision mold as shown in FIGS. 1-15 includes a bottom mold 1, a top mold 2, a bottom plate 3, a die-casting machine table plate 8, and a mold release ring 12, where the die-casting machine table plate 8 is arranged above the bottom plate 3 and externally connected to a die-casting machine, a mold release plate 7 is mounted at a middle portion of the die-casting machine table plate 8 through a hydraulic mechanism, an adapter plate 9 is mounted on each of two sides of a bottom surface of the die-casting machine table plate 8, the adapter plate 9 has a Z-shaped structure, a connecting plate 10 is suspended and connected to each adapter plate 9, the top mold 2 is mounted on the connecting plate 10, the bottom mold 1 is mounted on the bottom plate 3, a positioning column 4 is mounted at each of four corners of the bottom plate 3, a side mold 13 is provided between two adjacent positioning columns 4, an upper end of the positioning column 4 is mated with a positioning sleeve on the top mold 2, an ejection rod plate 11 is connected to the mold release ring 12 through connecting columns 5, the connecting columns 5 are slidably connected to the top mold 2, the side mold 13 is mounted on the bottom plate 3, the mold release ring 12 matches the side mold 13, a mold cavity for forming workpieces is formed through the bottom mold 1, the top mold 2 and the side molds 13, and a return column 6 is mounted on each of four sides of the ejection rod plate 11.

The return column 6 is arranged coaxially with the positioning column 4, the position of the ejection rod plate 11 is restricted or adjusted by the mating of the positioning column 4 and the return column 6, the top mold 2 is provided with a clearance groove 30 to ensure the smoothness of movement of the mold release ring 12, and the clearance groove 30 is arranged at a mating position between the mold release ring 12 and the top mold 2.

Each adapter plate 9 is provided with a mating plane I 15, a mating plane II 16, a mating plane III 17, and four bolt holes I 14; each adapter plate 9 is mounted on the bottom surface of the die-casting machine table plate 8 through four bolts I and the four corresponding bolt holes I 14; the mating plane I 15 is slidably connected to the connecting plate 10 to adjust the gap between the adapter plate 9 and the connecting plate 10 in a front-back direction, the mating plane II 16 is mated with the bottom surface of the die-casting machine table plate 8, a gap is provided between an upper end surface of the connecting plate 10 and a lower end surface of the die-casting machine table plate 8 to adjust a vertical direction position, and a gap is provided between the mating plane III 17 and the connecting plate 10 to adjust a horizontal direction.

The adapter plate 9 is mounted on the die-casting machine table plate 8 for a long time without disassembly. During the loading and unloading process of the mold, only the connecting plate 10 of the mold is suspended and mounted on the adapter plate 9. Meanwhile, the gaps in three directions between the adapter plate 9 and the connecting plate 10 ensure that the bottom mold 1 and the top mold 2 can be adaptively mated during assembly, and the top mold 2 does not need to be frequently tightened during loading and production, greatly improving loading efficiency and reducing labor intensity.

A lower end of the connecting plate 10 is provided with bolt holes II 19, the bolt holes II 19 are mounted at a top of the top mold 2 through bolts II, and an upper end of the connecting plate 10 is provided with a mating plane V 20 for mating with the mating plane III 17 and a mating plane IV 18 for mating with the mating plane I 15.

The connecting plate 10 is modular, and its size can be adjusted according to the sizes and requirements of different molds to meet the connection requirements of different molds, achieving strong compatibility, greatly improving the versatility and flexibility of the connecting plate 10, simplifying assembly steps, and improving assembly efficiency and accuracy.

A plurality of exhaust grooves 29 are circumferentially and uniformly provided at intervals on the mold release ring 12, the exhaust grooves 29 penetrate the mold release ring 12 to ensure smooth exhaust of the mold cavity, the mold release ring 12 is provided with eight bolt holes V 31, and the eight bolt holes V 31 are connected to the connecting columns 5 through corresponding bolts V to ensure the stability of the mold release ring 12 during operation. The exhaust grooves 29 provided on the mold release ring 12 ensure smooth exhaust of the mold cavity, and can effectively avoid defects caused by insufficient pouring and pores.

Guide flat keys 26 and two wear-resistant flat keys I 25 are provided on four sides of the bottom plate 3, the guide flat keys 26 are distributed at middle positions of the four sides of the bottom plate 3, the two wear-resistant flat keys I 25 are distributed on two sides of the guide flat keys 26 respectively, a bottom end of each side mold 13 is provided with guide wear-resistant keys 27 matching the guide flat keys 26, the guide wear-resistant keys 27 are mounted in the middle of the bottom end of the side mold 13 through four bolt holes IV and corresponding bolts IV, a lower portion of the guide wear-resistant key 27 is provided with a positioning slot 28, the positioning slot 28 is mated with the guide wear-resistant key 27, and two sides of the guide wear-resistant keys 27 are provided with wear-resistant flat keys II mated with the wear-resistant flat keys I 25.

Positioning key slots are provided at the middle positions of the four sides of the bottom plate 3, the positioning key slots are spaced apart from the guide flat keys 26, the positioning key slots are arranged between the center of the bottom plate 3 and the guide flat keys 26, a wedge-shaped positioning key 32 is mounted in each positioning key slot, and the bottom mold 1 is assembled to the bottom plate 3 through four wedge-shaped positioning keys 32.

The wear-resistant flat keys I 25 and the guide flat keys 26 are both made of high hardness and high wear resistance materials, with excellent wear resistance and corrosion resistance. The synergistic effect of the wear-resistant flat keys I 25 and the guide flat keys 26 prevents the side molds 13 from deviating or tilting during use and keeps the side molds always centered, improving the stability of the mold.

The lower end of each positioning column 4 is provided with a mounting seat 22, the upper end of each positioning column 4 is provided with a guide column 23, each guide column 23 is provided with a pin hole 24 for lifting, and each mounting seat 22 is provided with four bolt holes III 21 circumferentially; the pin hole 24, the guide column 23, the positioning column 4, and the mounting seat 22 are integrally formed to reduce assembly tolerances; the mounting seat 22 is mounted in a corresponding groove on the bottom plate 3, and the mounting seat 22 is mounted on the bottom plate 3 through the four bolt holes III 21 and bolts III. The positioning column 4 is manufactured through integrated molding technology and machined once without split assembly, fundamentally eliminating assembly tolerance of a split positioning column 4, ensuring high accuracy and stability of the positioning column 4, and further enhancing the assembly accuracy and stability of the entire mold.

The working principle of the present invention is as follows:

When the mold is closed: the external die-casting machine drives the adapter plates 9 to descend through the die-casting machine table plate 8, and the adapter plates 9 drive the top mold 2 to descend through the connecting plates 10; when the positioning sleeves on the top mold 2 descend to the upper ends of the positioning columns 4, the pin holes 24 and the guide columns 23 on the positioning columns 4 are inserted into the positioning sleeves, where the guide columns 23 ensure that the top mold 2 and the bottom mold 1 are coaxial; when the mating precision of the top mold 2 and the bottom mold 1 deviates due to mounting deviation, wear deformation, and the like of the top mold 2 and the bottom mold 1 or mating parts, the guide columns 23 will be subjected to extrusion force when inserted into the positioning sleeves; however, gaps convenient for adjusting positions are provided between the adapter plates 9 and the connecting plates 10 in the front-back direction, horizontal direction, and vertical direction, the adaptability between the adapter plates 9 and the connecting plates 10 in the three directions enables the guide columns 23 on the positioning columns 4 to be accurately inserted into the positioning sleeves of the top mold 2, keeping the top mold 2 and the bottom mold 1 in a coaxial state, and improving the mating precision between the top mold 2 and the bottom mold 1; the mold cavity for forming workpieces is formed through the bottom mold 1, the top mold 2, and the side molds 13, ensuring the forming quality of workpieces and improving the forming accuracy of workpieces; after the mold is closed, molten aluminum is poured into the mold cavity to form a workpiece.

When the mold is removed: the formed workpiece adheres to the top mold 2 after cooling; when the workpiece needs to be released from the mold, the external die-casting machine drives the adapter plates 9 to rise through the die-casting machine table plate 8, and the adapter plates 9 drive the top mold 2 to rise through the connecting plates 10; when the top mold 2 rises, the formed workpiece is driven to rise; after the workpiece rises to a certain height (set according to the actual use), the hydraulic mechanism drives the mold release plate 7 to descend; when the mold release plate 7 descends to contact the ejection rod plate 11, the ejection rod plate 11 is driven to descend, and the ejection rod plate 11 drives the mold release ring 12 to descend through the connecting columns 5; when the mold release ring 12 descends, the workpiece adhering to the top mold 2 is released, then the workpiece is released from the mold, and the hydraulic mechanism drives the mold release plate 7 back to its original position.

When the mold is closed again, the external die-casting machine drives the adapter plates 9 to descend through the die-casting machine table plate 8, and the adapter plates 9 drive the top mold 2 to descend through the connecting plates 10. At the same time, the return columns 6 on the ejection rod plate 11 contact the upper ends of the positioning columns 4, and the top mold 2 continues to descend. Due to the force generated by the positioning columns 4 and the return columns 6, the ejection rod plate 11 and the mold release ring 12 return to their original positions.

Through the mutual mating between the hydraulic mechanism, the mold release plate 7, the ejection rod plate 11, the connecting columns 5, and the mold release ring 12, the mold release process is smooth, the workpiece is subjected to uniform force with little deformation, and the mold does not need to be disassembled or replaced during maintenance. Therefore, the maintenance efficiency and cost of the mold are significantly better than those of conventional molds.

The flexible floating positioning between the adapter plates 9 and the connecting plates 10 in the present invention completely breaks conventional full rigid connection between the mold and the die-casting machine; the top mold 2 can achieve adaptive high-precision fit positioning with the bottom mold 1 by mating with the positioning columns 4 when the mold is opened and closed; meanwhile, conventional small ejection rods are completely replaced by the hydraulic mechanism, the mold release plate 7, the ejection rod plate 11, the connecting columns 5, and the mold release ring 12, thereby significantly improving the force and deformation of the workpiece, eliminating disassembly and replacement when the mold is maintained, greatly improving maintenance efficiency, and reducing maintenance costs.