Die casting process is a manufacturing technology that obtains high precision, high quality castings by injecting molten metal into a mold cavity and rapidly cooling and curing under high pressure. Die casting machine is the core equipment to realize this process, and the die closing mechanism is a crucial part of the die casting machine. It is responsible for the opening and closing action of the mold, which directly affects the stability of the production process and the quality of the casting.

With the intensification of market competition and the progress of technology, the requirement of die casting machine closing mechanism is getting higher and higher. The traditional design method has been difficult to meet the current needs, so the introduction of optimization design and simulation technology has become an inevitable trend.

1、The basic principle and structure of mold closing mechanism

The main function of the mold closing mechanism is to realize the accurate closing and smooth opening of the mold in the process of die casting. The common types of clamping mechanism include three plates and two plates, of which three plates are widely used because of its simple structure and easy maintenance.

The typical three-plate closing mechanism is composed of a fixed template, a moving template, a pull rod, a toggle rod, etc. When the hydraulic cylinder pushes the moving template forward, the pull rod drives the elbow rod to rotate, and then the mold is closed. Conversely, when the hydraulic cylinder moves in reverse, the mold is opened.

2、The necessity and goal of optimal design

2.1、Improve production efficiency: The optimized mold closing mechanism should have faster response speed and shorter working cycle.

2.2、Improve casting quality: reduce mold deformation and wear, ensure casting dimensional accuracy and surface quality.

2.3、Reduce energy consumption: Reduce energy consumption of hydraulic systems by optimizing structural design and material selection.

2.4、Enhance stability: improve the rigidity and vibration resistance of the mold closing mechanism to ensure long-term stable operation.

2.5、Prolong service life: reduce the wear and failure rate of parts and reduce maintenance costs.

3、Optimization design methods and steps

3.1、Preliminary design and modeling

Based on the existing experience data and design specifications, the preliminary structural design is carried out.

Use 3D modeling software (such as SolidWorks, CATIA, etc.) to build detailed geometric models.

3.2、Finite element analysis

The static and dynamic analysis of the clamping mechanism is carried out by using ANSYS and other finite element analysis software.

Identify stress concentration areas and potential failure points to provide basis for subsequent optimization.

3.3、Multi-objective optimization

Advanced algorithms such as genetic algorithm and particle swarm optimization are used to optimize key parameters (such as rod length ratio, section size, etc.).

Combining with orthogonal regression design method, the approximate function relationship between structural properties and design variables is established to reduce the calculation amount.

3.4、Topology optimization

Topological optimization techniques such as variable density method are applied to further reduce the weight of the structure while maintaining or improving the performance.

Use professional software such as OptiStruct for topology optimization design.

3.5、Virtual prototype simulation

Dynamic simulation software such as ADAMS was used to simulate the motion characteristics of the clamping mechanism under actual working conditions.

Verify the effectiveness of the optimized design and make adjustments according to the simulation results.

3.6、Experimental verification

Prototype and test.

The performance indexes before and after optimization were compared to evaluate the optimization effect.

4、Case study

Taking the hyperbolic toggle mold closing mechanism of a certain type of die casting machine as an example, through the above optimization process, the mold closing time is successfully shortened by 15%, the mold wear is reduced by 20%, and the machine energy consumption is reduced by 10%. In addition, the surface quality and dimensional accuracy of the castings have also been significantly improved.

5、conclusion

Through the optimization design and simulation analysis of die casting machine closing mechanism, the overall performance of the equipment can be significantly improved. In the future, with the development of artificial intelligence technology and big data analysis, the intelligence and refinement of die casting machine design will be further promoted, laying a solid foundation for the realization of efficient, green and intelligent casting production.