浇口和流道设计

点浇口流道设计标准点浇口流道设计是指在混凝土浇注过程中，在构件表面设置特定形状的沟槽，用于引导和控制混凝土流动。

点浇口流道设计的目的是保证浇注过程中混凝土能够均匀流动，并且确保构件表面不会产生堆积或漏浆现象。

下面是点浇口流道设计的一些标准和要求：1. 点浇口流道的形状应该是圆弧形或者椭圆形，这样能够有效地控制混凝土的流动，减少流速和冲击力，避免产生分层或者空洞等缺陷。

2. 点浇口流道的宽度要根据混凝土的流动性进行合理设计。

一般来说，流动性较好的混凝土，流道的宽度可以适当减小。

相反，流动性较差的混凝土，流道的宽度则需要适当增大。

3. 点浇口流道的深度应该根据浇注厚度和混凝土的性质来确定。

在混凝土浇注时，流道的深度要与浇注层的厚度保持一定比例。

一般来说，流道的深度可以略大于浇注层的厚度。

4. 点浇口流道的间距要根据浇筑施工的需要来确定。

一般来说，流道之间的间距可以根据施工的步骤和设备的要求来决定。

比如，如果使用振动器进行浇筑，流道之间的间距可以适当增大。

5. 点浇口流道的几何形状要符合混凝土浇筑施工的要求。

一般来说，流道的几何形状应该简单，造型规整，确保在浇筑过程中混凝土能够顺利流动。

6. 点浇口流道设置的位置要考虑结构的承重和抗震要求。

一般来说，流道的位置应该远离结构的边缘和受力部位，以避免影响结构的强度和稳定性。

综上所述，点浇口流道设计标准主要关注流道的形状、宽度、深度、间距、几何形状和位置等方面。

通过合理的设计和施工，能够保证混凝土在浇筑过程中的均匀流动，最大程度地避免产生缺陷。

同时也能够提高施工效率，减少浪费，保证结构的质量和安全。

2_05浇口和流道设计浇口和流道设计是塑料注塑成型过程中非常重要的一环，它们的设计质量直接关系到成型件的质量和生产过程的稳定性。

本文将详细介绍浇口和流道设计的意义、原则以及一些常见的设计方法。

一、浇口的设计意义1.提供熔融塑料进入模具腔体的通道，确保塑料充填腔体均匀；2.控制塑料进入速度和压力，避免短充、气泡等缺陷；3.有效防止熔融塑料对模具磨损和腐蚀；4.方便脱模和切除浇口处余料。

二、浇口设计的原则1.浇口位置应选择在产品外表面影响不大的部位，如底部、壁角等；2.浇口形状应简单，避免锐角和复杂几何形状，以利于塑料顺利进入腔体；3.浇口尺寸应合理，既能保证塑料充填，又不至于过大过长造成浪费和废料；4.浇口和产品分离的方式应考虑生产效率和产品外观要求；5.浇口设计要充分考虑熔融塑料的物理性质和流动性，避免局部过热或过冷。

三、流道设计的意义1.将浇注的熔融塑料传递到各个腔体，使得产品充填均匀；2.控制塑料的流速和压力，避免气泡、短充等缺陷；3.提供相对稳定的压力和温度环境，促进熔融塑料的密度均匀；4.对于多腔体模具，流道设计还要充分考虑产品产量的平衡。

四、流道设计的原则1.流道的直径、长度和截面积要合理选择，以保证塑料在流道内的流速符合流动性要求；2.流道和浇口的连接处要能够顺利过渡，避免过渡断面过小或过大造成流动不畅；3.流道的布置应考虑与模具结构的配合，以便于流道的加工和安装；4.尽量减少流道的弯曲和分支，以减小塑料流动阻力和热量损失；5.流道的表面要光滑，减小摩擦阻力和物料附着。

总之，浇口和流道设计是塑料注塑成型过程中关键的一环，其设计质量直接影响产品的质量和生产过程的稳定性。

合理的浇口和流道设计可以确保塑料充填均匀、避免气泡和短充等缺陷，并提高生产效率和降低生产成本。

因此，在进行浇口和流道设计时，需要综合考虑材料的流动性能、产品的几何形状、模具结构等因素，并遵循一定的设计原则。

压铸模流道与浇口设计压铸模流道设计是压铸模具设计中的重要环节，其质量的好与坏直接影响着铸件的质量和生产效果。

好的流道设计能够使得金属熔液在铸件中充分流动，保证铸件的充填性和凝固性，减少缩孔、破裂等缺陷。

因此，在进行压铸模具设计时，流道设计是需要重点考虑和完善的。

首先，流道设计需要考虑到金属熔液进入模腔的流动路径。

一般情况下，流道设计应遵循从大到小、从圆到方、从长到短的原则。

即，从金属熔液流动的开始到结束，流道的截面积逐渐减小，形状也从圆形转变为方形。

这样可以使得金属熔液在流动过程中更加平稳，避免较大的速度差异引起的涡流和过剩的测射。

其次，流道设计还应考虑到金属熔液的冷却影响。

流道的设计应使其能够迅速将熔液引导到模腔中，并确保流动的速度和温度均匀。

这样可以避免熔液在流动过程中过度冷却而凝固，造成流道堵塞或铸件表面不光滑的问题。

同时，流道设计还需要考虑到金属熔液的流动阻力。

流道的长度和弯曲度越小，流经流道的金属熔液的阻力就越小，流动能力就越好。

因此，在流道设计中应尽量减少流道的弯曲和咽喉，使金属熔液能够顺畅地流动。

另外，在流道设计中，浇口的位置和形状也是需要注意的。

浇口的位置应选择在铸件底部或靠近铸件底部的位置，以充分利用重力来推动金属熔液流动。

浇口的形状应选择为喇叭口状或倒喇叭口状，以便于金属熔液的顺畅流动和避免气泡和杂质的混入。

在进行流道设计时，还需要综合考虑模腔的结构和形状。

流道设计应适应模腔的形状，保证金属熔液能够均匀地流入并充填整个模腔。

同时，流道的尺寸也需要根据铸件的尺寸和结构来进行合理确定，以保证铸件的充填性能和凝固性能。

需要注意的是，流道设计还应结合具体的铸造材料和生产工艺来进行综合考虑和设计。

不同的铸造材料和生产工艺对流道的要求和设计方法也会有所不同。

总结起来，压铸模流道设计的目标是使金属熔液在模腔中充分流动，保证铸件的充填性能和凝固性能。

良好的流道设计能够避免铸件缺陷，提高生产效率和质量。

注塑模具设计之浇口与流道设计
1.浇口设计：
浇口是塑料进入模具腔体的通道，直接影响产品的质量和外观。

浇口设计应遵循以下原则：
1.1浇口的位置应尽量选择在产品的无重要表面或结构上，以减少产品上的痕迹和缺陷。

1.2浇口的形状应尽量简单，以便于注塑成型时的塑料流动，避免气泡和短流等缺陷。

1.3浇口的大小应根据产品的要求确定，过大会导致浇注时间过长，过小会导致注塑过程压力过高。

1.4浇口与产品的交界处应尽量平滑，以减少痕迹和切除时的损耗。

1.5浇口的数量应尽量减少，多个浇口可能导致注塑不平衡，造成产品尺寸不一致。

2.流道设计：
流道是浇口与模具腔体之间的连接通道，它将塑料从浇口引导到模具腔体中。

流道设计应遵循以下原则：
2.1流道的形状应尽量简单，避免过多的转弯或急角，以减少流动阻力和塑料流动不均匀导致的缺陷。

2.2流道的长度应尽量短，以减少注塑周期和塑料的凝结时间。

2.3流道的截面积应逐渐减小，以确保塑料在流道中均匀流动，避免气泡的产生。

2.4流道与模具腔体的接头处应尽量平滑，避免塑料流动时的冲击和挤压，以减少产品上的痕迹和缺陷。

总结起来，注塑模具设计中的浇口与流道设计需要考虑产品的要求、材料的特性和注塑工艺的要求等多个因素，以使得产品的质量达到最佳状态。

在实际设计中，需要结合实际情况进行调整和优化，不断改进和提高设计水平。

压铸模流道与浇口设计压铸是一种通过将熔融的金属注入到模具中，形成所需形状的工艺。

在这个过程中，流道和浇口是非常重要的，因为它们决定了金属液的流动路径和充模情况。

对于大多数压铸件而言，流道主要包括归流道和分流道。

归流道是将熔融金属从浇注口引导到模腔的通道，而分流道则将金属液引导到各个腔室中。

流道的设计应该尽可能地减小金属液的流速和流动阻力，确保金属液能够均匀地填充模腔，并且不会产生气泡或其他缺陷。

在设计流道时，要考虑到金属的流动行为和模具的结构。

流道的截面应该逐渐增大，以保证金属液能够均匀地流动。

此外，流道的长度和弯曲程度也需要适当调整，以减小流动阻力和流动速度。

在流道的设计中，还应该考虑到金属的流场分布和模具的加热和冷却情况，以确保金属液能够流动到模腔的每个角落。

浇口的设计也是非常重要的。

浇口是金属液注入模具的入口，直接影响到金属液的充模情况和充模速度。

一个合理的浇口设计应该能够使金属液均匀地分布到模腔中，并且不会产生气泡或其他缺陷。

浇口的设计要尽可能地减小气体的进入，并且能够方便地从铸件中排出。

浇口的位置和形状也需要仔细考虑。

一般来说，最好选择在模具的上部或侧部设置浇口，这样可以减少气体的进入并且方便排气。

浇口的形状可以是圆形、椭圆形或矩形，具体要根据铸件的形状来确定。

在浇口的设计中，还应该考虑到金属液的充模速度、充模压力和浇注温度，以确保铸件的质量。

在流道和浇口的设计中，还需要考虑到模具的制造成本和生产效率。

流道和浇口的设计应该尽可能地简单和经济，同时也要能够满足产品的质量要求。

此外，在模具的制造过程中，还需要考虑到流道和浇口的冷却和加热情况，以确保模具的寿命和稳定性。

总之，流道和浇口的设计是压铸工艺中非常重要的环节。

一个合理的流道和浇口设计可以确保金属液能够均匀地填充到模腔中，并且不会产生气泡或其他缺陷。

同时，流道和浇口的设计还需要考虑到模具的制造成本和生产效率。

通过合理的流道和浇口设计，可以提高压铸件的质量和性能。

一. 流道(RUNNER)
流道一般分為三種:圓形,梯形及U形.
1. 圓形: 表面積小,熱量不容易散失,流動陰力最小,但需要同開在母模和公模上,要保證兩半
圓完全吻合,制造困難.
2. 梯形: 加工容易,熱量散失和陰力也不大,是常用的一種.
3. U形: 加工困難,少用.
考慮壓力損失用圓形,考慮加工容易用U形.
二. 澆口(GATE)
1. 直接澆口
優點: 熔體直接通過主流進入形腔,流程短,進料快,流動陰力小,有利排氣,適用於兩板式模具.
缺點: 去除澆口不便,部品上有明顯的澆口痕跡.
2. 側澆口
優點: 一般開設在模具分型面上,從制品內側或外側邊緣進料,適用於一模多件,能提高生產率去除澆口容易.熔體通過主流道直接進入型腔,流程短,進料快.
缺點: 排氣不便,部口上有明顯的澆口痕跡.
3. 點澆口
優點: 這種澆口尺寸很小,去除澆口后,制品上留下的痕跡不明顯,開模后可自動拉斷,不需二次加工,有利於自動化操作,適用於雙分型的三板式模,以便脫出流道凝料.
缺點: 壓力損失大,制品收縮大,變形大.
4. 潛伏式澆口
優點: 澆口設在制品側面不影響制品外觀的較隱藏部位並與流道成一定角度,潛入母模下面斜向進料.
缺點: 排氣不便,不適用於強韌材料.
排氣系統:可使型腔和澆注系統中株有空氣及塑料受熱或凝固而產生的發揮物順利地排出模具之外,以保證熔體順利充滿型腔,否則,被壓縮的氣體所產生的高溫將引起部品局部碳化焦或
產生氣泡.。

Runner and gate design.The Important FeaturesIntroduction;The following is a brief summary of the important factors to consider when designing runner and gating systems for Zinc and Aluminium pressure die casting dies.In the past runner systems were designed using empirical knowledge and developed using trial and error methods which involved excessive time and often multiple die trials. Today, computer programmes exist which eliminate these problems and are able to give good results immediately but, many of the most basic design issues are often neglected during the design stage particularly if the die is designed by the tool maker without consultation to the die casting technicians.These brief notes are intended as guidelines for use during training and as an aide memoiré for die design technicians and designers. They are not intended to cover all aspects of die design practice.____________________________Objective:The runner and gate system should achieve the following in basic terms:•Produce a casting of the specified quality; in terms of finish, size and tolerance, casting integrity, mechanical properties, cycle time and consistency.••Achieve first time success; to avoid wasted time on successive machine trials, delays in delivery of samples, loss of customer confidence and excessive die developmentcosts.••Provide optimum yield; increases efficiency by optimising the casting to runner yield ratio, improve metal losses due to lower re-melt weights, reduces cycle times due toimproved thermal efficiency.THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.Runner and gate design.Influencing factors.Designing a runner system:Selection of the machine should be based on several factors but not just shot weight and platen area. Most machines are supplied with a PQ2 diagram or one exists from measurements taken on other similar machines. Runner designs should be based on machine performance with a given plunger or shot sleeve diameter, known hydraulic pressure and in the case of hot chamber die casting the nozzle size. Both projected area and lock tonnage should also be considered if the proposed runner plus casting is liable to approach the machine limits.Casting geometry:The cavity should be positioned to promote the best cavity fill conditions while accommodating essential die features such as core slides, cooling channels, sensitive casting features, number of cavities and robotic removal constraints. Other process criteria such as second operation locations, clipping orientation, break off de-gating and finishing requirements should also be considered before the cavity position is decided.Uniform flow path:The runner should establish a uniform metal flow rate deigned to promote the best hydraulic system, stable metal pressure and velocity. Most computer design programmes will control these features but the designer will still have institute a flow path allows these features conform to the desired parameters.Cavity fill conditions:Modern pressure die casting machines often have more power at the shot end than is required to achieve the optimum fill conditions. Consequently, the performance offers many gate area options capable of achieving the desired fill conditions – the designer must select the most suitable based on the casting specification and process limitations.Cavity fill pattern:Is invariably decided by the casting geometry and gate position but the metal pressure and velocity will have influence but to a lesser extent. The influence of casting features such as vertical surfaces and ribs, variable section thicknesses, isolated bosses and cores must be considered when the gate position is decided.Venting and overflow wells:Should all be considered at the design stage – are directly related to the cavity fill conditions and casting geometry but also the introduction of over flow wells or pockets may have significant cost implications.THE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.Runner and gate design.Machine Performance.Effects of change.Injection pressure: Reduce or increase .• Increased injection pressure – will increase flash, raise galvanising and die erosion.Optimum pressure levels will improve casting integrity, maintain speed and velocity and improve cavity fill conditions.Reduced injection pressure – reduces flow rates, and static metal pressure on hot chamber pressure die casting machines.• Plunger diameter – on hot chamber die casting machines smaller plungers give thebest casting results with higher injection pressure and faster delivery. On aluminium cold chamber machines plunger diameter choice is less critical but effect is far more significant in performance terms - increasing delivery velocity and reducing cavity fill times.• Plunger speeds - high terminal velocities can produce pressure spikes on older diecasting machines leading flash and die wear. High gate speeds result in expensive die maintenance due to die erosion and galvanising.• Runner Area/volume - die designer should create a uniform flow through the runnerby establishing nozzle area (hot chamber) as the largest section in the runner.Progressively reducing the cross sectional area of the runner at each section to the gate which should be the smallest area in the runner system. Similarly, on cold chamber dies the sprue post runner should be the largest runner section down to the gate which should be smallest section of the runner.Flow rate histogram.N o z z l e a r e aGateAreaTHE BROCK METAL COMPANY LIMITED,WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.Runner and gate design.Runner features‘Y’ Junction not ‘T’‘Y’ JunctionReduces area and increases pressure progressively.‘T’ JunctionIncreases volume at the junction creating low pressure area at the centre of the gate.THE BROCK METAL COMPANY LIMITED,WALSALL RO D. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.ARunner and gate design .Runner featuresTaper tangential runner - with shock absorber – showing section change A to B toSmaller diagram – illustrates poor runner design small access radius,increased e taper,maintain pressure and velocityrunner volume at the radius, small runner cross section at the end of th and no shock absorber.THE BROCK METAL COMPANY LIMITED,WALSALL RO D. NORTO NES, CANNOCK, STAFFS, UK WS11 9NR.A N CARunner and gate design .Runner featuresDrawings – Show section through sprue posts on Aluminium (top ) and Zinc (bottom )This area most commonly inte d incorrectly by toolmakers.Note; Th radiusdies.rprete e reduction from the sprue faces to die face and the size and blend which are struck from the same centre to ensure even transition from sprue to die.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD,. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR.Runner and gate design .Runner featuresRunner sections: Need to be adjusted by differing percentages tor l10% reduction in runnerarea- down stream of metalaccommodate larger angular direction changes30% reduction in runner a ea - down stream of meta flow – for 900 bend.flow – for a 200 bend.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Gate Areasate Areas:ptimum for Zinc alloy pressure die-casting :ed / velocity – 35 – 45 metres per second.ish – 20 milli seconds or functionalOptimum for Aluminium alloy pressure die casting:5 metres per second..ortant on large castings asFil a etry: has the largest influence on cavity flow paths – high metal velocitypplied to vertical casting faces causes turbulence, galvanising and impedes metal. All of which and areas; It is possible to assess parts of the casting separately nd this may be advantageous if they are unlikely to be fed directly from the gate. of a given part sing separate gates for each zoned area. This will often improve fill characteristics low: It must be stressed that the gates and runner both fluence flow direction. Once the runner is established metal under pressure will G O • Gate spe • Cavity fill time – plated or powder coated fin parts – 40 milli seconds.• Gate depth – 0.15 – 0.5 mm.• Gate speed / velocity – 25 to 3To avoid die erosion and control cavity fill characteristics • Cavity fill time – end of fill temperature is most imp solidification can occur prior to cavity filling.• Depth 1.25 – 3 mm (1.5 mm minimum for machine intensification to be effective ).l P ttern:Casting geom a can result in expensive die repairs / maintenance. Section changes and cores change pressure and direction and these effects need to be considered and understood when considering gate position options.Zones volumes a Using computer programmes allows each separate zone to be quantified in volume and surface area terms. If treated as un-gated the fill time and end of fill temperature can be determined as a comparison with the main body of the total casting.Gating separate zones: It is possible also to examine separate zones u and reduce the risks of defects. The uses of multiple gates are not a risk if designed and implemented correctly.Runner will direct metal f in enter the cavity in the same direction and flow angle. Varying injection speed and metal pressure may alter this angle slightly but this is only a fine tuning method.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTO NES, CANNOCK, STAFFS, UK WS11 9NR,N CARunner and gate design .Fill pattern.Influence of casting geometry ertain casting shapes are best filled in a predetermined way, if the toolingre the depth is 50% of the edge length or more he box :C configuration allows. Deep boxes, whe can be fed using the gate runner configuration shown below – alternatively t can be turned through 450 to shorten the runner distance and improve shot yield.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Fill pattern.vals or round castings: Try to fill the centre first using either a runneronfiguration below or a more traditional fan feed. With fan feeds it is essential to getO c the ratio of the approach angle and width of gate correct.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Fill pattern.nnular rings: Can be fed using the runner configuration indicated below. A smallver flow well should positioned in the centre hole to take away any lubrication fume A o and another well placed on the out side perimeter adjacent to the last segment of the part to fill.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Fill pattern.Rectangular Plates: Fill across shortest distance whenever possible – t cut downow distance and increase end of fill temperature. It is therefore advisable to avoido fl the option shown in the upper diagram if possible.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Fill pattern.Diagram show e – to resolve problems ofporosity and poor ximately 6 mm deep, with a gate depth of between 1.8 and 2.5 mm. Casting weighed approximately 5 Kg and with a flow distance of 510 m s: runner developed over a period of tim fill results. The darker blue area is appro m.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Fill pattern.Diagram show niform gate thickness of 2 mm. The runner and a subsequent increase in yield of 18% and a reduction in pr ected area of some 22% allowing improved shot speed and increased in injecs: Revised runner with balance fill and u shows reduced shot weight by over 1 Kg oj tion pressure.THE BROCK METAL COMPANY LIMITED, WALSALL ROAD. NORTON CANES, CANNOCK, STAFFS, UK WS11 9NR,Runner and gate design .Vents and Overflow wells.Points to remember:• Over flow w tal flow, but rarely remove gas and fume as the cavity is normal sealed before they become a .only work for less than half of the cavity fill time as they arefinal fill is achieved. • Over flow wells are a poor method of die heating both inefficient and wasteful.See reference material from ILZRO, IZA.JWTSep ells can be used to change or divert mective ly • Similarly vents can sealed off before the• Use only one connection per over flow to avoid back feeding through theoverflow and reintroducing gas and cold metal. • Always vent over flow wells – as a precaution.Many are lost before re-melting and therefore increase metal losses.t 05 – issue 5。

注塑模具的流道与浇口设计
塑料熔体从注射成型机的喷嘴经主流道、流道、浇口进人模腔。

模腔的人口被称为浇口。

为了防止喷嘴末端的固化冷料进人模腔，在流道的末端应该设计冷料井。

01流道
流道是从主流道到浇口间的重要通道，是注塑机喷嘴射出的熔融塑料的流动通道。

流道应被设计成低阻力和防止冷却。

通常，流道被设计成梯形或圆形。

常见流道的形状
对于多腔模具，为了得到好的尺寸精度，流道的设计十分重要，下图典型的多腔模具的流道设计。

多腔模具流道
02浇口
浇口系统设计，如位置、数目、几何形状和尺寸对生产效率和尺寸精度是十分重要的，浇口的作用总结如下：
1.控制流入模腔的塑料熔体的体积和方向
2.固化前，在模腔内封闭熔料并阻止熔体回流到流道
3.由于黏性耗散引起的热而生成
4.易于切下流道，简化制品的后处理
分类：
非限制性浇口称为直浇口，如下图所示，这种浇口形式的模具设计简单，操作容易，成型容易并减小收缩。

但这种浇口成型周期变长，并易出现如裂纹、翘曲和残余应力等成型缺陷。

直浇口。