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After reading this title, everyone must have thought that I drank too much. How could the guide column go inside the cavity?
At that time, I just graduated from the university and assigned to the state-run Changzhou Mould Factory to work (1981). The factory received a batch of die-casting molds from Shanghai Dahua Instrument Factory. One of the parts is called "outer frame", as shown in the figure: peripheral 400x300, internal size 300x200. The thickness is 5 mm. The product weighs 1.03 kg, aluminum alloy.
The mold has been designed and designed by Lu Hongliang engineers. There is no difficulty, the design is very formal, and the moving model is as follows: (There was no computer at the time, the picture below is based on the memory)
The mold size is 750x650x520. The mold weight is 1.9 tons. At the time of the factory trial, because the mold was too simple, no one raised any objection. However, after the other factory saw the design plan, they were greatly dissatisfied. They proposed that the largest die-casting machine in their factory is 350 tons, and the maximum width of the mold that can be accommodated cannot exceed 600. However, the width of the mold designed by our factory is 650. Because the maximum die-casting capacity of a 350-ton die-casting machine can reach 6 kg, the product is only about 1 kg in weight due to special circumstances. So resources are a big waste. Since I was assigned to the factory just after graduating from college, I can't say more, so I don't have to be reluctant. Later, the old factory director Jin Zhiliang came to talk to me, I must think of ways. Because the other party is indeed a reasonable request.
There is a historical reason. At that time, Liu Tao, the secretary of the mold factory, was a commune when I was decentralized. He was the deputy secretary of the Communist Party Committee. I was the director of the mold factory. We were very familiar with it. Later, Liu Shuji was transferred to Changzhou Mould. As a secretary of the factory, I was admitted to the university when I resumed the college entrance examination in 1977. (At the time, I was called Zhenjiang Agricultural Machinery College.) I was hired as a technical consultant by the factory during my sophomore year, and helped them draw drawings in their spare time because the engineers at the factory were all Turned from the tool manufacturing department of a military enterprise, it is not familiar with injection molds and die-casting molds. So in those years, more than 50% of the mold drawings of the factory were painted by me. Among them is the mold of "Suzhou Peacock TV".
I have performed the following analysis on the product:
1. The product thickness is 5 mm, the cavity depth of the single side is 2.5, and the pressure on the side wall of the cavity is very small. Therefore, there is no problem in the strength of the mold in the X and Y directions. Can take a small size.
2. Since the middle of the product is empty, the pressure on the moving template is also small.
That is to say, the length and width directions of the mold can be made as small as possible, and the moving template can be thinner. However, the position of the guide post and the position of the mold frame are calculated, and the design of the Lugong is the same. To meet the requirements of the other party, there must be other methods. Otherwise, the other factory can only buy a larger die casting machine. (450 tons) That is equivalent to fishing with a telephone pole.
After careful consideration, I came up with a design solution. As shown below:
In this program, I completely abandoned the model frame (the Hong Kong master called "the original body of the shirt") and arranged the guide column in the middle of the product. The mold size is 500x400x450. The weight is 0.7 tons. It is 63.2% lighter than the original.
This is definitely a deviant idea, too ridiculous. At the time, all people opposed my thoughts for the simple reason that I had never seen such a design. At that time, because I was in a state-owned enterprise, I had to take care of everyone’s face and I could not speak too professionally. Difficult.
Because the other factory is eager to ask us for a plan, but those "half buckets of water" are unanimously opposed to my plan. (In fact, it is a "state-run disease" blame) I am anxious, I can only put an oolong: "Please oppose the person to establish the 'fatigue model' of this program", do not understand the cow playing the piano. I added: "It's a common saying that the mold is working under what circumstances, and under what circumstances is it damaged?"
There is a female engineer named Xu Yihua who said: "Listen to you, I understand. If you say damage, you can't be bad if you use the mold for 100 years! But we have never seen the guide column run. Go inside the cavity."
Finally, this program has been recognized by the other factory and is greatly appreciated. As long as a 200-ton die-casting machine can be produced, the cost of die-casting is greatly reduced. There are no recordable stories of molds from manufacturing to use. (It's too simple, nothing is going on, for the mold factory, nothing is fine.)
Through this story, I want to tell you that the first question to consider when conceiving a mold is: How is the mold working under, and how is it damaged? Don't be tied to your mind by tradition.
The whimsical guide column is placed in the cavity
Author----Cha Hongda