Cooling‑channel performance directly influences gravity casting mold finished‑part yield. Temperature‑field difference, water‑flow parameter and hot‑spot scope are quantifiable indexes for EV structural‑part mold quality evaluation.
Maximum local temperature difference inside gravity casting mold should stay below 85 ℃ under stable production. Temperature‑difference above 110 ℃ produces obvious hot‑spots and raises shrinkage‑related casting porosity defect rate by 36 % for EV structural‑part mold.
Each cooling circuit water flow rate shall maintain ≥8 L/min for gravity casting mold thick‑wall zones. Flow rate dropping below 5 L/min reduces heat‑exchange efficiency by 47 %, extending solidification time of local hot‑spot zones in aluminum alloy foundry.
Procast CAE temperature‑field cloud map shows hot‑spot size and location. Hot‑spot region exceeding 35 mm diameter at casting thick section indicates insufficient cooling capacity; mold structure needs optimization before large‑batch EV structural‑part production.
Cooling‑channel distance to cavity surface shall keep 16‑22 mm for gravity casting mold. Distance below 14 mm increases H13 hot work steel thermal‑cracking risk; over 24 mm cannot achieve effective heat dissipation for thick‑wall castings.
Temperature difference between cooling‑water inlet and outlet normally reaches 8‑14 ℃. If ΔT stays below 5 ℃ under nominal flow rate, it implies actual heat‑transfer is insufficient for corresponding cavity zone of LPDC casting mold.
For thin‑thick transition zones of EV structural‑part mold, partial dense cooling layout is required. Without enhanced cooling, hot‑spot easily forms at junction; statistics show 29 % gravity‑casting shrinkage defects locate on wall‑thickness transition positions.
Cooling‑channel blockage risk needs periodic assessment. After 1000‑1400 casting cycles, scale accumulation may reduce effective inner diameter; flow‑rate drop over 25 % signals cleaning requirement for gravity casting mold cooling circuits.
Cavity insert wall thickness must coordinate with cooling‑channel layout. Wall thickness thinner than 15 mm brings thermal deformation risk even if cooling‑channel parameters satisfy flow requirement for aluminum wheel mass‑production.
Simulation‑predicted solidification time difference between adjacent casting zones should not exceed 22 s. Larger solidification time gap generates feeding shortage, forming scattered casting porosity defect inside gravity casting mold EV structural‑part castings.
Cooling‑channel position deviation inspected by CMM shall not exceed ±1.5 mm. Position drift causes local cooling deficiency, even when channel diameter, flow‑rate and distance‑to‑cavity all conform to drawing specification.
Comprehensive judgment combines Procast CAE output, on‑site flow‑temperature data and trial‑test casting section analysis. Single‑index compliance cannot guarantee overall cooling performance for complex gravity casting mold projects.
FAQ
Q: What maximum permitted mold internal temperature‑difference for gravity casting mold?
A: Keep below 85 ℃; over 110 ℃ lifts shrinkage‑porosity rate by 36 %.
Q: Minimum water‑flow rate for thick‑wall cooling circuits of gravity casting mold?
A: Not lower than 8 L/min; flow below 5 L/min cuts heat‑exchange by 47 %.
Q: What hot‑spot diameter indicates insufficient cooling capacity?
A: Hot‑spot over 35 mm diameter needs gravity casting mold cooling‑structure optimization.
Q: What inlet‑outlet temperature‑difference range for normal cooling‑circuit operation?
A: 8‑14 ℃; ΔT below 5 ℃ usually signals insufficient actual heat removal.
Q: What cycle threshold for gravity mold cooling‑channel scale‑accumulation assessment?
A: Evaluate scale risk after 1000‑1400 casting cycles of continuous production.
Q: What solidification‑time‑difference threshold for adjacent casting zones?
A: Should not exceed 22 s to avoid feeding shortage and shrinkage‑porosity.
Q: Can single parameter verify gravity casting mold cooling‑channel performance?
A: No; combine simulation, flow‑temperature data and trial‑test section analysis together.
