Cooling System Design for Automotive Die Casting

Cooling System Design for Automotive Die Casting  is the core factor determining production efficiency, mold lifespan, and casting quality. Rational mold cooling channel design must balance "uniformity," "intensity," and "controllability," along with intensified cooling for critical areas, where the advantages of mold point cooling tubes are prominently demonstrated.

Casting Structure Analysis:

Use CAE software (e.g., MAGMA, FLOW-3D) to conduct solidification simulation, precisely identifying thick sections of the casting (such as intersections of reinforcing ribs, boss columns, and areas of abrupt wall thickness changes), which are key focus areas for cooling.
Predict the temperature field and solidification sequence: Simulate the temperature distribution of the mold during the cycle, aiming to achieve "directional solidification"—gradual solidification from areas away from the gate toward the gate.

Mold Thermal Balance Calculation:

Estimate the total heat introduced by the molten metal with each injection.
Calculate the required total cooling water flow rate and heat exchange area to provide a theoretical basis for channel design.

Cooling System Channel Layout Design

Automotive die casting molds are large in volume and complex in structure, requiring a layered and zoned, designed cooling system.
Cavity/Core Channel Cooling (Basic Cooling)
Intensified Cooling for Critical Areas ("Point" and "Line" Cooling)
This is the essence of automotive die casting mold design, addressing local high thermal load areas that cannot be covered by channels.

Spot Cooling (Baffle/Spot Cooling):

Application Targets: Small cores, ejector pins, roots of deep and narrow ribs, gate impact areas.
Design Key Points: Employ a high-pressure point cooling system. Use stainless steel conduits, strictly sealed via vacuum brazing. Must be配合 with a high-pressure pump station (>40 bar) to prevent instant vaporization of cooling water upon contact with high-temperature surfaces.

Baffle Pins (Flow Directors):
Application Targets: Thicker cores, pin bushings, cylindrical sections within sliders.