Foundry Die Cooling System

2024-08-30 by Cherry

The foundry die cooling System is a key component

in the die-casting process and plays a vital role in

the die-casting process.

It can effectively control the solidification process

of the casting, improve product quality and production

efficiency, and directly affect the quality, production

efficiency, and service life of the mold.

For the die-casting machine, the foundry die-cooling System 

not only helps control the mold temperature but also

determines the molding time and surface quality of 

the product. 

If the foundry die cooling System is not designed

properly, it may cause defects in the product, such

as pores, cracks, or uneven hardness distribution.

The foundry die cooling System can reduce internal

and surface defects of the casting, improve the

grain structure and performance of the casting, 

speed up the cooling speed, and shorten the production

cycle. 

Therefore, understanding and optimizing the foundry

die cooling system a skill that every die-casting

industry the practitioner must master.

Working principle of the cooling system

The basic principle of the cooling system is to regulate

the temperature of the mold by controlling the flow of

coolant (such as water, oil, or air). 

Typically, cooling channels are embedded inside the mold,

and these channels are connected to external cooling 

devices. 

The coolant passes through these channels to remove

excess heat from the mold and keep the mold within

an ideal temperature range.

During the operation of the die-casting machine, 

the mold is subjected to high temperatures and high

pressure, so effective temperature control is essential.

Excessive mold temperature may cause the casting to 

shrink, affecting the dimensional accuracy and surface

quality of the product. 

Excessive low temperatures may cause the material to 

cool too quickly, generating internal stress, which may

cause cracks or deformation in the casting.

Different types of foundry die cooling System

Foundry die cooling System can be divided into many types according

to their design and application scenarios. 

The following are several common foundry die cooling Systems:

1. Direct foundry die cooling System: The direct foundry die 

cooling System introduces coolant directly into the mold 

and removes heat through contact.

This foundry die cooling System usually simple in design 

and has a significant cooling effect, which is suitable

for molds with high-cooling requirements. 

However, the direct foundry die cooling System may cause

uneven temperature on the inner surface of the mold,

which in turn affects the quality of the casting.

2. Indirect foundry die cooling System: The indirect cooling

system adjusts the temperature by setting a cooling 

circuit outside the mold.

The coolant flows on the surface of the mold to remove heat. 

The advantage of this system is that it cools evenly and does 

not directly contact the inner surface of the mold. 

It is suitable for applications with high-temperature control

requirements. However, its cooling efficiency is relatively 

low and is suitable for applications in processes with small

temperature changes.

3. Pulse foundry die cooling System: The pulse of the foundry

die cooling System is a more advanced cooling method 

that uses intermittent coolant flow to adjust the mold

temperature. 

By adjusting the flow rate and flow rate of the coolant,

precise temperature control can be achieved at different

production stages. 

This foundry die cooling System is suitable for the 

production of complex molds and high-precision castings.

4. Hybrid foundry die cooling System: The hybrid cooling

system combines the advantages of direct and indirect

cooling and controls temperature in a variety of ways. 

This system is usually used in large or complex molds,

can provide more uniform and efficient cooling effects, 

and is suitable for processes with high cooling requirements.

Key factors in foundry die cooling System design

Designing an effective casting mold foundry die-cooling 

system requires consideration of multiple factors,

that directly affect the performance of the cooling system 

and the quality of the castings.

1. Cooling channel layout: The layout of the cooling channel is the

core of the cooling system design. A reasonable channel layout

can ensure uniform distribution of coolant and avoid local 

overheating or overcooling. Generally speaking, the cooling 

channel should be as close to the mold surface as possible, 

but not too close to avoid affecting the mold strength.

2. Selection of coolant: Different coolants have different thermal

conductivity and flow characteristics. Water is the most commonly

used coolant, which has good thermal conductivity and cost advantages.

However, in some special cases, such as requiring higher cooling 

efficiency or avoiding reactions between water and mold materials,

oil or other cooling media can be selected.

3. Size and shape of the cooling channel: The size and shape of the

cooling channel will also affect the cooling effect. Larger

channels can increase the flow of coolant and improve 

cooling efficiency but may affect the structural integrity

of the mold. On the contrary, smaller channels may cause 

uneven cooling. Therefore, it is necessary to make a 

trade-off according to specific needs during design.

4. Control of foundry die cooling System: In the modern

die-casting process, the control of the cooling system

is increasingly dependent on automation technology.

Through sensors and control systems, the temperature and 

flow of coolant can be monitored and adjusted in real time, 

to achieve more precise temperature control. 

This is crucial to improve product quality and production efficiency.

5. Optimization method: Through thermal analysis simulation, 

heat treatment technology, the establishment of a stable cooling

medium circulation system, and regular maintenance and cleaning,

the performance of the foundry die cooling System can be further

optimized.

Relationship between the foundry die cooling System and

die-casting machine

The foundry die cooling System is inseparable from die casting.

During the die-casting process, the control of mold 

temperature not only affects the cooling speed of the

casting, but also affects the overall operating efficiency

of the die-casting machine.

Excessive mold temperature may increase the load of the 

die-casting machine, thereby shortening the service life 

of the machine. Excessive mold temperature may cause uneven

cooling of the casting and affect product quality.

Therefore, the operator of the die-casting machine needs 

to pay close attention to the operating status of the cooling

system. During the production process, timely adjusting

the parameters of the cooling system to ensure that the mold

temperature remains within the appropriate range is an

important measure to improve production efficiency and

ensure product quality.

Maintenance and maintenance of the foundry die cooling System

The maintenance and maintenance of the cooling system is 

the key to ensuring its long-term stable operation. 

The following are some common maintenance measures:

Regular cleaning of cooling channels: The cooling channel may

accumulate scale or impurities after long-term use, affecting

the cooling effect. Regular cleaning of the channel can 

maintain the efficient operation of the cooling system.

1. Check the quality of the coolant: The quality of the coolant

directly affects the cooling effect. The coolant should be

replaced regularly and checked for contamination or deterioration.

2. Check the sealing of the foundry die cooling System: 

The sealing of the cooling system is crucial to prevent 

coolant leakage. Check the seals regularly to ensure that

they are intact.

3. Monitor the operating parameters of the foundry die 

cooling System:

By monitoring the operating parameters of the cooling system,

such as flow rate, temperature, etc., potential problems

can be discovered and adjusted in time.

Emerging technologies and the development trend of 

foundry die cooling System

With the development of science and technology, the foundry

die cooling Systemof casting molds is also constantly 

improving. 

Some emerging technologies are gradually being applied

to the design and optimization of cooling systems.

1. Intelligent control system: Modern cooling systems are increasingly

adopting intelligent control technology. By real-time monitoring 

and automatic adjustment of the flow rate and temperature of the

coolant, the intelligent control system can achieve more precise

and efficient temperature control, further improving product quality.

2. Application of additive manufacturing technology: Additive manufacturing

technology (such as 3D printing) provides new possibilities for 

the design of cooling systems. Through additive manufacturing, 

complex cooling channels can be made, which can improve 

the cooling effect and reduce the cooling time.

3. Development of new cooling materials: The development of new

cooling materials provides more options for the optimization

of cooling systems. For example, nanofluids are becoming a 

potential substitute for coolants due to their excellent thermal

conductivity.

Conclusion

The cooling system of the casting mold plays a vital role

in the die-casting process. Through reasonable design and

maintenance, the cooling system can not only improve product

quality but also extend the service life of the mold and

die-casting machine. 

With the development of science and technology, the cooling

system will continue to evolve and be used in a more 

intelligent and efficient future.

Whether it is design, operation, or maintenance, understanding

and mastering the principles and technical points of the cooling

system are compulsory courses for practitioners in die-casting

industry to improve work efficiency and product quality. 

In practical applications, continuous optimization and improvement

of the cooling system will help companies stay ahead of the competition.

For more info, you can refer to: 

https://www.tiktok.com/@lk_diecastingmachine/video/7405113006880820522 

https://www.youtube.com/shorts/JLX410QV_kw

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