Die cooling apparatus and method thereof

Abstract

A die cooling system for cooling a cast wheel for an automotive vehicle is provided that includes a die, multiple thermocouples embedded in the die, which measure the actual cast metal temperature, adjustable cooling valves, and a control system. The control system receives actual casting metal temperature data from each thermocouple to control the operation of the adjustable cooling valves.

1 . A die cooling system for cooling cast metal comprising:
 a die;   a plurality of thermocouples embedded in the die, such that each thermocouple contacts the casting metal;   a plurality of cooling zones arranged such that cooling air is supplied to the cooling zones to cool the die; and   a feedback control system,   wherein each thermocouple measures the temperature of the cast metal, and   wherein the control system continuously receives temperature data from each thermocouple and controls the supply of cooling air to the cooling zones based on the temperature data.   
   
   
       2 . The die cooling system of  claim 1 , wherein a tip of each thermocouple is flush with an inside surface of the die. 
   
   
       3 . The die cooling system of  claim 2  further comprising a plurality of adjustable cooling valves to supply cooling air to the cooling zones, wherein the control system calculates a critical solidification rate of the cast metal and activates and deactivates the adjustable cooling valves to supply cooling air to corresponding cooling zones in such a manner that the die is gradually cooled at the critical solidification rate from an outer most portion of the die toward an inner most portion of the die. 
   
   
       4 . The die cooling system of  claim 3 , wherein during activation of the adjustable cooling valve the control system varies the cooling air flow rate of the adjustable cooling valve to maintain the critical solidification rate of the cast metal. 
   
   
       5 . The die cooling system of  claim 1 , wherein a tip of each thermocouple is embedded in the casting metal. 
   
   
       6 . The die cooling system of  claim 5  further comprising a plurality of adjustable cooling valves to supply cooling air to the cooling zones, wherein the control system calculates a critical solidification rate of the cast metal and activates and deactivates the adjustable cooling valves to supply cooling air to corresponding cooling zones in such a manner that the die is gradually cooled at the critical solidification rate from an outer most portion of the die toward an inner most portion of the die. 
   
   
       7 . The die cooling system of  claim 6 , wherein during activation of the adjustable cooling valve the control system varies the cooling air flow rate of the adjustable cooling valve to maintain the critical solidification rate of the cast metal. 
   
   
       8 . A die cooling system for cooling a cast wheel for an automotive vehicle comprising:
 a die;   a plurality of thermocouples embedded in the die such that each thermocouple contacts the cast wheel;   a plurality adjustable cooling valves to supply cooling air to various portions of the die; and   a feedback control system,   wherein each thermocouple measures the actual temperature of the cast wheel, and   wherein the control system continuously receives temperature data from each thermocouple and controls the operation of the adjustable cooling valves based on the temperature data.   
   
   
       9 . The die cooling system of  claim 8 , wherein a tip of each thermocouple is flush with an inside surface of the die. 
   
   
       10 . The die cooling system of  claim 9 , wherein the control system calculates a critical solidification rate of the cast wheel, wherein the control system includes a computer and a programmable controller, wherein the computer receives temperature data from each thermocouple and transmits the temperature data to the programmable controller, and wherein the programmable controller activates and deactivates the adjustable cooling valves to supply cooling air to corresponding cooling zones in such a manner that the die is gradually cooled at the critical solidification rate from an outer most portion of the die toward an inner most portion of the die. 
   
   
       11 . The die cooling system of  claim 10 , wherein during activation of the adjustable cooling valve the control system varies the cooling air flow rate of the adjustable cooling valve to maintain the critical solidification rate of the cast wheel. 
   
   
       12 . The die cooling system of  claim 8 , wherein a tip of each thermocouple is embedded in the cast wheel. 
   
   
       13 . The die cooling system of  claim 12 , wherein the control system calculates a critical solidification rate of the cast wheel, wherein the control system includes a computer and a programmable controller, wherein the computer receives temperature data from each thermocouple and transmits the temperature data to the programmable controller, and wherein the programmable controller activates and deactivates the adjustable cooling valves to supply cooling air to corresponding cooling zones in such a manner that the die is gradually cooled at the critical solidification rate from an outer most portion of the die toward an inner most portion of the die. 
   
   
       14 . The die cooling system of  claim 13 , wherein during activation of the adjustable cooling valve the control system varies the cooling air flow rate of the adjustable cooling valve to maintain the critical solidification rate of the cast wheel. 
   
   
       15 . A method of cooling a cast wheel for an automotive vehicle comprising the steps of:
 providing a die having a plurality of thermocouples embedded in the die such that each thermocouple contacts the cast wheel, a plurality of adjustable cooling valves to supply cooling air to the die, and a control system;   calculating a critical solidification rate of the cast wheel based on parameters of the wheel;   filling a cavity of the die with molten metal;   measuring the cast wheel temperature continuously at each thermocouple location; and   controlling the supply of cooling air from the adjustable cooling valves to achieve the critical solidification rate during a solidification period.   
   
   
       16 . The method of  claim 15  further comprising the steps of:
 activating and deactivating the adjustable cooling valves to supply cooling air to each cooling zone to gradually cool the die from an outer most portion of the die toward an inner most portion of the die; and   varying the cooling air flow rate of an activated adjustable cooling valve to maintain the critical solidification rate.   
   
   
       17 . The method of  claim 16  further comprising the steps of:
 transforming the molten metal from a liquid to a solid; and   cooling the entire die rapidly to a temperature such that the cast wheel can be extracted from the die.