Metal casting process

Abstract

The invention relates to the technical field of metal casting, and discloses a metal casting process which comprises the following steps: smelting a metal raw material to form a metal casting liquid; a sand box mold is manufactured, the total amount of molding sand is obtained, and sand injection operation is conducted; after sand injection is completed, molding sand distribution is analyzed, and a lacking area and an excess area are divided; recording the molding sand allowance of each excess area and the molding sand deficiency of each deficiency area; executing sand scraping blending operation, and then performing vibration leveling; detecting whether the molding sand is flat or not, and if yes, closing the mold and pouring the metal pouring liquid; if not, the distribution condition is obtained, sand supplementing operation is executed, and a sand supplementing area and the sand supplementing amount are recorded; if the same area is recorded for multiple times, marking the area as a marked area; the sand supplementing amount of the marked area is obtained, and molding sand reserving operation is executed; after sand supplementing is completed, the mold is closed, and metal pouring liquid is poured; the poured mold is cooled, and a metal casting is taken out; and finally, polishing treatment is conducted, and a cast metal product is obtained.

Description

Technical Field

[0001] The invention relates to the technical field of metal casting, in particular to a metal casting process. Background Art

[0002] Metal casting is an important manufacturing process, which is widely used in the automotive, aviation, machinery and other industries. The casting process involves multiple links, among which sand casting is widely used due to its strong adaptability and low cost. In sand casting, the uniform distribution of sand and the appropriate amount of sand are one of the key factors that determine the quality of castings.

[0003] Existing technologies mainly rely on manual or simple mechanical means to mix sand molds, and usually rely on experience to judge the filling and distribution of molding sand. This method is difficult to achieve precise control of the distribution of molding sand. There are problems such as uneven distribution of molding sand and uneven mold closing, which can easily lead to areas of insufficient or excessive molding sand in the casting process, thereby affecting the dimensional accuracy and surface quality of the casting, resulting in casting defects and material waste. At the same time, the process of manually mixing molding sand requires manual control of the amount of molding sand filled into the mold, and it is difficult to accurately control the amount of molding sand, which leads to insufficient filling of molding sand or excessive filling of molding sand resulting in waste; in addition, in the process of manually mixing molding sand, it is necessary to manually trim the filled molding sand and manually scrape the molding sand flat, which is inefficient and difficult to ensure the final trimming quality of the molding sand, and it is difficult to meet the needs of modern production.

[0004] Therefore, this method proposes a method that can add an appropriate amount of molding sand to the mold and effectively mix the molding sand according to the distribution of the molding sand; this process can not only ensure the accuracy of the molding sand mold and thus improve the quality of the casting, but also improve production efficiency, reduce material waste and reduce production costs. Summary of the invention

[0005] The present invention provides a metal casting process, which facilitates solving the problems mentioned in the above background technology.

[0006] The present invention provides the following technical solution: a metal casting process, comprising:

[0007] Melting metal raw materials to form metal pouring liquid;

[0008] Make sand box mold;

[0009] Get the total amount of molding sand required for the sand box mold;

[0010] According to the total amount of molding sand, sand is injected into the sand box mold;

[0011] After the sand injection operation is completed, the distribution of the sand in the current sand box mold is obtained;

[0012] According to the current distribution of sand in the sand box mold, the insufficient area and the excessive area are divided;

[0013] Obtain the excess amount of molding sand in each excess area, and record it as the residual amount of molding sand in each excess area;

[0014] Obtain the amount of molding sand missing in each missing area, and record it as the molding sand missing amount in each missing area;

[0015] Perform sand scraping and mixing operations according to the remaining and insufficient molding sand;

[0016] After completing the sand scraping and mixing operation, perform vibration leveling operation on the sand box mold;

[0017] After completing the vibration leveling operation, check whether the molding sand in the sand box mold is flat;

[0018] If it is flat, close the sand box mold and pour metal casting liquid into the closed sand box mold;

[0019] If it is not flat, the distribution of the current molding sand in the sand box mold is obtained, and the sand replenishment operation is performed, and the sand replenishment area and amount are recorded;

[0020] When the same sand replenishment area is recorded multiple times in the subsequent process of casting metal products, the sand replenishment area is marked as a marked area;

[0021] Obtain the amount of molding sand added to the marked area during each sand filling operation, and record it as the reserve amount;

[0022] In the subsequent casting process of metal products, the marked area is subjected to a reserved sand operation;

[0023] Closing the sand box mold after the sand filling operation is completed, and pouring metal pouring liquid into the closed sand box mold;

[0024] Cooling the sand box mold after the pouring operation is completed, and taking out the metal casting in the sand box mold after cooling;

[0025] The metal casting is polished to obtain a cast metal product.

[0026] Optionally, the making of the sand box mold includes:

[0027] Make product molds according to the metal products to be cast;

[0028] According to the product mold, make a rectangular sand box for sand casting;

[0029] The sand box is surrounded by four metal plates and has two opposite openings, one of which is welded with a grid-shaped metal strip, which is marked as the upper side of the sand box, and the other opening is a rectangular opening, which is marked as the lower side of the sand box;

[0030] Place the sand box on the product mold so that the bottom of the sand box overlaps with the bottom surface of the product mold, and the product mold is located in the middle position inside the sand box to form a sand box mold.

[0031] Optionally, the sand injection operation on the sand box mold according to the total amount of molding sand includes:

[0032] Place the sand box mold on a horizontal plane so that the bottom of the sand box in the sand box mold coincides with the horizontal plane;

[0033] The upper side of the sand box in the sand box mold is obtained as the upper side of the sand box mold, and grids of the same size exist on the upper side of the sand box mold;

[0034] Obtain two sets of parallel edges on the sand box mold, select one set of parallel edges as the upper edge and the lower edge, and record the other set of parallel edges as the left edge and the right edge;

[0035] For the grids on the top of the sand box mold, record each row of grids as the first row of grids, the second row of grids, the third row of grids, and so on to the Nth row of grids from top to bottom;

[0036] For each row of grids, the grid containing the left side is used as the starting grid of each row of grids, and the grid containing the right side is used as the ending grid of each row of grids;

[0037] Set the sand injection path, including:

[0038] Start from the starting grid of the first row of grids, move to the ending grid of the first row of grids, and pass through each grid of the first row of grids in turn;

[0039] When reaching the end grid of the first row of grids, it moves to the end grid of the second row of grids. When reaching the end grid of the second row of grids, it moves to the start grid of the second row of grids, passing through each grid of the second row of grids in turn.

[0040] When it reaches the starting grid of the second row of grids, it moves to the starting grid of the third row of grids. When it reaches the starting grid of the third row of grids, it moves to the ending grid of the third row of grids, passing through each grid of the third row of grids in turn.

[0041] When reaching the end grid of the third row of grids, it moves to the end grid of the fourth row of grids. When reaching the end grid of the fourth row of grids, it moves to the start grid of the fourth row of grids, passing through each grid of the fourth row of grids in turn.

[0042] Similarly, when passing through all the grids on the sand box mold, the movement stops and the path passed by is used as the sand injection path;

[0043] Inject molding sand into the sand box mold through the sand injection port, and control the sand injection port to move at a uniform speed along the sand injection path;

[0044] The amount of sand discharged from the sand injection port per unit time is controlled to be constant, and the amount of sand discharged from the sand injection port is controlled according to the total amount of molding sand required by the sand box mold, so that after the sand injection port has completely passed through the sand injection path, the total amount of molding sand injected into the sand box mold by the sand injection port is equal to the total amount of molding sand required by the sand box mold.

[0045] Optionally, dividing the under-quantity area and the over-quantity area according to the distribution of the molding sand in the current sand box mold includes:

[0046] Get the plane where the sand box mold is located, and record it as the reference plane;

[0047] On the reference plane, the area in the sand box mold where the height of the molding sand is lower than the reference plane is recorded as the missing area;

[0048] On the reference plane, the area in the sand box mold where the height of the molding sand accumulation is higher than the reference plane is recorded as the excess area;

[0049] The method of obtaining the excess amount of molding sand in each excess area, which is recorded as the residual amount of molding sand in each excess area, includes:

[0050] For each excess area, the amount of molding sand in the excess area that is higher than the reference plane is obtained as the molding sand surplus of each excess area;

[0051] The method of obtaining the amount of molding sand missing in each missing area, which is recorded as the missing amount of molding sand in each missing area, includes:

[0052] For each missing quantity area, the amount of molding sand required to add molding sand to the missing quantity area so that the height of the molding sand in the missing quantity area is flush with the reference plane is obtained, and recorded as the molding sand missing quantity of each missing quantity area.

[0053] Optionally, performing the sand scraping and mixing operation according to the molding sand surplus and the molding sand deficiency includes:

[0054] Obtaining the geometric center points of each excess area and each deficiency area respectively, and recording them as the excess point of each excess area and the deficiency point of each deficiency area respectively;

[0055] Acquire all the under-quantity areas adjacent to the over-quantity area and existing around the over-quantity area as the pre-selected under-quantity areas for each over-quantity area;

[0056] The under-quantity area adjacent to the excess area means that there is no other under-quantity area or excess area between the under-quantity area and the excess area;

[0057] Obtain the remaining amount of molding sand in the excess area, and respectively obtain the molding sand deficiency in each pre-selected deficiency area;

[0058] If there is a pre-selected under-quantity area where the amount of molding sand under-quantity is equal to the amount of molding sand remaining in the excess area, the pre-selected under-quantity area is marked as the first selected under-quantity area, and the molding sand in the excess area is scraped to the first selected under-quantity area in the direction from the excess point of the excess area to the under-quantity point of the first selected under-quantity area, and the amount of the scraped molding sand is equal to the amount of molding sand remaining in the excess area;

[0059] If there is no first selected underfill area, and there is a pre-selected underfill area where the molding sand underfill is greater than the molding sand surplus in the excess area, then the pre-selected underfill area with the largest molding sand underfill is obtained as the second selected underfill area;

[0060] Scrape the molding sand in the excess area to the second selected undersize area in the direction from the excess point of the excess area to the undersize point of the second selected undersize area, and the amount of the scraped molding sand is equal to the remaining amount of the molding sand in the excess area;

[0061] If there is no first-selected underfill area, and the molding sand underfill in each pre-selected underfill area is less than the molding sand surplus in the excess area, the existing pre-selected underfill areas are numbered in descending order according to the molding sand underfill;

[0062] According to the serial numbering sequence of the pre-selected under-quantity zones, one pre-selected under-quantity zone is selected each time, and the molding sand in the excess zone is scraped to the selected pre-selected under-quantity zone with the excess point of the excess zone pointing to the direction of the under-quantity point of the selected pre-selected under-quantity zone, and the amount of the scraped molding sand is equal to the molding sand under-quantity of the selected pre-selected under-quantity zone;

[0063] In the process of scraping the molding sand to each pre-selected under-quantity area in turn, after the molding sand is scraped and sent to each pre-selected under-quantity area, the remaining molding sand in the over-quantity area is obtained;

[0064] When the amount of molding sand remaining in the excess area is less than the amount of molding sand shortage in the next numbered pre-selected shortage area, the amount of molding sand remaining in the excess area is scraped and sent to the next numbered pre-selected shortage area, and the scraping of molding sand in the excess area is stopped;

[0065] After completing the scraping and delivery of the molding sand to each excess area, determine whether there is an excess area and an under-area;

[0066] If there is no excess area or insufficient area, the sand scraping and mixing operation is completed;

[0067] If there is an excess area and no under-measurement area, the molding sand in the excess area and the remaining molding sand in the excess area are scraped to the center position on the sand box mold to complete the sand scraping and mixing operation.

[0068] Optionally, after the vibration leveling operation is completed, detecting whether the molding sand in the sand box mold is flat includes:

[0069] After completing the vibration leveling operation, check whether there are under-measurement areas and over-measurement areas on the reference plane of the sand box mold;

[0070] If there is no excess area or under-measurement area, the molding sand in the sand box mold is considered to be flat;

[0071] If there are excess areas and insufficient areas, it is determined that the molding sand in the sand box mold is uneven.

[0072] Optionally, if the surface is uneven, the distribution of the current molding sand in the sand box mold is obtained, and the sand replenishment operation is performed, and the sand replenishment area and the amount of sand replenishment are recorded, including:

[0073] Obtain the excess area and the under-area existing on the datum plane of the sand box mold;

[0074] Scrape the molding sand in the excess area to the under-measurement area in the scraping direction of the under-measurement area, and the amount of the scraped molding sand is equal to the remaining amount of the molding sand in the excess area;

[0075] Treat the shortfall area as a sand replenishment area and record it;

[0076] The remaining amount of molding sand in the excess area shall be taken as the sand replenishment amount and recorded.

[0077] Optionally, when the same sand replenishment area is recorded multiple times in the subsequent process of casting the metal product, the sand replenishment area is marked as a marked area, including:

[0078] Set the number of times determination threshold;

[0079] When the same metal product is subsequently cast again, if the number of times that the sand replenishment area at the same position is recorded on the sand box mold is greater than or equal to the number determination threshold, the location of the sand replenishment area is obtained as the marking area.

[0080] Optionally, in the subsequent process of casting the metal product, performing a sand reservation operation on the marked area includes:

[0081] In the subsequent casting of new identical metal products, during the scraping and mixing operation:

[0082] If the marked area is a missing quantity area, the missing quantity of the molding sand in the missing quantity area is obtained, and the reserve quantity is added to the missing quantity of the molding sand, and the obtained result replaces the original missing quantity of the molding sand in the missing quantity area as the real missing quantity of the molding sand in the missing quantity area;

[0083] If the marked area is an excess area, the remaining amount of the molding sand in the under-measurement area is obtained, and the reserve amount is subtracted from the remaining amount of the molding sand, and the result is used to replace the original remaining amount of the molding sand in the excess area as the real remaining amount of the molding sand in the excess area;

[0084] If the marked area is neither a shortage area nor an excess area, the marked area will be regarded as a shortage area, and the reserve amount will be regarded as the sand shortage in the shortage area.

[0085] The present invention has the following beneficial effects:

[0086] 1. Optimize the filling efficiency and uniformity of the molding sand in the metal casting process through sand injection operation to ensure the quality of the final casting; First, place the sand box mold on a horizontal plane, and divide the grid by obtaining its upper, lower, left and right boundaries, which provides a basis for the planning of the sand injection path. This measure helps to accurately control the sand injection process; when setting the sand injection path, pass through each row of grids in turn to ensure that the molding sand can be evenly distributed in the entire sand box mold, reducing the risk of casting defects; in addition, through the row-by-row sand injection of the grid, the distribution of the molding sand can be monitored in real time, and the sand injection strategy can be further adjusted to meet actual needs; by controlling the sand output of the sand injection port, the sand output per unit time is kept constant, ensuring that the total amount of molding sand required by the sand box mold can be met during the sand injection process. This precise control improves the filling efficiency of the sand box and avoids unnecessary material waste and subsequent correction work. This process not only improves production efficiency, but also reduces casting costs.

[0087] 2. By setting the reference plane, the stacking height of the molding sand can be determined intuitively, and then the underfill area and overfill area can be effectively identified. This zoning method not only simplifies the operating process, but also enhances the management of the distribution of molding sand in the sand box; in the underfill area, the molding sand height is lower than the reference plane, which means that there is a problem of insufficient molding sand in these areas; after identifying the underfill area, supplementary measures can be taken quickly to ensure that the molding sand is evenly filled to avoid the occurrence of casting defects; the overfill area indicates that the molding sand height is higher than the reference plane, which may lead to excessive accumulation of molding sand, thereby affecting the quality of casting; obtaining the molding sand surplus in each overfill area is helpful to timely adjust the distribution of molding sand to avoid pouring difficulties and casting defects caused by uneven distribution of molding sand.

[0088] 3. By clarifying the geometric center points of the excess area and the under-measurement area, the key position of each area can be intuitively identified. This method not only improves work efficiency, but also provides a reference for the direction of scraping and conveying molding sand for subsequent molding sand mixing.

[0089] 4. In the process of selecting the pre-selected shortfall area, priority is given to the situation where the shortfall of molding sand is equal to the surplus in the excess area, ensuring that the amount of molding sand scraped each time fully matches the demand of the shortfall area. This refined allocation strategy can avoid the waste of molding sand to the greatest extent, while achieving accurate replenishment and ensuring the quality of castings. This process not only improves the qualified rate of casting products, but also effectively reduces the casting defects caused by insufficient or excessive molding sand in certain areas of the sand box mold.

[0090] 5. When there is no first-selected shortfall area, select a pre-selected shortfall area with the largest sand shortfall as the second-selected shortfall area, and scrape the sand from the excess area to this area; by allocating the sand from the excess area to the area with the largest shortfall, it can effectively reduce resource waste and ensure that every part of the sand can be effectively utilized. At the same time, the sand is preferentially allocated to the area with the largest shortfall, which can restore the overall balance of the sand box mold more quickly and reduce the number of subsequent sand scraping and mixing operations as much as possible. This method helps to improve the consistency and quality of casting products, and also improves the efficiency of sand scraping and mixing operations.

[0091] 6. When there is no first-selected shortfall area, and the shortfall of molding sand in each pre-selected shortfall area is less than the remaining amount of molding sand in the excess area, the pre-selected shortfall areas are numbered from large to small according to the shortfall of molding sand, and the molding sand is scraped in sequence; this method numbers the pre-selected shortfall areas in order from large to small, ensuring that the areas with the largest shortfall of molding sand are processed first; this method can not only quickly fill the most urgent needs, but also minimize the number of shortfall areas, thereby improving the overall stability of the casting process; secondly, in the process of scraping and delivering the molding sand, the remaining molding sand surplus in the excess area is obtained in real time, and the subsequent molding sand allocation strategy can be dynamically adjusted. When the surplus in the excess area is not enough to meet the needs of the next pre-selected shortfall area, the scraping is stopped in time; this flexible adjustment mechanism not only avoids the waste of molding sand, but also ensures that every part of the resources can play the greatest effect. Such a strategy greatly improves production efficiency during the casting process.

[0092] 7. After completing the scraping of the molding sand in each excess area, all the insufficient areas disappear, but there are still excess areas, indicating that there are voids inside the sand box mold. The location of the voids cannot be determined from the surface, so the excess molding sand in the existing excess area is scraped to the center position of the sand box mold. When the vibration adjustment operation is completed later, the internal voids are eliminated and the insufficient area appears. At this time, the excess molding sand at the center position is scraped to the revealed insufficient area. This method of scraping the excess molding sand to the center position first can, to a certain extent, reduce the distance required to scrape the molding sand from the center position to the insufficient area, thereby reducing the operation time and improving work efficiency.

[0093] 8. Set a threshold for number of times during the casting process, and mark the sand replenishment area based on the threshold. Setting the threshold for number of times means that when the number of times the same sand replenishment area is recorded on the sand box mold reaches or exceeds this threshold during subsequent casting of the same metal product, the area will be marked. This approach can effectively identify defects that appear repeatedly in multiple castings, and provide reliable data support for subsequent castings.

[0094] 9. When performing the reserved molding sand operation in the marked area, for the insufficient area, obtain the original molding sand shortage and add the reserve amount, so as to ensure that the molding sand height in this area is effectively supplemented in the subsequent casting, avoiding casting defects caused by insufficient molding sand; and for the excess area, adjust the molding sand surplus by subtracting the reserve amount, so that after the subsequent vibration leveling strategy, the amount of molding sand in the excess area is equal to the amount of molding sand required in this area; this sophisticated management method makes the configuration of molding sand more scientific and reasonable, thereby improving the quality of castings; at the same time, this method can reduce the number of times the molding sand is scraped and delivered during the sand scraping and mixing operation when casting the same metal product in the subsequent casting, thereby reducing the time consumed by the sand scraping and mixing operation and improving casting efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0095] Figure 1 It is the upper schematic diagram of the sand box of the present invention.

[0096] Figure 2 It is the upper schematic diagram of the sand box mold of the present invention. DETAILED DESCRIPTION

[0097] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0098] Embodiment 1, a metal casting process, comprising:

[0099] Melting metal raw materials to form metal pouring liquid;

[0100] Make sand box mold;

[0101] Get the total amount of molding sand required for the sand box mold;

[0102] According to the total amount of molding sand, sand is injected into the sand box mold;

[0103] After the sand injection operation is completed, the distribution of the sand in the current sand box mold is obtained;

[0104] According to the current distribution of sand in the sand box mold, the insufficient area and the excessive area are divided;

[0105] Obtain the excess amount of molding sand in each excess area, and record it as the residual amount of molding sand in each excess area;

[0106] Obtain the amount of molding sand missing in each missing area, and record it as the molding sand missing amount in each missing area;

[0107] Perform sand scraping and mixing operations according to the remaining and insufficient molding sand;

[0108] After completing the sand scraping and mixing operation, perform vibration leveling operation on the sand box mold;

[0109] After completing the vibration leveling operation, check whether the molding sand in the sand box mold is flat;

[0110] If it is flat, close the sand box mold and pour metal casting liquid into the closed sand box mold;

[0111] If it is not flat, the distribution of the current molding sand in the sand box mold is obtained, and the sand replenishment operation is performed, and the sand replenishment area and amount are recorded;

[0112] When the same sand replenishment area is recorded multiple times in the subsequent process of casting metal products, the sand replenishment area is marked as a marked area;

[0113] Obtain the amount of molding sand added to the marked area during each sand filling operation, and record it as the reserve amount;

[0114] In the subsequent casting process of metal products, the marked area is subjected to a reserved sand operation;

[0115] Closing the sand box mold after the sand filling operation is completed, and pouring metal pouring liquid into the closed sand box mold;

[0116] Cooling the sand box mold after the pouring operation is completed, and taking out the metal casting in the sand box mold after cooling;

[0117] The metal casting is polished to obtain a cast metal product.

[0118] The method for making a sand box mold comprises:

[0119] Make product molds according to the metal products to be cast;

[0120] According to the product mold, make a rectangular sand box for sand casting;

[0121] The sand box is surrounded by four metal plates and has two opposite openings, one of which is welded with a grid-like metal strip, which is marked as the upper side of the sand box. Figure 1 As shown, the other opening is a rectangular opening, which is marked as the bottom of the sand box;

[0122] Place the sand box on the product mold so that the bottom of the sand box overlaps with the bottom surface of the product mold, and the product mold is located in the middle position inside the sand box to form a sand box mold.

[0123] The sand injection operation on the sand box mold according to the total amount of molding sand includes:

[0124] Place the sand box mold on a horizontal plane so that the bottom of the sand box in the sand box mold coincides with the horizontal plane;

[0125] The upper side of the sand box in the sand box mold is obtained as the upper side of the sand box mold, and grids of the same size exist on the upper side of the sand box mold;

[0126] Reference Figure 2 , obtain two sets of parallel edges on the sand box mold, select one set of parallel edges and record them as the upper edge and the lower edge, and record the other set of parallel edges as the left edge and the right edge;

[0127] For the grids on the top of the sand box mold, record each row of grids as the first row of grids, the second row of grids, the third row of grids, and so on to the Nth row of grids from top to bottom;

[0128] Reference Figure 2 , for each row of grids, the grid containing the left side is used as the starting grid of each row of grids, and the grid containing the right side is used as the ending grid of each row of grids;

[0129] Set the sand injection path, including:

[0130] Start from the starting grid of the first row of grids, move to the ending grid of the first row of grids, and pass through each grid of the first row of grids in turn;

[0131] When reaching the end grid of the first row of grids, it moves to the end grid of the second row of grids. When reaching the end grid of the second row of grids, it moves to the start grid of the second row of grids, passing through each grid of the second row of grids in turn.

[0132] When it reaches the starting grid of the second row of grids, it moves to the starting grid of the third row of grids. When it reaches the starting grid of the third row of grids, it moves to the ending grid of the third row of grids, passing through each grid of the third row of grids in turn.

[0133] When reaching the end grid of the third row of grids, it moves to the end grid of the fourth row of grids. When reaching the end grid of the fourth row of grids, it moves to the start grid of the fourth row of grids, passing through each grid of the fourth row of grids in turn.

[0134] Similarly, when passing through all the grids on the sand box mold, the movement stops and the path passed by is used as the sand injection path;

[0135] Inject molding sand into the sand box mold through the sand injection port, and control the sand injection port to move at a uniform speed along the sand injection path;

[0136] The sand output of the sand injection port is controlled to be constant per unit time, and the amount of sand output of the sand injection port is controlled according to the total amount of molding sand required by the sand box mold, so that after the sand injection port has completely passed through the sand injection path, the total amount of molding sand injected into the sand box mold by the sand injection port is equal to the total amount of molding sand required by the sand box mold; the sand filling efficiency and uniformity in the metal casting process are optimized through the sand injection operation to ensure the quality of the final casting; first, the sand box mold is placed on a horizontal plane, and the grid is divided by obtaining its upper, lower, left and right boundaries, which provides a basis for the planning of the sand injection path. This measure helps to accurately control the sand filling efficiency and uniformity in the metal casting process ... Sand injection process: When setting the sand injection path, the sand is passed through each row of the grid in turn to ensure that the molding sand can be evenly distributed in the entire sand box mold, reducing the risk of casting defects; in addition, by injecting sand row by row of the grid, the distribution of the molding sand can be monitored in real time, and the sand injection strategy can be further adjusted to meet actual needs; by controlling the amount of sand discharged from the sand injection port, the amount of sand discharged per unit time is kept constant, ensuring that the total amount of molding sand required by the sand box mold can be met during the sand injection process. This precise control improves the filling efficiency of the sand box and avoids unnecessary material waste and subsequent correction work. This process not only improves production efficiency, but also reduces casting costs.

[0137] According to the distribution of the current sand in the sand box mold, the under-quantity area and the over-quantity area are divided, including:

[0138] Get the plane where the sand box mold is located, and record it as the reference plane;

[0139] On the reference plane, the area in the sand box mold where the height of the molding sand is lower than the reference plane is recorded as the missing area;

[0140] On the reference plane, the area in the sand box mold where the height of the molding sand accumulation is higher than the reference plane is recorded as the excess area;

[0141] The method of obtaining the excess amount of molding sand in each excess area, which is recorded as the residual amount of molding sand in each excess area, includes:

[0142] For each excess area, the amount of molding sand in the excess area that is higher than the reference plane is obtained as the molding sand surplus of each excess area;

[0143] The method of obtaining the amount of molding sand missing in each missing area, which is recorded as the missing amount of molding sand in each missing area, includes:

[0144] For each undercount area, the amount of molding sand required to add molding sand to the undercount area so that the height of the molding sand in the undercount area is flush with the reference plane is obtained, and the molding sand undercount of each undercount area is recorded; by setting the reference plane, the stacking height of the molding sand can be intuitively determined, and then the undercount area and excess area can be effectively identified. This zoning method not only simplifies the operating process, but also enhances the management of the distribution of molding sand in the sand box; in the undercount area, the molding sand height is lower than the reference plane, which means that there is a problem of insufficient molding sand in these areas; after identifying the undercount area, supplementary measures can be taken quickly to ensure that the molding sand is evenly filled to avoid the occurrence of casting defects; the excess area means that the molding sand height is higher than the reference plane, which may lead to excessive accumulation of molding sand, thereby affecting the quality of casting; obtaining the remaining molding sand in each excess area is helpful to timely adjust the distribution of molding sand to avoid pouring difficulties and casting defects caused by uneven distribution of molding sand.

[0145] The sand scraping and mixing operation is performed according to the excess amount of molding sand and the shortage of molding sand, including:

[0146] The geometric center points of each excess area and each insufficient area are obtained respectively, and recorded as the excess point of each excess area and the insufficient point of each insufficient area respectively; by clarifying the geometric center points of the excess area and the insufficient area, the key position of each area can be intuitively identified. This method not only improves work efficiency, but also provides a reference for the direction of scraping and conveying molding sand for subsequent molding sand preparation.

[0147] Acquire all the under-quantity areas adjacent to the over-quantity area and existing around the over-quantity area as the pre-selected under-quantity areas for each over-quantity area;

[0148] The under-quantity area adjacent to the excess area means that there is no other under-quantity area or excess area between the under-quantity area and the excess area;

[0149] Obtain the remaining amount of molding sand in the excess area, and respectively obtain the molding sand deficiency in each pre-selected deficiency area;

[0150] If there is a pre-selected shortage area where the shortage of molding sand is equal to the surplus of molding sand in the excess area, the pre-selected shortage area will be marked as the first selected shortage area, and the molding sand in the excess area will be scraped to the first selected shortage area with the excess point of the excess area pointing to the shortage point of the first selected shortage area, and the amount of molding sand scraped is equal to the surplus of molding sand in the excess area; in the process of selecting the pre-selected shortage area, priority will be given to the situation where the shortage of molding sand is equal to the surplus in the excess area, ensuring that the amount of molding sand scraped each time is fully matched with the demand of the shortage area. This refined allocation strategy can avoid molding sand waste to the greatest extent, while achieving accurate replenishment to ensure the quality of castings. This process not only improves the qualified rate of casting products, but also effectively reduces casting defects caused by insufficient or excessive molding sand in certain areas of the sand box mold.

[0151] If there is no first selected underfill area, and there is a pre-selected underfill area where the molding sand underfill is greater than the molding sand surplus in the excess area, then the pre-selected underfill area with the largest molding sand underfill is obtained as the second selected underfill area;

[0152] The molding sand in the excess area is scraped to the second selected shortfall area in the direction that the excess point of the excess area points to the shortfall point of the second selected shortfall area, and the amount of the scraped molding sand is equal to the remaining molding sand in the excess area; when the first selected shortfall area does not exist, a pre-selected shortfall area with the largest shortfall of molding sand is selected as the second selected shortfall area, and the molding sand in the excess area is scraped to this area; by allocating the molding sand in the excess area to the area with the largest shortfall, the waste of resources can be effectively reduced, ensuring that each part of the molding sand can be effectively utilized, and at the same time, the molding sand is preferentially allocated to the area with the largest shortfall, which can restore the overall balance of the sand box mold more quickly and reduce the number of subsequent sand scraping and mixing operations as much as possible. This method helps to improve the consistency and quality of casting products, and also improves the efficiency of sand scraping and mixing operations.

[0153] If there is no first-selected underfill area, and the molding sand underfill in each pre-selected underfill area is less than the molding sand surplus in the excess area, the existing pre-selected underfill areas are numbered in descending order according to the molding sand underfill;

[0154] According to the serial numbering sequence of the pre-selected under-quantity zones, one pre-selected under-quantity zone is selected each time, and the molding sand in the excess zone is scraped to the selected pre-selected under-quantity zone with the excess point of the excess zone pointing to the direction of the under-quantity point of the selected pre-selected under-quantity zone, and the amount of the scraped molding sand is equal to the molding sand under-quantity of the selected pre-selected under-quantity zone;

[0155] In the process of scraping the molding sand to each pre-selected under-quantity area in turn, after the molding sand is scraped and sent to each pre-selected under-quantity area, the remaining molding sand in the over-quantity area is obtained;

[0156] When the amount of molding sand remaining in the excess area is less than the amount of molding sand missing in the next numbered pre-selected shortfall area, the remaining molding sand in the excess area will be scraped and sent to the next numbered pre-selected shortfall area, and the scraping of the molding sand in the excess area will be stopped; when there is no first-selected shortfall area, and the amount of molding sand missing in each pre-selected shortfall area is less than the amount of molding sand remaining in the excess area, the pre-selected shortfall areas will be numbered from large to small according to the amount of molding sand missing, and the molding sand will be scraped in sequence; this method numbers the pre-selected shortfall areas in order from large to small to ensure that the area with the largest amount of molding sand missing is processed first; this method can not only It can quickly fill the most urgent needs and minimize the number of shortfall areas, thereby improving the overall stability of the casting process. Secondly, in the process of scraping and delivering molding sand, the remaining molding sand residue in the excess area can be obtained in real time, and the subsequent molding sand distribution strategy can be dynamically adjusted. When the residue in the excess area is not enough to meet the needs of the next pre-selected shortfall area, the scraping and delivery is stopped in time. This flexible adjustment mechanism not only avoids the waste of molding sand, but also ensures that every part of the resources can play the greatest role. Such a strategy greatly improves production efficiency during the casting process.

[0157] After completing the scraping and delivery of the molding sand to each excess area, determine whether there is an excess area and an under-area;

[0158] If there is no excess area or insufficient area, the sand scraping and mixing operation is completed;

[0159] If there is an excess area and no under-measurement area, the molding sand in the excess area equal to the remaining molding sand in the excess area is scraped to the center position above the sand box mold to complete the sand scraping and mixing operation; after completing the scraping of the molding sand in each excess area, all under-measurement areas disappear, but there are still excess areas, indicating that there are voids inside the sand box mold, and the location of the voids cannot be determined from the surface, so the excess molding sand in the existing excess area is scraped to the center position above the sand box mold. When the vibration adjustment operation is completed later, the internal voids are eliminated and the under-measurement area appears. At this time, the excess molding sand at the center position is scraped to the revealed under-measurement area. This method of scraping the excess molding sand to the center position first can, to a certain extent, reduce the distance required for scraping the molding sand from the center position to the under-measurement area, thereby reducing the time required for operation and improving work efficiency.

[0160] After the vibration leveling operation is completed, the molding sand in the sand box mold is checked to see if it is flat, including:

[0161] After completing the vibration leveling operation, check whether there are under-measurement areas and over-measurement areas on the reference plane of the sand box mold;

[0162] If there is no excess area or under-measurement area, the molding sand in the sand box mold is considered to be flat;

[0163] If there are excess areas and insufficient areas, it is determined that the molding sand in the sand box mold is uneven.

[0164] If it is not flat, the distribution of the current molding sand in the sand box mold is obtained, and the sand replenishment operation is performed, and the sand replenishment area and sand replenishment amount are recorded, including:

[0165] Obtain the excess area and the under-area existing on the datum plane of the sand box mold;

[0166] Scrape the molding sand in the excess area to the under-measurement area in the scraping direction of the under-measurement area, and the amount of the scraped molding sand is equal to the remaining amount of the molding sand in the excess area;

[0167] Treat the shortfall area as a sand replenishment area and record it;

[0168] The remaining amount of molding sand in the excess area shall be taken as the sand replenishment amount and recorded.

[0169] When the same sand replenishment area is recorded multiple times in the subsequent process of casting the metal product, the sand replenishment area is marked as a marked area, including:

[0170] Setting a number determination threshold; the number determination threshold is a constant, which can be set to 3, indicating that when the same metal product is cast again in the subsequent casting, if the number of times the sand replenishment area at the same position is recorded on the sand box mold reaches or exceeds 3, the location of the sand replenishment area is used as a marking area;

[0171] When the same metal product is cast again in the subsequent casting, if the number of times the sand replenishment area in the same position is recorded on the sand box mold is greater than or equal to the number determination threshold, the location of the sand replenishment area is obtained as the marking area; the number determination threshold is set during the casting process, and the sand replenishment area is marked according to the threshold; setting the number determination threshold means that when the same metal product is cast subsequently, when the number of times the same sand replenishment area is recorded on the sand box mold reaches or exceeds this threshold, the area is marked. This approach can effectively identify defects that appear repeatedly in multiple castings, and provide reliable data support for subsequent castings.

[0172] In the subsequent process of casting the metal product, the operation of reserving molding sand for the marked area includes:

[0173] In the subsequent casting of new identical metal products, during the scraping and mixing operation:

[0174] If the marked area is a missing quantity area, the missing quantity of the molding sand in the missing quantity area is obtained, and the reserve quantity is added to the missing quantity of the molding sand, and the obtained result replaces the original missing quantity of the molding sand in the missing quantity area as the real missing quantity of the molding sand in the missing quantity area;

[0175] If the marked area is an excess area, the remaining amount of the molding sand in the under-measurement area is obtained, and the reserve amount is subtracted from the remaining amount of the molding sand, and the result is used to replace the original remaining amount of the molding sand in the excess area as the real remaining amount of the molding sand in the excess area;

[0176] If the marked area is neither a shortage area nor an excess area, the marked area is regarded as a shortage area, and the reserve amount is used as the shortage of molding sand in the shortage area; when performing the reserved molding sand operation in the marked area, for the shortage area, the original shortage of molding sand is obtained and the reserve amount is added, so as to ensure that the molding sand height of this area is effectively supplemented in subsequent castings, thereby avoiding casting defects caused by insufficient molding sand; and for the excess area, the molding sand residue is adjusted by subtracting the reserve amount, so that after the subsequent vibration leveling strategy, the amount of molding sand in the excess area is equal to the amount of molding sand required in this area; this sophisticated management method makes the configuration of molding sand more scientific and reasonable, thereby improving the quality of castings; at the same time, this method can reduce the number of times the molding sand is scraped and delivered during the sand scraping and mixing operation when casting the same metal product in the subsequent casting, thereby reducing the time consumed by the sand scraping and mixing operation and improving casting efficiency.

[0177] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0178] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A metal casting process, characterized in that: include: Melting metal raw materials to form metal pouring liquid; Make sand box mold; Get the total amount of molding sand required for the sand box mold; According to the total amount of molding sand, sand is injected into the sand box mold; After the sand injection operation is completed, the distribution of the sand in the current sand box mold is obtained; According to the current distribution of sand in the sand box mold, the insufficient area and the excessive area are divided; Obtain the excess amount of molding sand in each excess area, and record it as the residual amount of molding sand in each excess area; Obtain the amount of molding sand missing in each missing area, and record it as the molding sand missing amount in each missing area; Perform sand scraping and mixing operations according to the remaining and insufficient molding sand; After completing the sand scraping and mixing operation, perform vibration leveling operation on the sand box mold; After completing the vibration leveling operation, check whether the molding sand in the sand box mold is flat; If it is flat, close the sand box mold and pour metal casting liquid into the closed sand box mold; If it is not flat, the distribution of the current molding sand in the sand box mold is obtained, and the sand replenishment operation is performed, and the sand replenishment area and amount are recorded; When the same sand replenishment area is recorded multiple times in the subsequent process of casting metal products, the sand replenishment area is marked as a marked area; Obtain the amount of molding sand added to the marked area during each sand filling operation, and record it as the reserve amount; In the subsequent casting process of metal products, the marked area is subjected to a reserved sand operation; Closing the sand box mold after the sand filling operation is completed, and pouring metal pouring liquid into the closed sand box mold; Cooling the sand box mold after the pouring operation is completed, and taking out the metal casting in the sand box mold after cooling; The metal casting is polished to obtain a cast metal product.

2. A metal casting process according to claim 1, characterized in that: The method for making a sand box mold comprises: Make product molds according to the metal products to be cast; According to the product mold, make a rectangular sand box for sand casting; The sand box is surrounded by four metal plates and has two opposite openings, one of which is welded with a grid-shaped metal strip, which is marked as the upper side of the sand box, and the other opening is a rectangular opening, which is marked as the lower side of the sand box; Place the sand box on the product mold so that the bottom of the sand box overlaps with the bottom surface of the product mold, and the product mold is located in the middle position inside the sand box to form a sand box mold.

3. A metal casting process according to claim 1, characterized in that: The sand injection operation on the sand box mold according to the total amount of molding sand includes: Place the sand box mold on a horizontal plane so that the bottom of the sand box in the sand box mold coincides with the horizontal plane; The upper side of the sand box in the sand box mold is obtained as the upper side of the sand box mold, and grids of the same size exist on the upper side of the sand box mold; Obtain two sets of parallel edges on the sand box mold, select one set of parallel edges as the upper edge and the lower edge, and record the other set of parallel edges as the left edge and the right edge; For the grids on the top of the sand box mold, record each row of grids as the first row of grids, the second row of grids, the third row of grids, and so on to the Nth row of grids from top to bottom; For each row of grids, the grid containing the left side is used as the starting grid of each row of grids, and the grid containing the right side is used as the ending grid of each row of grids; Set the sand injection path, including: Start from the starting grid of the first row of grids, move to the ending grid of the first row of grids, and pass through each grid of the first row of grids in turn; When reaching the end grid of the first row of grids, it moves to the end grid of the second row of grids. When reaching the end grid of the second row of grids, it moves to the start grid of the second row of grids, passing through each grid of the second row of grids in turn. When it reaches the starting grid of the second row of grids, it moves to the starting grid of the third row of grids. When it reaches the starting grid of the third row of grids, it moves to the ending grid of the third row of grids, passing through each grid of the third row of grids in turn. When reaching the end grid of the third row of grids, it moves to the end grid of the fourth row of grids. When reaching the end grid of the fourth row of grids, it moves to the start grid of the fourth row of grids, passing through each grid of the fourth row of grids in turn. Similarly, when passing through all the grids on the sand box mold, the movement stops and the path passed by is used as the sand injection path; Inject molding sand into the sand box mold through the sand injection port, and control the sand injection port to move at a uniform speed along the sand injection path; The amount of sand discharged from the sand injection port per unit time is controlled to be constant, and the amount of sand discharged from the sand injection port is controlled according to the total amount of molding sand required by the sand box mold, so that after the sand injection port has completely passed through the sand injection path, the total amount of molding sand injected into the sand box mold by the sand injection port is equal to the total amount of molding sand required by the sand box mold.

4. A metal casting process according to claim 1, characterized in that: According to the distribution of the current sand in the sand box mold, the under-quantity area and the over-quantity area are divided, including: Get the plane where the sand box mold is located, and record it as the reference plane; On the reference plane, the area in the sand box mold where the height of the molding sand is lower than the reference plane is recorded as the missing area; On the reference plane, the area in the sand box mold where the height of the molding sand accumulation is higher than the reference plane is recorded as the excess area; The method of obtaining the excess amount of molding sand in each excess area, which is recorded as the residual amount of molding sand in each excess area, includes: For each excess area, the amount of molding sand in the excess area that is higher than the reference plane is obtained as the molding sand surplus of each excess area; The method of obtaining the amount of molding sand missing in each missing area, which is recorded as the missing amount of molding sand in each missing area, includes: For each missing quantity area, the amount of molding sand required to add molding sand to the missing quantity area so that the height of the molding sand in the missing quantity area is flush with the reference plane is obtained, and recorded as the molding sand missing quantity of each missing quantity area.

5. A metal casting process according to claim 1, characterized in that: The sand scraping and mixing operation is performed according to the excess amount of molding sand and the shortage of molding sand, including: Obtaining the geometric center points of each excess area and each deficiency area respectively, and recording them as the excess point of each excess area and the deficiency point of each deficiency area respectively; Acquire all the under-quantity areas adjacent to the over-quantity area and existing around the over-quantity area as the pre-selected under-quantity areas for each over-quantity area; The under-quantity area adjacent to the excess area means that there is no other under-quantity area or excess area between the under-quantity area and the excess area; Obtain the remaining amount of molding sand in the excess area, and respectively obtain the molding sand deficiency in each pre-selected deficiency area; If there is a pre-selected under-quantity area where the amount of molding sand under-quantity is equal to the amount of molding sand remaining in the excess area, the pre-selected under-quantity area is marked as the first selected under-quantity area, and the molding sand in the excess area is scraped to the first selected under-quantity area in the direction from the excess point of the excess area to the under-quantity point of the first selected under-quantity area, and the amount of the scraped molding sand is equal to the amount of molding sand remaining in the excess area; If there is no first selected underfill area, and there is a pre-selected underfill area where the molding sand underfill is greater than the molding sand surplus in the excess area, then the pre-selected underfill area with the largest molding sand underfill is obtained as the second selected underfill area; Scrape the molding sand in the excess area to the second selected undersize area in the direction from the excess point of the excess area to the undersize point of the second selected undersize area, and the amount of the scraped molding sand is equal to the remaining amount of the molding sand in the excess area; If there is no first-selected underfill area, and the molding sand underfill in each pre-selected underfill area is less than the molding sand surplus in the excess area, the existing pre-selected underfill areas are numbered in descending order according to the molding sand underfill; According to the serial numbering sequence of the pre-selected under-quantity zones, one pre-selected under-quantity zone is selected each time, and the molding sand in the excess zone is scraped to the selected pre-selected under-quantity zone with the excess point of the excess zone pointing to the direction of the under-quantity point of the selected pre-selected under-quantity zone, and the amount of the scraped molding sand is equal to the molding sand under-quantity of the selected pre-selected under-quantity zone; In the process of scraping the molding sand to each pre-selected under-quantity area in turn, after the molding sand is scraped and sent to each pre-selected under-quantity area, the remaining molding sand in the over-quantity area is obtained; When the amount of molding sand remaining in the excess area is less than the amount of molding sand shortage in the next numbered pre-selected shortage area, the amount of molding sand remaining in the excess area is scraped and sent to the next numbered pre-selected shortage area, and the scraping of molding sand in the excess area is stopped; After completing the scraping and delivery of the molding sand to each excess area, determine whether there is an excess area and an under-area; If there is no excess area or insufficient area, the sand scraping and mixing operation is completed; If there is an excess area and no under-measurement area, the molding sand in the excess area and the remaining molding sand in the excess area are scraped to the center position on the sand box mold to complete the sand scraping and mixing operation.

6. A metal casting process according to claim 1, characterized in that: After the vibration leveling operation is completed, the molding sand in the sand box mold is checked to see if it is flat, including: After completing the vibration leveling operation, check whether there are under-measurement areas and over-measurement areas on the reference plane of the sand box mold; If there is no excess area or under-measurement area, the molding sand in the sand box mold is considered to be flat; If there are excess areas and insufficient areas, it is determined that the molding sand in the sand box mold is uneven.

7. A metal casting process according to claim 5, characterized in that: If it is not flat, the distribution of the current molding sand in the sand box mold is obtained, and the sand replenishment operation is performed, and the sand replenishment area and sand replenishment amount are recorded, including: Obtain the excess area and the under-area existing on the datum plane of the sand box mold; Scrape the molding sand in the excess area to the under-measurement area in the scraping direction of the under-measurement area, and the amount of the scraped molding sand is equal to the remaining amount of the molding sand in the excess area; Treat the shortfall area as a sand replenishment area and record it; The remaining amount of molding sand in the excess area shall be taken as the sand replenishment amount and recorded.

8. A metal casting process according to claim 1, characterized in that: When the same sand replenishment area is recorded multiple times in the subsequent process of casting the metal product, the sand replenishment area is marked as a marked area, including: Set the number of times determination threshold; When the same metal product is subsequently cast again, if the number of times that the sand replenishment area at the same position is recorded on the sand box mold is greater than or equal to the number determination threshold, the location of the sand replenishment area is obtained as the marking area.

9. A metal casting process according to claim 1, characterized in that: In the subsequent process of casting the metal product, the operation of reserving molding sand for the marked area includes: In the subsequent casting of new identical metal products, during the scraping and mixing operation: If the marked area is a missing quantity area, the missing quantity of the molding sand in the missing quantity area is obtained, and the reserve quantity is added to the missing quantity of the molding sand, and the obtained result replaces the original missing quantity of the molding sand in the missing quantity area as the real missing quantity of the molding sand in the missing quantity area; If the marked area is an excess area, the remaining amount of the molding sand in the under-measurement area is obtained, and the reserve amount is subtracted from the remaining amount of the molding sand, and the result is used to replace the original remaining amount of the molding sand in the excess area as the real remaining amount of the molding sand in the excess area; If the marked area is neither a shortage area nor an excess area, the marked area will be regarded as a shortage area, and the reserve amount will be regarded as the sand shortage in the shortage area.

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