Application of a method for manufacturing a complex mold of a machine body with metal and wood structure

Abstract

The present invention belongs to the technical field of casting molds, and discloses a method for making a complex mold of a metal and wood structure of a machine body and its application. The method adopts a structure combining frame-off and disassembly, track split, metal integral inlay, and dovetail metal live assembly to integrate multiple functional parts of the machine body such as crankshaft cavity, cylinder hole, and base plate to make cores, and the core heads on both sides of the core cylinder hole and crankshaft observation window are positioned on the outer mold to achieve accurate mold size. The manufacturing method provided by the present invention effectively integrates multiple functional parts of the machine body such as crankshaft cavity, cylinder hole, and base plate to make cores, and the core heads on both sides of the core cylinder hole and crankshaft observation window are positioned on the outer mold to achieve accurate size. The overall positioning of key dimensional elements of different parts of the machine body is achieved. It solves the difficulty of dimensional control in the assembly process of large and complex machines, and the dimensional problems such as thin walls of camshafts and crankshaft observation windows, drilling through the clasp, and drilling holes off center after processing.

Description

Technical Field

[0001] The present invention belongs to the technical field of casting molds, and in particular relates to a method for manufacturing a complex mold of a metal and wood structure of an engine body and its application. Specifically, it relates to a method for manufacturing a complex mold of a metal and wood structure of a large diesel engine body and its application. Background Art

[0002] At present, the MAN32 / 40 engine body is a large and complex cast iron part, with the maximum outline size of the engine body: 5730×1590×1761. The casting deviation is required to be implemented according to GTB18 DIN1685 and 1686. The engine body has a compact structure and high dimensional accuracy requirements. The cylinder head bolt hole saddle and main bearing bolt hole saddle, the main bearing lubricating oil channel of the engine body are integrated and connected from the top surface of the cylinder hole to the bearing seat, from the fuel side to the intake and exhaust side, forming a "#-shaped" stable structure inside the engine body. The size is relatively thick (105×40), while the wall thickness between the cylinder hole and the crankshaft chamber is at least 12, which is relatively small. In the past, due to the low strength and rigidity of the mold, it was not possible to integrate the core of multiple different functional parts such as the engine body crankshaft cavity, cylinder hole, and base plate. The side of the core was positioned on the outer mold, and the size control during the box matching process was difficult. After processing, the camshaft and crankshaft observation windows often had thin walls, saddle drilling, and drilling deviation from the center.

[0003] Through the above analysis, the problems and defects of the prior art are as follows:

[0004] (1) In the prior art, the crankshaft cavity, cylinder hole, base plate and other different functional parts of the engine body are not integrated into the core making, resulting in inaccurate positioning dimensions of the core heads on both sides of the core cylinder hole and the crankshaft observation window on the outer mold.

[0005] (2) The prior art does not improve the required dimensional accuracy of the machine body by comprehensively adopting the methods of removing the frame and disassembling, splitting the tracks, metal integral inlaying, and dovetail metal movable structure.

[0006] (3) In the prior art, the characteristics of the frame removal (fixed) and disassembly (movable) structures are not fully utilized, resulting in low precision of the mold size. Summary of the invention

[0007] In order to solve the problems existing in the prior art, the present invention provides a method for manufacturing a complex mold of a machine body with a metal and wood structure and its application.

[0008] The present invention is achieved in this way: a method for manufacturing a complex mold of a machine body metal and wood structure adopts a method combining frame-off and disassembly, track splitting, metal integral inlaying, and dovetail metal assembly to integrate multiple functional parts of the machine body crankshaft cavity, cylinder hole, and base plate to make cores, and the core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to determine the mold size.

[0009] Furthermore, the method for making the complex metal-wood structure mold of the machine body further comprises:

[0010] Step 1: Overall structural analysis and mold design. The crankshaft cavity, cylinder bore, and base plate of the MAN32 / 40 engine are integrated into the core. The core heads on both sides of the core cylinder bore and the crankshaft observation window are positioned on the outer mold to achieve the overall positioning of the key dimensional elements of different parts of the engine. The mold design is carried out using a structure that combines the frame-off and disassembly types on the track. The frame-off (fixed) and disassembly (mobile) structures are fitted and positioned at multiple angles and large slopes on a base plate, making full use of the characteristics of the frame-off (fixed) and disassembly (mobile) structures to achieve accurate mold size.

[0011] Step 2: weld the bottom plate of the entire mold and install rollers on both sides of the mold;

[0012] Step 3: The cylinder hole is designed by adopting a sunken frame-off structure, and part of the mold is sunk below the geometric center of the bottom plate plane for fixed production;

[0013] Step 4: The intersection and segmentation of the cylinder bore and the crankshaft cavity, the stripping frame and the disassembly structure are positioned on the bottom plate with multiple angles and large slopes to determine the mold size;

[0014] Step 5: Design of the crankshaft cavity. The crankshaft cavity above the cylinder bore adopts a disassembly structure with a mold opening track and a split mold with the crankshaft observation window as the center.

[0015] Step 6: Design the base plate. The shape of the part where the crankshaft cavity and the base plate are connected is a curved surface transition. The base plate is straight and made as a whole. The oil return groove is small and adopts a large-angle long-size dovetail metal live assembly.

[0016] Step seven, positioning with the external model, by integrating multiple functional parts of the engine body such as the crankshaft cavity, cylinder hole, and base plate into cores, and positioning the core heads on both sides of the core cylinder hole and the crankshaft observation window on the external mold to achieve the overall positioning of the key dimensional elements of different parts of the engine body.

[0017] Furthermore, in step 1, the integrated core making of the crankshaft cavity, cylinder bore, and base plate of the engine body with different functional parts specifically includes:

[0018] 1) Determination of the size of the machine body model: 〈〔Part size + (machining allowance)〕〉×(1+reduction)+core size;

[0019] 2) Determination of mold outline dimensions: model + filler + outer frame.

[0020] Furthermore, in the step 2, a frame is made of steel pipes, steel plates are welded on both sides of the top surface of the frame, tracks are laid on the upper parts of the steel plates, and rollers are installed on both sides of the mold, which can be opened and closed freely along the tracks.

[0021] Furthermore, in the step 3, the cylinder bore portion adopts a sinking frame-off structure, the mold height 300 is sunk below the geometric center of the bottom plate plane for fixed production, the remaining portion of the cylinder bore is 340 above the bottom plate plane, and 350 is left between the two sides of the cylinder bore outer frame and the crankshaft cavity model;

[0022] The internal shape of the cylinder hole is 35 outwards from the thinnest part of the filler, and the cylinder hole filler is divided into four parts of loose blocks horizontally and vertically along the center of the cylinder hole. The connecting part has an R50 rounded transition, and the side surface is fitted with the outer frame at 5 degrees. When the crankshaft cavity models on both sides are opened along the track and the mud core is lifted as a whole, the loose blocks are separated from the outer frame and then fall out separately.

[0023] Further, in the step 4, the crankshaft cavity part and the cylinder hole part are 45 degrees below the top surface of the cylinder hole with an inclined surface with an angle of 10 degrees, a width of 188.54, and a length of 2061.55, and the two side surfaces are inclined surfaces with an angle of 10 degrees, a width of 377.45, and a height of 801.44 to perform mold fitting and positioning of the two parts, so as to accurately connect the shape of the cylinder hole and the crankshaft;

[0024] The part 45cm above the top of the cylinder bore is made of a metal block with a rounded corner at the crankshaft cavity joint; it is used to ensure the dimensional stability after repeated use; the stripping frame and disassembly structure are fitted and positioned on the bottom plate with multiple angles and large slopes to determine the mold size;

[0025] The shape of the cylinder bore top surface and the crankshaft cavity are divided according to the principle of ensuring strength and thick mouth fitting; the two side surfaces in the length direction are divided 45 degrees downward along the transition fillet between the crankshaft cavity partition casting rib and the cylinder bore top surface; the width direction is 45 degrees upward along the transition fillet between the crankshaft observation window side wall and the crankshaft cavity bottom side wall, and then 10 degrees upward to intersect with the length direction dividing line for division; the height direction is centered on the crankshaft observation window and downward, and the fuel side is divided along the center of the crankshaft observation window and the intersection of the width direction dividing line; the upper edge of the intake and exhaust side is divided along the center of the crankshaft observation window, and the two sides of the lower edge are inclined downward 10 degrees along the crankshaft observation window fillet, avoiding the casting ribs and the clasp on the inner cavity side and intersecting with the width direction dividing line for division.

[0026] Furthermore, the step five includes: the upper and lower inner cavity sides of the crankshaft observation window on both sides of the crankshaft cavity are provided with long strips, the shape of the part connected to the base plate is transformed into a curved surface, and is inlaid by a metal inlay method.

[0027] Further, the step six includes: the junction between the top surface of the base plate and the outer wall of the crankshaft observation window is provided with a reflux groove for the engine body oil, and a large-angle long-size dovetail structure is selected to make the metal movable block:

[0028] The height direction is from the bottom of the base plate upward, the width direction is from the side of the metal insert inward and downward at an angle of 20 degrees to the inside of the reflux groove, and it is divided from the side of the metal insert outward and downward at an angle of 20 degrees to the bottom plane of the base plate. The length direction is flush with the shapes of the two ends and is divided obliquely to both sides from the center of the cylinder hole for determining the size of the base plate.

[0029] Furthermore, the step seven includes: the cylinder hole and the bottom of the model are positioned by using a mold-based positioning core head, and a core head positioning notch is made inward on the fuel side of the core head; the outer core head part of the crankshaft observation window and the outer mold are positioned by the positioning core head and the outer mold; the core seat is made in cooperation with the outer mold, and a sand collecting groove is made according to the edge of the core seat.

[0030] Another object of the present invention is to provide a large diesel engine body metal-wood structure mold made using the method for making the body metal-wood structure complex mold.

[0031] Combining all the above technical solutions, the advantages and positive effects of the present invention are as follows: the present invention is achieved by comprehensively adopting a structure combining frame-off and disassembly, track splitting, metal integral inlaying, and dovetail metal movable assembly.

[0032] The present invention follows the principle of integrated engine design, integrates multiple functional parts such as the engine crankshaft cavity, cylinder hole, and base plate into core making, and positions the core heads on both sides of the core cylinder hole and the crankshaft observation window on the outer mold to achieve accurate size. Limited by the large differences in structure and shape of different parts, and the large number of clasps and ribs, the required dimensional accuracy of the engine body is improved by combining the frame-off and disassembly types, track splitting, metal integral inlay, and dovetail metal movable structure.

[0033] The entire mold uses a solid and stable base plate, with high-precision tracks laid on the upper part, and corresponding ball bearings installed on the molds on both sides. The overall structure adopts a split track, which allows smooth opening and closing and accurate size control. The cylinder bore part adopts a sunken frame-off structure and opens upward. The crankshaft cavity part adopts thick-mouth split and metal integral inlay. The base plate part is made as a whole and has a large-angle and long-size dovetail metal live assembly. The frame-off (fixed) and disassembly (mobile) structures are fitted and positioned at multiple angles and large slopes on a base plate, making full use of the characteristics of the frame-off (fixed) and disassembly (mobile) structures to achieve precise mold size.

[0034] Compared with the prior art, the advantages of the present invention further include: the method of the present invention effectively integrates the core making of multiple different functional parts of the engine body, such as the crankshaft cavity, cylinder hole, and base plate, and the core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to achieve accurate dimensions. The overall positioning of key dimensional elements of different parts of the engine body is achieved. It solves the difficulty of dimensional control in the assembly process of large and complex engines, and the dimensional problems such as thin walls of the camshaft and crankshaft observation windows, drilling through the brackets, and drilling holes off the center after processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments of the present application. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0036] Figure 1 It is a flow chart of a method for manufacturing a complex metal and wood structure mold for a machine body provided by an embodiment of the present invention.

[0037] Figure 2 It is a schematic diagram of the internal structure of a mold provided by an embodiment of the present invention.

[0038] Figure 3 It is a schematic diagram of the crankshaft cavity observation window insert structure provided by an embodiment of the present invention.

[0039] Figure 4 It is a schematic diagram of the structure of the docking portion between the cylinder hole and the crankshaft cavity provided by an embodiment of the present invention.

[0040] Figure 5 It is a schematic diagram of a cylinder hole sinking type frame-off structure provided by an embodiment of the present invention.

[0041] Figure 6 It is a schematic diagram of a track split mold opening structure provided in an embodiment of the present invention.

[0042] Figure 7 It is a schematic diagram of the cylinder hole and crankshaft cavity positioning structure provided by an embodiment of the present invention.

[0043] Figure 8 It is a schematic diagram of the mold appearance structure provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0044] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0045] In the prior art, multiple functional parts of the engine body such as the crankshaft cavity, cylinder hole, and base plate are not integrated for core making, resulting in inaccurate positioning dimensions of the core heads on both sides of the core cylinder hole and the crankshaft observation window on the outer mold.

[0046] The prior art does not improve the required dimensional accuracy of the machine body by comprehensively adopting the methods of taking off the frame type and disassembling type, rail splitting, metal integral inlaying, and dovetail type metal movable structure.

[0047] In the prior art, the characteristics of the frame removal (fixed) and disassembly (movable) structures are not fully utilized, resulting in low precision of the mold size.

[0048] In view of the problems existing in the prior art, the present invention provides a method for manufacturing a complex mold of a machine body metal and wood structure and its application. The present invention is described in detail below in conjunction with the accompanying drawings.

[0049] like Figure 1 As shown, the method for manufacturing a complex metal-wood structure mold of a machine body provided by an embodiment of the present invention includes:

[0050] S101, overall structure analysis and mold design, integrates the core of multiple functional parts of the MAN32 / 40 engine body, such as the crankshaft cavity, cylinder hole, and base plate; the core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to achieve the overall positioning of the key dimensional elements of different parts of the engine body. The mold design is carried out using a structure that combines the frame-off and disassembly types on the track; the frame-off (fixed) and disassembly (movable) structures are fitted and positioned with multiple angles and large slopes on a base plate, making full use of the characteristics of the frame-off (fixed) and disassembly (movable) structures to achieve accurate mold size.

[0051] S102, a bottom plate is welded to the bottom of the entire mold, and rollers are installed on both sides of the mold.

[0052] S103, adopts the sunken frame-off structure to design the cylinder hole, and part of the mold is sunk below the geometric center of the bottom plate plane for fixed production;

[0053] S104, the intersection and segmentation of the cylinder bore and the crankshaft cavity, the fitting and positioning of the stripping frame and the disassembly structure on the bottom plate with multiple angles and large slopes, and the determination of the mold size;

[0054] S105, crankshaft cavity design, the crankshaft cavity above the cylinder hole adopts a disassembly structure with a split mold and mold opening track centered on the crankshaft observation window.

[0055] S106, foot plate design, the shape of the connecting part between the crankshaft cavity and the foot plate is a curved surface transition, the foot plate part is straight and made as a whole, and the small oil return groove adopts a large-angle long-size dovetail metal live assembly;

[0056] S107, positioning of the external model, by integrating the core making of multiple different functional parts such as the engine body crankshaft cavity, cylinder hole, base plate, etc., and positioning the core heads on both sides of the core cylinder hole and crankshaft observation window on the external mold, the overall positioning of the key dimensional elements of different parts of the engine body is achieved.

[0057] In the present invention, the production requirements include: the mold is made according to the DIN1511-H1a (JB / T7699-95Ⅰ) grade requirements, the mold surface is a multi-layer plywood that meets the DIN1511-H1a standard production requirements; all the mold surfaces are made of high-strength dense plywood and processed by CNC machine tools, and the resistance surface in the demoulding direction must be covered with multi-layer boards along the grain. The plates with a thickness of less than 30mm (the upper rib plate of the model, the partition in the core box, etc.), the brackets and the thin-mouth parts are made of cast aluminum, and the core box is sanded and inlaid with bakelite. All working surfaces of the mold must be treated with atomic putty, polished and then painted with polyurethane paint, and the final surface roughness reaches Ra1.6. The core box outer frame and the bottom plate are welded with rectangular square tubes. The mold has a mold opening track and an opening mechanism is set. All movable blocks should be reliably connected, and positioning and demoulding devices are installed.

[0058] In the present invention, the auxiliary tool includes:

[0059] 1) Core box frame:

[0060] Length direction: 200×70 rectangular square tubes are used, with a welding area of ​​2580×1580 frames at a spacing of 645×395, 2 pieces in quantity.

[0061] Width direction: 120×120 rectangular square tube is used as the skeleton, 120×60 rectangular square tube is welded in two passes with a frame area of ​​1580×750, quantity 4.

[0062] 2) Locking device: The height of the outer frame in the width direction of the core box is evenly distributed, equipped with a φ20 locking bolt, one end of which is fixed on the locking device, the axis can rotate, and one end is equipped with a locking handwheel for easy locking.

[0063] 3) Mold release device:

[0064] Mold demoulding: Make a demoulding template of 100×100 and height 10 at different heights on both sides of the outer frame in the width direction of the core box.

[0065] Loose block demolding: When using screw holes as demolding holes and the material is cast aluminum, wire screw sleeves need to be installed in the screw holes.

[0066] 4) Moving device: Two high-precision rollers with a diameter of φ50 are installed on each side of the bottom of the outer frame in the width direction of the core box, and a high-precision track is laid on the upper part of the bottom plate.

[0067] 5) Lifting device: Make two lifting ears for lifting and turning devices with a load weight ≥ 10 tons and a weight greater than 10Kg on the side of the bottom plate in the length direction, and the quantity is 4.

[0068] 6) Ladder: A ladder is made with the core box frame to facilitate operation.

[0069] In the present invention, in step S101, the integration of multiple functional parts such as the crankshaft cavity, cylinder bore, and base plate of the MAN32 / 40 engine body into cores specifically includes:

[0070] 1) Machine body (casting) model size: (part size + (machining allowance)) × (1 + reduction) + core head size.

[0071] Height: 〈〔1761+(10+15)〕〉×(1+0.06)+80=〔1786〕×1.006+80=1876.72

[0072] Width: 〈〔1590+(10+10)〕〉×(1+0.06)+140+140=〔1610〕×1.006+280=1899.66

[0073] Length: 〈530〉×(1+0.09)=534.77.

[0074] Model dimensions: 534.77×2442.9×1876.72.

[0075] 2) Mold outline size: model + filler + outer frame

[0076] Height: 1876.72+100+120=2096.72.

[0077] Width: 1899.66+350×2+120×2=2789.66.

[0078] Length: 534.77+300×2+120×2=1074.77.

[0079] Mould dimensions: 1074.77×2789.66×2096.72.

[0080] In the present invention, the whole mold has a large outline, and the cylinder hole, crankshaft cavity, and bottom plate are of different shapes, and they are all important parts of the machine body. The size control requires high precision. It is required that the mold structure should be advanced, reliable, and reasonable while ensuring the strength, rigidity, and appearance quality of the mold structure. The mold's performance, safety, maintainability, and certain production efficiency are guaranteed. The overall structural solution adopts a combination of track split frame type and disassembly type.

[0081] In the present invention, in step S102, in order to achieve smooth translation of the entire mold, smooth opening and closing, and accurate size control, the entire mold requires a solid and stable bottom plate.

[0082] The frame is made of high-strength 280×65 square steel pipes. The bottom plate size is 3275×2400×280, the square steel pipe spacing is welded at 800×655, and the top surface is welded with 20, 2400×400 steel plates on both sides to ensure that high-precision tracks are laid on the upper part. After the molds on both sides are installed with corresponding high-precision rollers, they can be opened and closed freely along the track.

[0083] In the present invention, in step S103, in order to reduce the height of the entire track opening and closing mold and facilitate the core making process, the cylinder hole part adopts a sinking frame-off structure, the mold height is 300 sunk below the geometric center of the bottom plate plane for fixed production, the remaining part of the cylinder hole is 340 above the bottom plate plane, and 350 is left between the two sides of the cylinder hole outer frame and the crankshaft cavity model.

[0084] The internal shape of the cylinder hole is 35 outwards from the thinnest part of the filler, and the cylinder hole filler is divided into four parts of loose blocks horizontally and vertically along the center of the cylinder hole. The connecting part has an R50 rounded transition, and the side surface is fitted with the outer frame at 5 degrees. When the crankshaft cavity models on both sides are opened along the track and the mud core is lifted as a whole, the loose blocks are separated from the outer frame and then fall out separately.

[0085] In the present invention, in step S104, the cylinder bore portion and the crankshaft cavity portion are separated and manufactured, and the portion above the cylinder bore adopts a track split disassembly structure.

[0086] The crankshaft cavity part and the cylinder bore part are positioned by a slope with an angle of 10 degrees, a width of 188.54, and a length of 2061.55, 45 degrees below the top surface of the cylinder bore, and the two sides are positioned by a slope with an angle of 10 degrees, a width of 377.45, and a height of 801.44, to ensure the accurate docking of the shape between the cylinder bore and the crankshaft. The part 45 degrees above the top surface of the cylinder bore is made of a metal block with a rounded shape of the crankshaft cavity joint. Ensure that the size is stable and accurate after repeated use. The frame removal (fixed) and disassembly (movable) structures are positioned by multi-angle and large slopes on a bottom plate, making full use of the characteristics of the frame removal (fixed) and disassembly (movable) structures to achieve accurate mold size.

[0087] The top surface of the cylinder bore and the shape of the crankshaft cavity are divided according to the principle of ensuring strength and thick mouth fitting. The two sides in the length direction are divided 45 degrees downward along the transition fillet between the crankshaft cavity partition casting rib and the top surface of the cylinder bore; in the width direction, the transition fillet between the side wall of the crankshaft observation window and the bottom side wall of the crankshaft cavity is upward 45 degrees, and then 10 degrees upward to intersect with the length direction dividing line for division; in the height direction, the crankshaft observation window is centered downward, and the fuel side is divided along the intersection of the crankshaft observation window center and the width direction dividing line. The upper edge of the intake and exhaust side is divided along the center of the crankshaft observation window, and the two sides of the lower edge are inclined downward 10 degrees along the crankshaft observation window fillet, avoiding the casting ribs and the clasp on the inner cavity side and intersecting with the width direction dividing line for division.

[0088] In the present invention, in step S105, the crankshaft cavity portion above the cylinder bore adopts a disassembly structure with a mold opening track that is split in half with the crankshaft observation window as the center.

[0089] The wall thickness of the crankshaft observation window on both sides of the crankshaft cavity is 25, and the upper and lower inner cavity sides of the window are equipped with a long strip with a height of 17 and a length of 110. The shape of the part connected to the base plate is mainly a curved surface transition, which is easily damaged by repeated demolding, so the metal inlay method is selected. Width direction: the inner wall of the cavity is divided by the cast ribs and the fillet of the partition, and the outer wall of the crankshaft cavity extends outward by 25; height direction: from the R32 fillet on the inside of the base plate to the bottom of the core head 30 outward, length direction: along the crankshaft observation window to the crankshaft cavity partition, it is made of integral metal, and the core head with a depth of 60 is made according to the shape to position it with the mold, and it is fixed to the outer frame with multiple points of φ10 bolts to ensure that the integral metal inlay part is firmly and accurately fixed on the mold.

[0090] The bottom of the crankshaft cavity is fixed on both sides of the top surface of the cylinder hole according to its shape, and the intake and exhaust crankshaft observation window part and the casting ribs on the side of the inner cavity are fixed by metal inlay.

[0091] The use of integral metal inlays in large molds utilizes both the air permeability of wooden molds and the high strength of metal molds, so that the draft angles of the small parts of the mold and the rib strips can be smoothly demolded along the length of the mold, thereby increasing the overall service life of large wooden molds.

[0092] In the present invention, in step S106, the shape of the connecting portion between the crankshaft cavity and the base plate is mainly a curved surface transition, and the shape of the base plate portion is relatively straight. In order to ensure the strength of the mold, the base plate and the crankshaft cavity are made as a whole.

[0093] The intersection of the top surface of the foot plate and the outer wall of the crankshaft observation window has an oil return groove with the same length as the engine body, 15 degrees deep and 20 degrees wide. The shape is small and not easy to demold. A large-angle long dovetail structure metal block is selected for production: the height direction is 45 degrees upward from the bottom of the foot plate, the width direction is 35 degrees inward from the side of the metal insert, 20 degrees downward to the R10 position in the return groove, and 25 degrees outward from the side of the metal insert, 20 degrees downward to the bottom plane of the foot plate. The length direction is flush with the shape of the two ends, and the cylinder hole center is divided at an angle of 15 degrees to both sides to ensure the accurate size of the foot plate.

[0094] In the present invention, in step S107, unification of casting matching datum with processing marking datum and design datum is a key factor for successful production of large complex engine body molds. By integrating multiple functional parts of the engine body such as crankshaft cavity, cylinder hole, and base plate, the core heads on both sides of the core cylinder hole and crankshaft observation window are positioned on the outer mold, and the overall positioning of key dimensional elements of different parts of the engine body is achieved.

[0095] The cylinder bore and the bottom of the model adopt a positioning core head with a height of 80, a slope of 5 degrees, and a gap of 1. The core head is made 40 degrees inward on the fuel side to make a core head positioning notch. The core head part outside the crankshaft observation window and the outer mold are positioned with a positioning core head with a height of 200, a length of 380, a width of 50, a slope of 3 degrees, and a gap of 2. The outer mold cooperates to make a core seat, and a sand collecting groove is made on the edge of the core seat.

[0096] The technical effects of the present invention are further described below in conjunction with experiments.

[0097] The present invention follows the principle of integrated engine design, integrates multiple functional parts of the engine such as the crankshaft cavity, cylinder hole, and base plate into core making, and positions the core heads on both sides of the core cylinder hole and the crankshaft observation window on the outer mold to achieve accurate dimensions. The overall positioning of key dimensional elements of different parts of the engine is achieved.

[0098] The entire mold uses a solid and stable base plate, with high-precision tracks laid on the upper part, and corresponding high-precision rollers installed on the molds on both sides. The overall structure adopts track splits, which allows smooth opening and closing and accurate size control. The cylinder bore part adopts a sunken frame-off structure that opens upward, the crankshaft cavity part adopts thick-mouth splits and overall metal inlays, and the base plate part is made as a whole and has a large-angle and long-size dovetail metal live assembly. The frame-off (fixed) and disassembly (mobile) structures are fitted and positioned at multiple angles and large slopes on a base plate, making full use of the characteristics of the frame-off (fixed) and disassembly (mobile) structures to achieve precise size of large and complex molds.

[0099] like Figure 2As shown in the figure, following the principle of integrated engine design, the engine crankshaft cavity, cylinder hole, foot plate and other different functional parts are integrated into the core. The cylinder hole part adopts a sunken frame-off structure, which opens upwards. The crankshaft cavity part adopts a thick opening and metal integral inlay. The foot plate part adopts an integral production and large-angle long-size dovetail metal live assembly. The core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to achieve accurate size, realizing the overall positioning of key size elements in different parts of the engine. The frame-off (fixed) and disassembly (movable) structures are fitted and positioned with multiple angles and large slopes on a bottom plate, making full use of the characteristics of the frame-off (fixed) and disassembly (movable) structures, and achieving the precision of the size of large and complex molds.

[0100] like Figure 3 As shown, the crankshaft cavity observation window part adopts a thick-mouthed, metal-inlaid structure. The wall thickness of the crankshaft observation window on both sides of the crankshaft cavity is 25, and the upper and lower inner cavity sides of the window are equipped with a long strip of 17 in height and 110 in length. The shape of the part connected to the base plate is mainly a curved surface transition, which is easily damaged by repeated demolding, so the metal inlay method is selected. The bottom of the crankshaft cavity is fixed on both sides of the top surface of the cylinder hole according to the shape, and the intake and exhaust crankshaft observation window part and the cast ribs on the inner cavity side are fixed by metal inlay. The use of integral metal inlay in large molds not only utilizes the air permeability of wooden molds, but also utilizes the high strength of metal molds, so that the draft angle of the small parts of the mold and the rib strips can be smoothly demolded along the length direction of the mold, thereby improving the overall service life of large wooden molds.

[0101] like Figure 4 As shown, the bottom of the crankshaft cavity is fixed on both sides of the top surface of the cylinder hole according to the shape, and the intake and exhaust crankshaft observation window part and the cast ribs on the side of the inner cavity are fixed by metal inlay to ensure the accurate docking between the cylinder hole and the crankshaft. The part 45cm above the top surface of the cylinder hole is made of a metal block with a rounded corner shape at the joint of the crankshaft cavity. It ensures that the size is stable and accurate after repeated use. The use of integral metal inlay and large metal blocks in large molds not only utilizes the air permeability of wooden molds, but also utilizes the high strength of metal molds, so that the draft angle of the small parts of the mold and the rib strips can be smoothly demolded along the length of the mold, thereby improving the overall service life of large wooden molds.

[0102] like Figure 5 As shown in the figure, the cylinder bore part adopts a sunken frame-off structure, the mold height is 300 and sunk below the geometric center of the bottom plate plane for fixed production, the remaining part of the cylinder bore is 340 above the bottom plate plane, and 350 is left between the two sides of the cylinder bore outer frame and the crankshaft cavity model. The height of the overall mold is reduced, the convenience of on-site operation is improved, and the mold cost is reduced.

[0103] like Figure 6As shown in the figure, the whole mold adopts a solid and stable bottom plate, a high-precision track is laid on the upper part, and corresponding high-precision rollers are installed on the molds on both sides. The overall structure adopts track splitting, the mold is flexible to open and close, the opening and closing docking is smooth, and the size control is accurate, which greatly improves the operability of the mold.

[0104] like Figure 7 As shown in the figure, the crankshaft cavity, cylinder hole, foot plate and other different functional parts of the engine body are integrated into the core. The cylinder hole part adopts a sunken frame-off structure, which opens upwards. The crankshaft cavity part adopts a thick opening and metal integral inlay. The foot plate part adopts an integral production and large-angle long-size dovetail metal live assembly. The core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to achieve accurate size, realizing the overall positioning of key dimensional elements of different parts of the engine body. The frame-off (fixed) and disassembly (movable) structures are fitted and positioned with multiple angles and large slopes on a bottom plate, making full use of the characteristics of the frame-off (fixed) and disassembly (movable) structures, and achieving the precision of the size of large and complex molds.

[0105] like Figure 8 As shown in the figure, the entire mold core box outer frame and bottom plate are welded with rectangular square tubes, a solid and stable bottom plate is used, a high-precision track is laid on the upper part, and corresponding high-precision rollers are installed on the molds on both sides. The overall structure adopts track split, smooth opening and closing, and accurate size control. In order to facilitate operation and improve the overall function of the mold, auxiliary structures such as handwheel locking device, lifting plate, ladder, and lifting device are set.

[0106] The above description is only a specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by any technician familiar with the technical field within the technical scope disclosed by the present invention and within the spirit and principle of the present invention should be covered by the protection scope of the present invention.

Claims

1. A method for making a complex metal and wood structure mold for a machine body, characterized in that: The method for making a complex metal and wood structure mold of the engine body adopts a method combining frame-off and disassembly, track splitting, metal integral inlaying, and dovetail metal live assembly to integrate multiple functional parts of the engine body crankshaft cavity, cylinder hole, and base plate to make cores, and the core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to achieve accurate mold size; The method for making the complex metal-wood structure mold of the machine body comprises: Step 1: Overall structural analysis and mold design. The crankshaft cavity, cylinder bore, and base plate of the MAN32 / 40 engine are integrated into the core. The core heads on both sides of the core cylinder bore and the crankshaft observation window are positioned on the outer mold to achieve the overall positioning of the key dimensional elements of different parts of the engine. The mold design is carried out using a structure that combines the frame-off and disassembly types with the track. The frame-off and disassembly structures are fitted and positioned on a base plate with multiple angles and large slopes to achieve accurate mold size. Step 2: weld the bottom plate of the entire mold and install rollers on both sides of the mold; Step 3: The cylinder hole is designed by adopting a sunken frame-off structure, and part of the mold is sunk below the geometric center of the bottom plate plane for fixed production; Step 4: The intersection and segmentation of the cylinder bore and the crankshaft cavity, the stripping frame and the disassembly structure are positioned on the bottom plate with multiple angles and large slopes to determine the mold size; Step 5: Design of the crankshaft cavity. The crankshaft cavity above the cylinder bore adopts a disassembly structure with a mold opening track and a split mold with the crankshaft observation window as the center. The stripping frame and the disassembly structure are fitted and positioned on a bottom plate with multiple angles and large slopes to achieve accurate mold size. Step 6: Design the base plate. The shape of the part where the crankshaft cavity and the base plate are connected is a curved surface transition. The base plate is straight and the reflux groove is small, which is not convenient for demolding. A large-angle and long-size dovetail structure metal block is used for production. Step seven, positioning with the external model, by integrating multiple functional parts of the engine body such as the crankshaft cavity, cylinder hole, and base plate into cores, and positioning the core heads on both sides of the core cylinder hole and the crankshaft observation window on the external mold to achieve the overall positioning of the key dimensional elements of different parts of the engine body.

2. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: In the step 1, the integrated core making of the crankshaft cavity, cylinder bore, and base plate of the engine body specifically includes: 1) Determination of the size of the machine body model: 〈〔Part size + (machining allowance)〕〉×(1+reduction)+core size; 2) Determination of mold outline dimensions: model, filler and outer frame; 3) The core heads on both sides of the core cylinder hole and the crankshaft observation window are positioned on the outer mold to achieve the overall positioning of the key dimensional elements of different parts of the engine body; 4) The mold design is carried out by using a track-opening structure that combines the frame-off type and the disassembly type; the frame-off type and the disassembly type are fitted and positioned on a base plate with multiple angles and large slopes to achieve accurate mold size.

3. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: In the step 2, a frame is made of steel pipes, a steel plate is welded to the top of the frame, a track is laid on the upper part of the steel plate, rollers are installed on both sides of the mold, and the mold is opened and closed freely along the track.

4. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: In the step 3, the cylinder bore portion adopts a sinking frame-off structure, a portion of the mold is sunk below the geometric center of the bottom plate plane for fixed production, the remaining portion of the cylinder bore is raised above the bottom plate plane, and a portion is left between the two sides of the cylinder bore outer frame and the crankshaft cavity model; The internal shape of the cylinder hole is from the thinnest part of the filler outward, and the cylinder hole filler is divided into four parts of loose blocks horizontally and vertically along the center of the cylinder hole. The joint parts have rounded transitions, and the sides are fitted with the outer frame at 5 degrees. When the crankshaft cavity models on both sides are opened along the track and the clay core is lifted as a whole, the loose blocks are detached from the outer frame and then fall out separately.

5. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: In the fourth step, the crankshaft cavity part and the cylinder hole part are molded and positioned with an inclined surface at an angle of 10 degrees below the top surface of the cylinder hole, and the two side surfaces are inclined surfaces at an angle of 10 degrees, so as to accurately connect the shape of the cylinder hole and the crankshaft; The part away from the top surface of the cylinder hole is made of a metal block with a rounded corner shape at the joint of the crankshaft cavity; Used to ensure the dimensional stability after multiple uses; the frame removal and disassembly structure are fitted and positioned on the bottom plate with multiple angles and large slopes to determine the mold size; The shape of the cylinder bore top surface and the crankshaft cavity are divided according to the principle of ensuring strength and thick mouth fitting; the two side surfaces in the length direction are divided downward along the transition fillet between the crankshaft cavity partition casting rib and the cylinder bore top surface; the width direction is divided upward along the transition fillet between the crankshaft observation window side wall and the crankshaft cavity bottom side wall, and then slanted upward 10 degrees to intersect with the length direction dividing line for division; the height direction is centered on the crankshaft observation window and downward, and the fuel side is divided along the center of the crankshaft observation window and the intersection of the width direction dividing line; the upper edge of the intake and exhaust side is divided along the center of the crankshaft observation window, and the two sides of the lower edge are slanted downward 10 degrees along the crankshaft observation window fillet, avoiding the casting ribs and the clasp on the inner cavity side and intersecting with the width direction dividing line for division.

6. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: The step five further comprises: The upper and lower inner cavity sides of the crankshaft observation windows on both sides of the crankshaft cavity are equipped with long strips, and the shape of the part connected to the base plate is transformed into a curved surface and inlaid with metal.

7. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: The step six further comprises: The intersection between the top surface of the base plate and the outer wall of the crankshaft observation window is equipped with a return groove for the oil in the engine body, and a large-angle long-size dovetail structure is used to make the metal movable block; The height direction is from the bottom of the base plate upward, the width direction is from the side of the metal insert inward and downward at an angle of 20 degrees to the inside of the reflux groove, and it is divided from the side of the metal insert outward and downward at an angle of 20 degrees to the bottom plane of the base plate. The length direction is flush with the shapes of the two ends and is divided obliquely to both sides from the center of the cylinder hole for determining the size of the base plate.

8. The method for making a complex metal-wood structure mold of a machine body as claimed in claim 1, characterized in that: The step seven further comprises: The cylinder hole and the bottom of the model are positioned by a core head made according to the shape, and a core head positioning notch is made inward on the fuel side; the core head part outside the crankshaft observation window and the outer mold are positioned by the positioning core head and the outer mold; the outer mold is cooperated with the core seat to make a sand collecting groove according to the edge of the core seat.

9. A large diesel engine body metal-wood structure mould made by using the method for making a body metal-wood structure complex mould as described in any one of claims 1 to 8.

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