A single-mode casting machine for tilting 90° to pour aluminum piston blanks and its usage method

Abstract

The present invention relates to a single-mold casting machine for casting aluminum piston blanks by tilting 90 degrees and a method for using the same. The casting machine includes a frame, a workbench, a tilting oil cylinder, a casting system, a hydraulic system and an electrical system, wherein a workbench is provided on the frame, a casting system is provided on the workbench, and the piston blank is cast by introducing molten aluminum into the casting system. Tilting oil cylinders are provided on both sides of the bottom of the frame, and the other end of the tilting oil cylinder is connected to the workbench. The tilting oil cylinder and the casting system are both connected to the hydraulic system, and the hydraulic system is connected to the electrical system. The present invention tilts 90 degrees to cast the piston blank, so that the molten aluminum is inertially cast under the action of gravity, and the molten aluminum fills the casting cavity from bottom to top, avoiding the air gap effect of plane casting. At the same time, the shrinkage compensation position of the piston blank is adjusted to the side to avoid affecting the performance of the piston combustion chamber, thereby improving the mechanical properties and heat fatigue resistance of the piston blank.

Description

Technical Field

[0001] The invention relates to a single-die casting machine tilted 90 degrees for casting an aluminum piston blank and a use method thereof, belonging to the technical field of piston casting. Background Art

[0002] The mainstream aluminum piston blank casting machine currently used in the market includes the machine body, electrical system, hydraulic system and cooling system. The machine-cast piston blank is an upright structure, that is, the head is on top and the skirt is on the bottom. However, there will be a thick and large shrinkage hole in the combustion chamber area on the top surface of the cast blank piston head. It is difficult to achieve rapid cooling after molding, which will result in coarse grain structure, poor metallographic structure, and easy appearance of pores and sand holes. After installation, the piston has to withstand high temperature and high explosive pressure. The poor metallographic structure and pores and sand holes will affect the mechanical properties of the piston and reduce its heat fatigue resistance.

[0003] Chinese patent document CN106735142B discloses an automatic casting machine for producing aluminum piston blanks. The machine features a casting machine, a casting removal and quenching robot, and a pouring robot. The casting machine comprises a bed and a main frame, the main frame being mounted on the upper end of the bed. A central core mechanism is mounted within the bed. An outer mold mechanism and a top mold mechanism are mounted on the main frame. The outer mold mechanism operates the opening and closing of the left and right outer mold halves, the top mold mechanism operates the opening and closing of the top and outer mold halves, and the central core mechanism operates the raising and lowering of the central core. The casting removal and quenching robot comprises a main frame, a three-axis linkage mechanism mounted on the main frame, and an air gripper mounted on the three-axis linkage mechanism. The air gripper is used to remove the casting from the casting machine. This casting machine improves production efficiency, but does not address the technical issues of poor metallographic structure and the susceptibility of cast piston blanks to porosity and sand holes. Summary of the Invention

[0004] In response to the shortcomings of the existing technology, the present invention provides a single-mold casting machine for casting aluminum piston blanks with a 90° tilt. The cast piston blanks have fine grain structure and good metallographic structure, avoid the occurrence of pores and sand holes, and improve the mechanical properties and heat fatigue resistance of the piston blanks.

[0005] The present invention also improves the use method of the above-mentioned single-die casting machine tilted 90 degrees for casting aluminum piston blanks.

[0006] The technical solutions of the present invention are as follows:

[0007] A single-mold casting machine for casting aluminum piston blanks with a 90-degree tilt, comprising a frame, a workbench, a tilting oil cylinder, a casting system, a hydraulic system and an electrical system. The frame is provided with a workbench, the workbench is provided with a casting system, and the piston blank is cast by introducing molten aluminum into the casting system. Tilting oil cylinders are respectively provided on both sides of the bottom of the frame, the other end of the tilting oil cylinder is connected to the workbench, the tilting oil cylinder and the casting system are both connected to the hydraulic system, and the hydraulic system is connected to the electrical system.

[0008] Preferably, the workbench includes an upper base plate and a lower base plate, the upper base plate and the lower base plate are connected by four columns, both sides of the lower base plate are connected to the frame through rotating shafts, and the tilting cylinder is connected to the columns.

[0009] Further preferably, the pouring system includes an upper tooling, a lower tooling, a left tooling and a right tooling, telescopic cylinders are respectively arranged on both sides of the lower base plate, the telescopic cylinders are respectively connected to the left tooling and the right tooling through brackets, a telescopic cylinder is arranged on the lower side of the lower base plate, the telescopic cylinder is connected to the lower tooling through a lower cylindrical guide rail, a telescopic cylinder is arranged on the upper side of the upper base plate, the telescopic cylinder is connected to the upper tooling through an upper cylindrical guide rail, the shape of the pouring cavity after the upper tooling, the lower tooling, the left tooling and the right tooling are closed is a piston shape, and each telescopic cylinder is respectively connected to the hydraulic system.

[0010] Preferably, square guide rails are provided on the lower base plates on both sides of the left tooling and the right tooling, and the left tooling and the right tooling are extended and retracted along the square guide rails with fixed directions, thereby ensuring that no directional deviation occurs during the extension and retraction process.

[0011] Preferably, a salt core support rod is provided on the lower tooling to support the salt core, thereby preventing the salt core from being deflected when the pouring system moves.

[0012] Preferably, an air suction device is provided on the frame, and the air suction device is connected to the salt core support rod. The air suction device absorbs the gas generated by the salt core when heated, thereby reducing the porosity of the piston blank.

[0013] Preferably, a positioning plate is fixedly provided on the lower base plate, the lower tooling passes through the positioning plate, and the upper tooling, left tooling and right tooling are respectively attached to the positioning plate. The positions of the upper tooling, lower tooling, left tooling and right tooling are corrected through the positioning plate to ensure accurate positioning and improve product quality.

[0014] Further preferably, positioning pins are respectively provided on the inner and outer sides of the positioning plate, the inner positioning pins match and fix the lower tooling, the outer positioning pins match and fix the left tooling and the right tooling, positioning columns are respectively provided on both sides of the lower end face of the upper tooling, positioning holes corresponding to the positions of the positioning columns are provided on the left tooling and the right tooling, and the upper tooling is positioned by the positioning columns.

[0015] Preferably, temperature sensors are respectively provided on the upper tooling, lower tooling, left tooling and right tooling, and the temperature sensors are connected to the electrical system. The pouring temperature is detected by the temperature sensors, and an alarm is issued when the temperature does not meet the standard to ensure the solidification grain structure of the piston blank.

[0016] Preferably, cooling water channels are respectively provided inside the upper tooling, lower tooling, left tooling and right tooling to cool down the workpiece by introducing cooling water to accelerate the cooling of the blank. Cooling water channels are provided inside the bracket to prevent heat from being transferred to the frame and telescopic cylinder, which affects the service life. Flow sensors and solenoid valves are provided in the external pipes of the cooling water channels to control the flow rate and time of the cooling water introduction to ensure uniform cooling of each part.

[0017] Preferably, a gate is provided on one side of the upper tooling, the gate is connected to the pouring cavity through a vertical runner and a horizontal runner, the horizontal runner extends to the right tooling through the upper tooling, a feeding port is provided on one side of the pouring cavity, and the feeding port and the inlet of the aluminum liquid into the pouring cavity are symmetrically arranged, so that the pouring is smoother, and the solidification position of the piston after pouring is at the contact surface between the horizontal runner and the feeding port and the piston, and will not appear in the combustion chamber at the top of the piston, thereby accelerating the cooling rate of the top of the piston, making the grain structure fine and the metallographic structure good.

[0018] Further preferably, a filter is provided at the connection between the horizontal runners of the upper tooling and the right tooling to filter impurities in the molten aluminum.

[0019] Preferably, a groove is provided at the connection between the top surfaces of the left tooling and the right tooling, and an iron ring is provided in the groove.

[0020] The method of using the above-mentioned single-die casting machine for casting aluminum piston blanks with a 90° tilt is as follows:

[0021] (1) Turn on the electrical system, the hydraulic system drives the casting machine to start working, the lower tooling moves upward, passes through the positioning plate, the top of the lower tooling is exposed upward from the positioning plate, and the salt core is set on the salt core support rod;

[0022] (2) The left tooling and the right tooling move toward the positioning plate until they fit into the positioning plate. The left tooling and the right tooling are closed, and the iron ring is installed in the groove;

[0023] (3) The upper tooling moves downward and is pressed onto the left and right toolings, closing the entire tooling to form a sealed casting cavity;

[0024] (4) The tilting cylinder retracts, causing the workbench and pouring system to tilt 90°. At this time, the gate is facing upwards, and the aluminum liquid is poured through the gate;

[0025] (5) The aluminum liquid enters the pouring cavity through the vertical runner and the horizontal runner until the pouring cavity is filled, and the shrinkage is fed through the feeding port to make the pouring more stable;

[0026] (6) After pouring is completed, the tilting cylinder is extended to reset the workbench and pouring system, and then the upper tooling, left tooling, right tooling and lower tooling are reset in sequence, and the blank is taken out and placed in the water tank for cooling.

[0027] The beneficial effects of the present invention are:

[0028] 1. The present invention tilts 90° for casting the piston blank, so that the aluminum liquid is inertially poured under the action of gravity. The aluminum liquid fills the casting cavity from bottom to top, avoiding the air gap effect of flat casting and the generation of pores. At the same time, the shrinkage feeding position of the piston blank is adjusted to the side to avoid affecting the performance of the piston combustion chamber. The cast piston blank has a fine grain structure and a good metallographic structure, avoiding the generation of pores and sand holes, and improving the mechanical properties and heat fatigue resistance of the piston blank.

[0029] 2. The present invention is provided with an air suction device, which is connected to the salt core support rod. The air suction device absorbs the gas generated by the salt core when heated, thereby reducing the porosity of the piston blank.

[0030] 3. The present invention corrects the positions of the upper tooling, lower tooling, left tooling and right tooling through the positioning plate to ensure accurate positioning and improve product quality.

[0031] 4. Cooling water channels are set inside the upper tooling, lower tooling, left tooling and right tooling respectively. Cooling water is introduced to reduce the temperature and accelerate the cooling of the blank. Cooling water channels are set inside the bracket to prevent heat from being transferred to the frame and telescopic cylinder, which will affect the service life. Flow sensors and solenoid valves are set in the external pipes of the cooling water channels to control the flow and time of cooling water introduction to ensure uniform cooling of each part. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a structural schematic diagram of the present invention;

[0033] Figure 2 This is a schematic diagram of the closed state structure of the present invention;

[0034] Figure 3 It is a schematic diagram of the pouring state structure of the present invention;

[0035] Figure 4 This is a schematic diagram of the structure of the present invention in an open state;

[0036] Figure 5 It is a schematic diagram of the positioning plate structure of the present invention;

[0037] Figure 6 This is a schematic diagram of the positioning plate of the present invention in use;

[0038] Figure 7 It is a schematic diagram of the upper tooling structure of the present invention;

[0039] Among them: 1. Frame; 2. Workbench; 3. Hydraulic system; 4. Electrical system; 5. Casting system; 6. Suction device; 7. Bracket; 8. Column; 9. Positioning plate; 10. Tilt cylinder; 11. Square guide rail; 12. Lower cylindrical guide rail; 13. Upper cylindrical guide rail; 14. Left tooling; 15. Right tooling; 16. Upper tooling; 17. Lower tooling; 18. Salt core support rod; 19. Shrinkage feeding port; 20. Gate; 21. Filter placement groove; 22. Locating pin; 23. Locating column; 24. Locating hole; 25. Groove; 26. Vertical runner; 27. Horizontal runner. DETAILED DESCRIPTION

[0040] The present invention will be further described below with reference to embodiments and accompanying drawings, but is not limited thereto.

[0041] Example 1:

[0042] like Figure 1-7 As shown, this embodiment provides a single-mold casting machine for casting aluminum piston blanks with a 90° tilt, including a frame 1, a workbench 2, a tilting cylinder 10, a casting system 5, a hydraulic system 3 and an electrical system 4, wherein a workbench 2 is provided on the frame 1, and a casting system 5 is provided on the workbench 2. The piston blank is cast by passing aluminum liquid into the casting system 5. Tilting cylinders 10 are respectively provided on both sides of the bottom of the frame 1, and the other end of the tilting cylinder 10 is connected to the workbench 2. The tilting cylinder 10 and the casting system 5 are both connected to the hydraulic system 3, and the hydraulic system 3 is connected to the electrical system 4.

[0043] The workbench 2 includes an upper base plate and a lower base plate, which are connected by four columns 8. Both sides of the lower base plate are connected to the frame through rotating shafts, and the tilting cylinder is connected to the columns.

[0044] The pouring system 5 includes an upper tooling 16, a lower tooling 17, a left tooling 14 and a right tooling 15. Telescopic cylinders are respectively arranged on both sides of the lower base plate, and the telescopic cylinders are respectively connected to the left tooling 14 and the right tooling 15 through the bracket 7. A telescopic cylinder is arranged on the lower side of the lower base plate, and the telescopic cylinder is connected to the lower tooling 17 through the lower cylindrical guide rail 12. A telescopic cylinder is arranged on the upper side of the upper base plate, and the telescopic cylinder is connected to the upper tooling 16 through the upper cylindrical guide rail 13. After the upper tooling 16, the lower tooling 17, the left tooling 14 and the right tooling 15 are closed, the shape of the pouring cavity is a piston shape, and each telescopic cylinder is respectively connected to the hydraulic system 3.

[0045] Square guide rails 11 are provided on the lower bottom plates on both sides of the left tooling 14 and the right tooling 15. The left tooling 14 and the right tooling 15 are extended and retracted along the square guide rails with fixed directions to ensure that no directional deviation occurs during the extension and retraction process.

[0046] A salt core support rod 18 is provided on the lower tooling 17 to support the salt core so as to prevent the salt core from deflecting when the salt core moves with the pouring system.

[0047] A positioning plate 9 is fixed on the lower base plate, the lower tooling 17 passes through the positioning plate 9, and the upper tooling 16, the left tooling 14 and the right tooling 15 are respectively attached to the positioning plates. The positions of the upper tooling, the lower tooling, the left tooling and the right tooling are corrected through the positioning plate 9 to ensure accurate positioning and improve product quality.

[0048] Locating pins 22 are respectively provided on the inner and outer sides of the positioning plate 9. The inner positioning pin matches and fixes the lower tooling 17, and the outer positioning pin matches and fixes the left tooling 14 and the right tooling 15. Positioning columns 23 are respectively provided on both sides of the lower end surface of the upper tooling 16. Positioning holes 24 corresponding to the positions of the positioning columns are provided on the left tooling 14 and the right tooling 15, and the upper tooling is positioned by the positioning columns.

[0049] Cooling water channels are set inside the upper tooling, lower tooling, left tooling and right tooling respectively. Cooling water is introduced to reduce the temperature and accelerate the cooling of the blank. Cooling water channels are set in the bracket to prevent heat from being transferred to the frame and telescopic cylinder, which will affect the service life. Flow sensors and solenoid valves are set in the external pipes of the cooling water channel to control the flow and time of the cooling water to ensure uniform cooling of each part.

[0050] A gate 20 is provided on one side of the upper tooling 16, and the gate 20 is connected to the pouring cavity through a vertical runner 26 and a horizontal runner 27. The horizontal runner extends to the right tooling through the upper tooling. A feeding port 19 is provided on one side of the pouring cavity. The feeding port 19 is symmetrically arranged with the inlet of the aluminum liquid entering the pouring cavity, so that the pouring is smoother. The solidification position of the piston after pouring is at the contact surface between the horizontal runner and the feeding port and the piston, and will not appear in the combustion chamber on the top of the piston, which accelerates the cooling speed of the top of the piston, makes the grain structure fine, and has a good metallographic structure.

[0051] A filter is set at the connection between the horizontal runner of the upper tooling and the right tooling, and the filter placement groove 21 is as shown in FIG. Figure 6 As shown, filter the impurities in the aluminum liquid.

[0052] A groove 25 is provided at the top surface connection of the left tooling and the right tooling, and an iron ring is provided in the groove 25 to fix the salt core and the piston blank through the iron ring. The casting machine is tilted 90° for pouring so that the iron ring and the salt core are arranged horizontally, and position displacement and falling off will not occur, thereby ensuring the pouring effect.

[0053] The method of using the above-mentioned single-die casting machine for casting aluminum piston blanks with a 90° tilt is as follows:

[0054] (1) Turn on the electrical system, the hydraulic system drives the casting machine to start working, the lower tooling moves upward, passes through the positioning plate, the top of the lower tooling is exposed upward from the positioning plate, and the salt core is set on the salt core support rod;

[0055] (2) The left tooling and the right tooling move toward the positioning plate until they fit into the positioning plate. The left tooling and the right tooling are closed, and the iron ring is installed in the groove;

[0056] (3) The upper tooling moves downward and is pressed onto the left and right toolings, closing the entire tooling to form a sealed casting cavity;

[0057] (4) The tilting cylinder retracts, causing the workbench and pouring system to tilt 90°. At this time, the gate is facing upwards, and the aluminum liquid is poured through the gate;

[0058] (5) The aluminum liquid enters the pouring cavity through the vertical runner and the horizontal runner until the pouring cavity is filled, and the shrinkage is fed through the feeding port to make the pouring more stable;

[0059] (6) After pouring is completed, the tilting cylinder is extended to reset the workbench and pouring system, and then the upper tooling, left tooling, right tooling and lower tooling are reset in sequence, and the blank is taken out and placed in the water tank for cooling.

[0060] Example 2:

[0061] A single-mold casting machine for casting aluminum piston blanks tilted 90° has a structure as described in Example 1, except that temperature sensors are respectively provided on the upper tooling, lower tooling, left tooling and right tooling, and the temperature sensors are connected to the electrical system. The casting temperature is detected by the temperature sensors, and an alarm is triggered when the temperature does not meet the standard to ensure the solidification grain structure of the piston blank.

[0062] Example 3:

[0063] A single-mold casting machine for casting aluminum piston blanks tilted 90° has a structure as described in Example 1, except that an air suction device 6 is provided on the frame 1, and the air suction device 6 is connected to the salt core support rod 18. The air suction device absorbs the gas generated by the heating of the salt core, thereby reducing the porosity of the piston blank.

Claims

1. A single-mold casting machine for casting aluminum piston blanks tilted 90 degrees, characterized in that: It includes a frame, a workbench, a tilting oil cylinder, a pouring system, a hydraulic system and an electrical system. The workbench is set on the frame, and the pouring system is set on the workbench. The piston blank is poured by passing aluminum liquid into the pouring system. Tilt oil cylinders are set on both sides of the bottom of the frame. The other end of the tilting oil cylinder is connected to the workbench. The tilting oil cylinder and the pouring system are both connected to the hydraulic system, and the hydraulic system is connected to the electrical system. The pouring system includes an upper tooling, a lower tooling, a left tooling, and a right tooling. Telescopic cylinders are respectively provided on both sides of the lower base plate, and the telescopic cylinders are respectively connected to the left tooling and the right tooling through brackets. A telescopic cylinder is provided on the lower side of the lower base plate, and the telescopic cylinder is connected to the lower tooling through a lower cylindrical guide rail. A telescopic cylinder is provided on the upper side of the upper base plate, and the telescopic cylinder is connected to the upper tooling through an upper cylindrical guide rail. The pouring cavity shape after the upper tooling, lower tooling, left tooling, and right tooling are closed is a piston shape. Each telescopic cylinder is respectively connected to the hydraulic system. Square guide rails are provided on the lower base plates on both sides of the left tooling and the right tooling. A gate is set on one side of the upper tooling, and the gate is connected to the pouring cavity through a vertical runner and a horizontal runner. The horizontal runner extends to the right tooling through the upper tooling. A shrinkage feeding port is set on one side of the pouring cavity, and the shrinkage feeding port is symmetrically arranged with the inlet of the aluminum liquid entering the pouring cavity.

2. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 1, characterized in that: The workbench includes an upper base plate and a lower base plate, which are connected by four columns. Both sides of the lower base plate are connected to the frame through rotating shafts, and the tilting cylinder is connected to the columns.

3. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 2, characterized in that: A salt core support rod is provided on the lower tooling.

4. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 3, characterized in that: An air suction device is arranged on the frame and is connected to the salt core supporting rod.

5. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 4, characterized in that: A positioning plate is fixed on the lower base plate, the lower tooling passes through the positioning plate, and the upper tooling, left tooling and right tooling are respectively attached to the positioning plate; Locating pins are set on the inner and outer sides of the positioning plate respectively. The inner positioning pin matches and fixes the lower tooling, and the outer positioning pin matches and fixes the left tooling and the right tooling. Positioning columns are set on both sides of the lower end surface of the upper tooling respectively, and positioning holes corresponding to the positions of the positioning columns are set on the left tooling and the right tooling.

6. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 5, characterized in that: Temperature sensors are respectively provided on the upper tooling, the lower tooling, the left tooling and the right tooling, and the temperature sensors are connected to the electrical system; Cooling water channels are respectively arranged inside the upper tooling, the lower tooling, the left tooling and the right tooling, a cooling water channel is arranged inside the bracket, and a flow sensor and a solenoid valve are arranged in the external pipeline of the cooling water channel.

7. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 6, characterized in that: A filter is installed at the connection between the horizontal runners of the upper tooling and the right tooling.

8. The single-mold casting machine for casting aluminum piston blanks tilted 90 degrees according to claim 7, characterized in that: A groove is arranged at the connection position of the top surfaces of the left tooling and the right tooling, and an iron ring is arranged in the groove.

9. A method for using the single-mold casting machine for casting aluminum piston blanks tilted 90 degrees as claimed in claim 8, characterized in that: The steps are as follows: (1) Turn on the electrical system, the hydraulic system drives the casting machine to start working, the lower tooling moves upward, passes through the positioning plate, the top of the lower tooling is exposed upward from the positioning plate, and the salt core is set on the salt core support rod; (2) The left tooling and the right tooling move toward the positioning plate until they fit into the positioning plate. The left tooling and the right tooling are closed, and the iron ring is installed in the groove; (3) The upper tooling moves downward and is pressed onto the left and right toolings, closing the entire tooling to form a sealed casting cavity; (4) The tilting cylinder retracts, causing the workbench and pouring system to tilt 90°. At this time, the gate is facing upwards, and the aluminum liquid is poured through the gate; (5) The aluminum liquid enters the pouring cavity through the vertical runner and the horizontal runner until the pouring cavity is filled, and the shrinkage is fed through the feeding port to make the pouring more stable; (6) After pouring is completed, the tilting cylinder is extended to reset the workbench and pouring system, and then the upper tooling, left tooling, right tooling and lower tooling are reset in sequence, and the blank is taken out and placed in the water tank for cooling.

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