3D printing sand mold and molding method of supercharger exhaust shell

Abstract

The present application relates to the technical field of sand casting, in particular to a 3D printing sand mold of a supercharger combustion shell and a molding method; the 3D printing sand mold of the supercharger combustion shell comprises a lower box sand mold, a lower box cross runner sand core, a lower box inner gate sand core, a middle box sand mold, a middle box water cavity sand core, a middle box air duct sand core, an upper box sand mold, an upper box reinforcing rib, four first air outlet pieces and three second air outlet pieces; the supercharger combustion shell can be prepared by pouring through the upper box sand mold, the middle box sand mold and the lower box sand mold; the lower box sand mold, the middle box sand mold and the upper box sand mold are all 3D printing sand molds, which are convenient and fast to combine, and can realize integrated design of original scattered parts through assembly, shorten the development cycle, improve the dimensional accuracy and appearance quality of the casting, and are low in research and development cost, can improve the production efficiency of the supercharger combustion shell, and improve the production efficiency of the supercharger combustion shell.

Description

Technical Field

[0001] This invention relates to the field of sand casting technology, and in particular to a 3D printed sand mold and molding method for a turbocharger exhaust shell. Background Technology

[0002] Currently, in the production of turbocharger exhaust housings, most manufacturers use wooden or metal molds. Raw materials are poured into these molds and left to harden and solidify, resulting in a corresponding sand mold. However, the existing wooden or metal mold production process requires a set of molds for each model and specification of turbocharger exhaust housing. The mold structure needs to consider draft angle, movable blocks, material cutting, blanking, processing, assembly, and polishing, resulting in a long production cycle. This leads to poor speed in turbocharger exhaust housing production, thus affecting the production efficiency of turbocharger exhaust housings. Summary of the Invention

[0003] The purpose of this invention is to provide a 3D printing sand mold and molding method for turbocharger exhaust housing, which integrates the design of the assembled components and produces the sand mold through 3D printing, thereby improving the speed of turbocharger exhaust housing production.

[0004] To achieve the above objectives, in a first aspect, the present invention provides a 3D printed sand mold for a turbocharger exhaust housing, comprising a lower housing sand mold, a lower housing horizontal runner sand core, a lower housing inner gate sand core, a middle housing sand mold, a middle housing water cavity sand core, a middle housing air passage sand core, an upper housing sand mold, an upper housing reinforcing rib, four first air outlet plates, and three second air outlet plates.

[0005] The lower box horizontal gating sand core and the lower box inner gating sand core are respectively disposed inside the lower box sand mold; the middle box sand mold is located above the lower box sand mold, and the middle box water cavity sand core and the middle box air passage sand core are respectively disposed inside the middle box sand mold; the upper box sand mold is located above the middle box sand mold, the upper box reinforcing rib is fixedly connected to the upper box sand mold and is located above the upper box sand mold, the four first air outlet plates are respectively fixedly connected to the upper box reinforcing rib and penetrate the upper box reinforcing rib, and the three second air outlet plates are respectively fixedly connected to and communicate with the upper box sand mold and are respectively located inside the upper box sand mold.

[0006] The upper sand mold has an upper sand reduction hole, an upper sprue, an upper guide hole, a casting cavity, three hidden risers, three vents, three first overflow channels, and three second overflow channels.

[0007] The upper mold sand reduction hole is located at the top of the upper mold sand mold; the upper mold sprue and the upper mold guide hole respectively penetrate the upper mold sand mold; the casting cavity is located at the bottom of the upper mold sand mold; the three hidden risers are respectively connected to the casting cavity and located on one side of the casting cavity; the three vents are respectively connected to the three hidden risers and located at the top of the three hidden risers; the three first overflow channels are respectively connected to the three vents and located at the top of the three vents; the three second overflow channels are respectively connected to the three second vent plates and located at the top of the three second vent plates.

[0008] The middle box sand mold has a conformal positioning stop and a middle box direct sprue; the conformal positioning stop is located on the side of the middle box sand mold close to the lower box sand mold, and the middle box direct sprue is connected to the upper box direct sprue and penetrates the middle box sand mold.

[0009] The middle box sand mold has a conformal positioning stop; the conformal positioning stop is located on the side of the middle box sand mold close to the lower box sand mold.

[0010] The middle chamber air passage sand core has a middle chamber sand reduction hole and a protruding core head;

[0011] The sand reduction hole in the middle box is located inside the sand core of the middle box air passage, and the protruding core head is located on the side of the middle box air passage sand core near the upper box sand mold.

[0012] The lower box sand mold has two inner gates, two lower horizontal runners, a filter screen horizontal runner, a filter screen groove, a first upper horizontal runner, a slag collection groove, a second upper horizontal runner, a lower box sand reduction hole, and a lower box straight runner.

[0013] The two ingates are respectively connected to the casting cavity and located on both sides of the lower box sand mold; the two lower runners are respectively connected to the two ingates and located on one side of the two ingates; the filter screen runner is respectively connected to the two lower runners and located between the two lower runners; the filter screen groove is located at the top of the filter screen runner; the first upper runner is located at the top of the filter screen groove; the slag collection groove is connected to the first upper runner and located on one side of the first upper runner; the second upper runner is connected to the side of the first upper runner away from the slag collection groove; the lower box sand reduction hole is located at the bottom of the lower box sand mold; the lower box sprue is respectively connected to the middle box sprue and the second upper runner.

[0014] The lower box horizontal pouring channel sand core has L-shaped sand reduction holes; the L-shaped sand reduction holes are located at the top of the filter screen groove.

[0015] Secondly, the present invention also provides a 3D printing sand mold modeling method for a turbocharger exhaust housing, comprising:

[0016] Design three-dimensional models of the lower box sand mold, middle box sand mold, upper box sand mold, lower box horizontal runner sand core, and lower box inner gate sand core based on the turbocharger exhaust shell casting drawing;

[0017] After converting the 3D model to STL 3D printing format, 3D printing is performed to complete the model.

[0018] This invention discloses a 3D-printed sand mold and molding method for a turbocharger exhaust shell. Utilizing the upper, middle, and lower sand molds, along with the lower sand mold's horizontal runner core, lower sand mold's inner gating core, middle sand mold's water cavity core, and middle sand mold's air passage core, the turbocharger exhaust shell can be fabricated through casting. Four first air vents and three second air vents are used for exhaust during casting. The lower, middle, and upper sand molds are all 3D-printed, facilitating quick and easy assembly. This integrated design improves product functionality and casting performance, shortens new product development cycles, enhances dimensional accuracy and appearance quality of castings, and reduces R&D costs. It also improves the speed and efficiency of turbocharger exhaust shell production. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a front cross-sectional view of a 3D printed sand mold for a turbocharger exhaust housing according to the present invention.

[0021] Figure 2 This is a side cross-sectional view of a 3D-printed sand mold for a turbocharger exhaust housing according to the present invention.

[0022] Figure 3 This is a top view of the upper sand mold of the present invention.

[0023] Figure 4 This is a flowchart of a 3D printing sand mold modeling method for a turbocharger exhaust housing according to the present invention.

[0024] Figure 5 This is a schematic diagram of the tool used in the 3D printing sand mold modeling method for a turbocharger exhaust housing according to the present invention.

[0025] 1-Lower box sand mold, 2-Lower box horizontal runner sand core, 3-Lower box inner gate sand core, 4-Middle box sand mold, 5-Middle box water cavity sand core, 6-Middle box vent sand core, 7-Upper box sand mold, 8-Upper box reinforcing rib, 9-First vent plate, 10-Second vent plate, 11-Upper box sprue, 12-Upper box guide hole, 13-Casing cavity, 14-Dark riser, 15-Vent hole, 16-First overflow groove, 17-Second overflow groove, 18-Upper box conformal positioning stop, 19-Middle box conformal positioning stop, 20-Middle box sprue, 21-Middle box sand reduction hole, 2 2-Protruding core head, 23-Inner gate, 24-Lower horizontal runner, 25-Filter screen horizontal runner, 26-Filter screen groove, 27-First upper horizontal runner, 28-Slag collection trough, 29-Second upper horizontal runner, 30-Lower box sand reduction hole, 31-Lower box straight runner, 32-L-shaped sand reduction hole, 33-Lower box lifting lug, 34-Middle box lifting lug, 35-Upper box lifting lug, 36-Sand core reinforcing rib, 37-Sand mixing tank, 38-Liquid material tank, 39-Sand spreader, 40-Lifting mechanism, 41-Print head, 42-Molding area, 43-Printing box, 44-Upper box sand reduction hole. Detailed Implementation

[0026] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0027] In the description of this invention, it should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, in the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0028] Please see Figures 1-5 In a first aspect, the present invention provides a 3D printed sand mold for a turbocharger exhaust housing: including a lower box sand mold 1, a lower box horizontal runner sand core 2, a lower box inner gate sand core 3, a middle box sand mold 4, a middle box water cavity sand core 5, a middle box air passage sand core 6, an upper box sand mold 7, an upper box reinforcing rib 8, four first air outlet plates 9 and three second air outlet plates 10;

[0029] The lower box horizontal gating sand core 2 and the lower box inner gating sand core 3 are respectively disposed inside the lower box sand mold 1; the middle box sand mold 4 is located above the lower box sand mold 1, and the middle box water cavity sand core 5 and the middle box air passage sand core 6 are respectively disposed inside the middle box sand mold 4; the upper box sand mold 7 is located above the middle box sand mold 4, the upper box reinforcing rib 8 is fixedly connected to the upper box sand mold 7 and located above the upper box sand mold 7, the four first air outlet plates 9 are respectively fixedly connected to the upper box reinforcing rib 8 and penetrate the upper box reinforcing rib 8, and the three second air outlet plates 10 are respectively fixedly connected to and communicate with the upper box sand mold 7 and are respectively located inside the upper box sand mold 7.

[0030] In this embodiment, using the upper box sand mold 7, the middle box sand mold 4, and the lower box sand mold 1, along with the lower box horizontal runner sand core 2, the lower box inner gate sand core 3, the middle box water cavity sand core 5, and the middle box air passage sand core 6, a turbocharger exhaust shell can be produced by casting. The four first air outlet plates 9 and the three second air outlet plates 10 are used for exhaust during casting. The lower box sand mold 1, the middle box sand mold 4, and the upper box sand mold 7 are all 3D printed sand molds, which are convenient and quick to assemble. The original scattered parts that were assembled are integrated into a single design to improve the product's functional requirements and the performance of the casting, shorten the new product development cycle, improve the dimensional accuracy and appearance quality of the casting, and reduce the R&D cost. This improves the speed of turbocharger exhaust shell production, thereby increasing the production efficiency of turbocharger exhaust shells.

[0031] Furthermore, the upper sand mold 7 has an upper sand reduction hole 44, an upper sprue 11, an upper guide hole 12, a casting cavity 13, three hidden risers 14, three vent holes 15, three first overflow grooves 16 and three second overflow grooves 17;

[0032] The upper box sand reduction hole 44 is located at the top of the upper box sand mold 7; the upper box sprue 11 and the upper box guide hole 12 respectively penetrate the upper box sand mold 7; the casting cavity 13 is located at the bottom of the upper box sand mold 7; the three hidden risers 14 are respectively connected to the casting cavity 13 and located on one side of the casting cavity 13; the three vents 15 are respectively connected to the three hidden risers 14 and are respectively located at the top of the three hidden risers 14; the three first overflow channels 16 are respectively connected to the three vents 15 and are respectively located at the top of the three vents 15; the three second overflow channels 17 are respectively connected to the three second vent plates 10 and are respectively located at the top of the three second vent plates 10.

[0033] In this embodiment, both the middle box sand mold 4 and the lower box sand mold 1 are provided with guide holes that are compatible with the upper box guide hole 12. By using guide rods passing through the upper box guide hole 12 and the guide holes on the middle box sand mold 4 and the lower box sand mold 1, the upper box sand mold 7, the middle box sand mold 4, and the lower box sand mold 1 can be connected. The middle box air passage sand core 6 and the middle box water cavity sand core 5 are respectively connected to the outer mold sand mold of the casting cavity 13 to form an integral whole. During pouring, the molten metal enters from the upper box sprue 11 and flows to the middle box sand mold 4 and the lower box sand mold 1.

[0034] Furthermore, the upper box sand mold 7 also has an upper box conformal positioning stop 18; the upper box conformal positioning stop 18 is located on the side of the upper box sand mold 7 close to the middle box sand mold 4.

[0035] In this embodiment, the upper box conformal positioning stop 18 forms a gap fit with the top of the middle box sand mold 4, which serves to position and prevent fire from escaping.

[0036] Furthermore, the middle box sand mold 4 has a middle box conformal positioning stop 19 and a middle box direct pouring channel 20; the middle box conformal positioning stop 19 is located on the side of the middle box sand mold 4 near the lower box sand mold 1, the middle box direct pouring channel 20 is connected to the upper box direct pouring channel 11 and penetrates the middle box sand mold 4.

[0037] In this embodiment, the conformal positioning stop 19 of the middle box forms a gap fit with the top of the sand mold 1 of the lower box, which serves to position the mold and prevent fire from escaping.

[0038] Furthermore, the middle box air passage sand core 6 has a middle box sand reduction hole 21 and a protruding core head 22;

[0039] The sand reduction hole 21 in the middle box is located inside the sand core 6 of the middle box air passage, and the protruding core head 22 is located on the side of the middle box air passage sand core 6 near the upper box sand mold 7.

[0040] In this embodiment, a sand cleaning hole is provided at the center of the bottom of the middle chamber air passage sand core 6, and the protruding core head 22 cooperates with the bottom of the upper chamber sand mold 7 to achieve positioning.

[0041] Furthermore, the lower box sand mold 1 has two inner gates 23, two lower horizontal runners 24, a filter screen horizontal runner 25, a filter screen groove 26, a first upper horizontal runner 27, a slag collection groove 28, a second upper horizontal runner 29, a lower box sand reduction hole 30, and a lower box straight runner 31.

[0042] The two ingates 23 are respectively connected to the casting cavity 13 and are located on both sides of the lower box sand mold 1; the two lower runners 24 are respectively connected to the two ingates 23 and are located on one side of the two ingates 23; the filter screen runner 25 is respectively connected to the two lower runners 24 and is located between the two lower runners 24; the filter screen groove 26 is located at the top of the filter screen runner 25; the first upper runner 27 is located at the top of the filter screen groove 26; the slag collection groove 28 is connected to the first upper runner 27 and is located on one side of the first upper runner 27; the second upper runner 29 is connected to the side of the first upper runner 27 away from the slag collection groove 28; the lower box sand reduction hole 30 is located at the bottom of the lower box sand mold 1; the lower box sprue 31 is respectively connected to the middle box sprue 20 and the second upper runner 29.

[0043] In this embodiment, the filter screen groove 26 can hold a ceramic filter screen. During casting, the molten metal flows through the upper gating channel 11, the middle gating channel 20, the lower gating channel 31, the second upper horizontal gating channel 29, the filter screen groove 26, the lower horizontal gating channel 24, the filter screen horizontal gating channel 25, and the first upper horizontal gating channel 27. The molten metal flows into the lower horizontal gating channel 24 through the filter screen in the filter screen groove 26 under the first upper horizontal gating channel 27, thereby playing a role in slag blocking.

[0044] Furthermore, the lower box horizontal pouring channel sand core 2 has an L-shaped sand reduction hole 32; the L-shaped sand reduction hole 32 is located at the top of the filter screen groove 26.

[0045] In this embodiment, the L-shaped sand-reducing hole 32 facilitates the hand-holding, dropping, and removal of the lower box horizontal pouring channel sand core 2.

[0046] Furthermore, the 3D printed sand mold for the turbocharger exhaust housing also includes two lower housing lifting lugs 33, two middle housing lifting lugs 34, and two upper housing lifting lugs 35; the two lower housing lifting lugs 33 are respectively fixedly connected to the lower housing sand mold 1 and located on both sides of the lower housing sand mold 1; the two middle housing lifting lugs 34 are respectively fixedly connected to the middle housing sand mold 4 and located on both sides of the middle housing sand mold 4; the two upper housing lifting lugs 35 are respectively fixedly connected to the upper housing sand mold 7 and located on both sides of the upper housing sand mold 7.

[0047] In this embodiment, the two lower box lifting lugs 33, the two middle box lifting lugs 34, and the two upper box lifting lugs 35 facilitate the lifting of the lower box sand mold 1, the middle box sand mold 4, and the upper box sand mold 7.

[0048] Furthermore, the 3D printed sand mold of the turbocharger exhaust housing also includes a sand core reinforcing rib 36; the sand core reinforcing rib 36 is fixedly connected to the middle box air passage sand core 6 and is located inside the middle box air passage sand core 6.

[0049] In this embodiment, the strength of the middle chamber air passage sand core 6 can be improved by the sand core reinforcing rib 36.

[0050] Secondly, the present invention also provides a 3D printing sand mold modeling method for a turbocharger exhaust housing, comprising:

[0051] S1 designs three-dimensional models of the lower box sand mold 1, middle box sand mold 4, upper box sand mold 7, lower box horizontal runner sand core 2, and lower box inner gate sand core 3 based on the turbocharger exhaust shell casting drawing;

[0052] Design three-dimensional models of the lower box sand mold 1, the middle box sand mold 4, the upper box sand mold 7, the lower box horizontal runner sand core 2, and the lower box inner gate sand core 3 based on the turbocharger exhaust shell casting drawing.

[0053] S2 converts the 3D model to STL 3D printing format and then performs 3D printing to complete the model.

[0054] The 3D model format is converted to STL 3D printing format, and the printer conditions are determined according to the size of the 3D model. Then, 70 / 140 mesh ceramsite sand is added to the sand mixing tank 37, and 3D printing furan resin is added to the liquid tank. Then, the furan resin addition amount is set to 1.7%, the curing agent addition amount is 0.7%, and the printing layer thickness is 0.3mm in the control panel. The curing agent is then added to the sand mixing tank 37 and stirred evenly. A layer of sand is spread from left to right in the molding area 42 through the sand spreader 39. Then, the print head 41 sprays resin ink onto the sand surface according to the instruction. Then, the lifting mechanism 40 is lowered by 0.3mm, and the sand spreader 39 spreads another layer of sand from right to left in the molding area 42. Then, the print head 41 sprays resin ink onto the sand surface according to the instruction. This process is repeated multiple times until the instruction ends. Finally, the printing box 43 is lifted out and placed in the storage area to stand for a few minutes. After the sand mold is completely cured, the printing box 43 is lifted to the cleaning area to remove the sand mold. After cleaning up the uncured sand, the molding is completed.

[0055] The above description discloses only one preferred embodiment of the present invention, and should not be construed as limiting the scope of the present invention. Those skilled in the art will understand that all or part of the processes of the above embodiments can be implemented, and equivalent changes made in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. A 3D-printed sand mold for a turbocharger exhaust housing, characterized in that, It includes a lower box sand mold, a lower box horizontal runner sand core, a lower box inner gate sand core, a middle box sand mold, a middle box water cavity sand core, a middle box air passage sand core, an upper box sand mold, an upper box reinforcing rib, four first air outlet plates and three second air outlet plates; The lower box horizontal gating sand core and the lower box inner gating sand core are respectively disposed inside the lower box sand mold; the middle box sand mold is located above the lower box sand mold, and the middle box water cavity sand core and the middle box air passage sand core are respectively disposed inside the middle box sand mold; the upper box sand mold is located above the middle box sand mold, the upper box reinforcing rib is fixedly connected to the upper box sand mold and located above the upper box sand mold, the four first air outlet plates are respectively fixedly connected to the upper box reinforcing rib and penetrate the upper box reinforcing rib, and the three second air outlet plates are respectively fixedly connected to the upper box reinforcing rib and penetrate the upper box reinforcing rib. The plates are respectively fixedly connected and communicated with the upper box sand mold, and are respectively located inside the upper box sand mold; the 3D printed sand mold of the turbocharger exhaust shell also includes two lower box lifting lugs, two middle box lifting lugs and two upper box lifting lugs; the two lower box lifting lugs are respectively fixedly connected to the lower box sand mold and are located on both sides of the lower box sand mold; the two middle box lifting lugs are respectively fixedly connected to the middle box sand mold and are located on both sides of the middle box sand mold; the two upper box lifting lugs are respectively fixedly connected to the upper box sand mold and are located on both sides of the upper box sand mold; The upper sand mold has an upper sand reduction hole, an upper sprue, an upper guide hole, a casting cavity, three hidden risers, three vents, three first overflow channels, and three second overflow channels. The upper sand reduction hole is located at the top of the upper sand mold. The upper sprue and the upper guide hole pass through the upper sand mold. The casting cavity is located at the bottom of the upper sand mold. The three hidden risers are connected to the casting cavity and are located on one side of the casting cavity. The three vents are connected to the three hidden risers and are located at the top of the three hidden risers. The three first overflow channels are connected to the three vents and are located at the top of the three vents. The three second overflow channels are connected to the three second vent plates and are located at the top of the three second vent plates. The middle box sand mold has a middle box direct pouring channel, which is connected to the upper box direct pouring channel and runs through the middle box sand mold; The lower mold has two ingates, two lower runners, a filter screen runner, a filter screen groove, a first upper runner, a slag collection groove, a second upper runner, a lower mold sand reduction hole, and a lower mold sprue. The two ingates are respectively connected to the casting cavity and located on both sides of the lower mold. The two lower runners are respectively connected to the two ingates and located on one side of each ingate. The filter screen runner is respectively connected to the two lower runners and located between them. The filter screen groove is located at the top of the filter screen runner. The first upper runner is located at the top of the filter screen groove. The slag collection groove is connected to the first upper runner and located on one side of the first upper runner. The second upper runner is connected to the side of the first upper runner away from the slag collection groove. The lower mold sand reduction hole is located at the bottom of the lower mold. The lower mold sprue is respectively connected to the middle mold sprue and the second upper runner. The 3D printed sand mold of the turbocharger exhaust housing also includes a sand core reinforcing rib; the sand core reinforcing rib is fixedly connected to the middle box air passage sand core and is located inside the middle box air passage sand core.

2. The 3D printed sand mold for a turbocharger exhaust housing as described in claim 1, characterized in that, The upper box sand mold also has a conformal positioning stop; the conformal positioning stop is located on the side of the upper box sand mold close to the middle box sand mold.

3. The 3D printed sand mold for a turbocharger exhaust housing as described in claim 2, characterized in that, The middle box sand mold has a conformal positioning stop; the conformal positioning stop is located on the side of the middle box sand mold close to the lower box sand mold.

4. The 3D printed sand mold for a turbocharger exhaust housing as described in claim 3, characterized in that, The middle chamber air passage sand core has a middle chamber sand reduction hole and a protruding core head; The sand reduction hole in the middle box is located inside the sand core of the middle box air passage, and the protruding core head is located on the side of the middle box air passage sand core near the upper box sand mold.

5. The 3D printed sand mold for a turbocharger exhaust housing as described in claim 4, characterized in that, The lower box horizontal pouring channel sand core has L-shaped sand reduction holes; the L-shaped sand reduction holes are located at the top of the filter screen groove.

6. A 3D printing sand mold molding method for a turbocharger exhaust housing, employing a 3D printing sand mold for a turbocharger exhaust housing as described in any one of claims 1 to 5, characterized in that, include: Design three-dimensional models of the lower box sand mold, middle box sand mold, upper box sand mold, lower box horizontal runner sand core, and lower box inner gate sand core based on the turbocharger exhaust shell casting drawing; After converting the 3D model to STL 3D printing format, 3D printing is performed to complete the model.

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