A mold for making a plenum core with exhaust passages and a method of using the same

Abstract

The application belongs to the technical field of molds, and particularly relates to a mold for manufacturing a gas chamber core with an exhaust passage and a use method thereof. In order to solve the problems in the prior art that, when the exhaust passage of the gas chamber core is manufactured, the mold for the gas chamber core is provided with a movable block, the movable block cannot be placed with a filler, the punching method is used to cause low production efficiency and high production cost, and manual placement of the movable block causes production safety risks in the prior art. The application comprises a mold body, a movable block and a power device. The mold body is internally provided with a cavity of the gas chamber core, and a sand shooting port is arranged on the side surface and communicates with the cavity. The cavity comprises a cavity of the gas chamber core body and a connecting side cavity. The position of the connecting side cavity corresponds to the position of a connecting end of the gas chamber core and a runner core. The cavity of the gas chamber core body communicates with the connecting side cavity. The movable block is slidingly installed in the connecting side cavity, one end of the movable block is connected with a power end of the power device, and the other end of the movable block is internally provided with a hollow cavity. A heat insulation piece is installed in the hollow cavity.

Description

Technical Field

[0001] This invention belongs to the technical field of molds, specifically relating to a mold for making an air chamber core with an exhaust channel and its method of use. Background Technology

[0002] A turbocharger uses the inertial force of the exhaust gas from the engine to drive a turbine in the turbine housing. The turbine then drives a coaxial impeller, which compresses the air supplied by the air filter and forces it into the cylinder.

[0003] With the development of the turbocharger industry, the structure of turbine housings is also constantly changing. Currently, most turbine housings have added exhaust gas chambers. The quality of the exhaust gas chamber directly affects the operation of the turbocharger. During the casting process, defects such as porosity in the flow channel and exhaust gas chamber often occur. In order to reduce porosity defects in the flow channel and exhaust gas chamber, the existing production method is to use the core-making method to produce turbocharger housings. That is, the flow channel core and exhaust gas chamber core are manufactured first, and then the turbine housing is produced. The exhaust gas chamber core is called the gas chamber core. Since the core produced by the core-making method is mostly a solid body, gas will also be generated during the casting process, which will also lead to porosity defects. Therefore, in the existing technology, the method of manufacturing exhaust channels in the core is used to reduce porosity defects.

[0004] Existing techniques for creating venting channels in cores involve placing filler material inside the core mold during core making, and then removing the filler material after core completion to form the venting channel. Alternatively, holes are drilled in the core after core making to create the venting channel. Since runner cores have relatively simple shapes, venting channels are easily created. However, air chamber cores have complex shapes. During core making, a movable block is placed in the cavity at the connection end with the runner core within the core mold, making it impossible to place filler material. Therefore, when creating venting channels in air chamber cores, only the drilling method can be used. This leads to the following problems when manufacturing air chamber cores: 1. Making the core first and then drilling wastes coating sand and incurs additional labor costs and is time-consuming and labor-intensive. 2. The complex shape of the air chamber core requires drilling from different locations to form venting channels that penetrate into the interior of the air chamber core. However, because different parts of the air chamber core have different thicknesses, the drilling size and depth are inconsistent, making it difficult to guarantee quality. In addition, due to the complex structure of the air chamber core, the movable block is manually placed into the mold before the air chamber core is made. After the production is completed, the movable block is removed from the air chamber core for the production of the next mold. The placement of the movable block has problems such as high operation difficulty, low production efficiency, and easy damage to the movable block. Moreover, the surface temperature of the movable block is high after heating, which also poses a safety risk of burns to the operators. Summary of the Invention

[0005] To address the problems and shortcomings of existing technologies, this application provides a mold for manufacturing an air chamber core with an exhaust channel and a method for using the same. A cylinder-driven movable block is installed in the air chamber core mold to replace manual placement of the movable block. By using a split movable block, a hollow cavity is formed inside the movable block, and a heat insulation component is placed there to reduce heat transfer from the movable block to the air needle, thereby reducing the thickness of the cured layer at the corresponding position of the air needle in the air chamber core, making it easier to directly pierce with a tool to form a through hole.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0007] A mold for manufacturing an air chamber core with an exhaust channel includes a mold body, a movable block, and a power unit. The mold body has an air chamber core cavity inside and a sand injection port on the side. The sand injection port is connected to the cavity. The cavity includes an air chamber core body cavity and a connecting side cavity. The position of the connecting side cavity corresponds to the position of the connection end between the air chamber core and the runner core. The air chamber core body cavity is connected to the connecting side cavity. The power unit is fixedly installed on the outside of the mold body. The movable block is slidably installed in the connecting side cavity, and one end of the movable block is connected to the power end of the power unit. The other end of the movable block has a hollow cavity inside. A heat insulation component is installed in the hollow cavity.

[0008] Specifically, there are two connecting side cavities; each connecting side cavity is equipped with a movable block; the number of power units is the same as the number of movable blocks.

[0009] Specifically, the movable block includes the movable block body and the air needle; the air needle is closed at the top, open at the bottom, and has a hollow internal structure; one end of the movable block body is connected to the power end of the power device, and the other end is connected to the bottom opening of the air needle, and a hollow cavity is formed between the hollow internal structure of the air needle and the movable block body.

[0010] Specifically, the outer side of the connecting end between the movable block body and the air needle is provided with external threads, and the inner wall of the air needle is provided with internal threads. The movable block body and the air needle are connected as a whole by the external threads and internal threads.

[0011] Specifically, the insulation material is asbestos.

[0012] Specifically, the air chamber core has two cavities.

[0013] Specifically, the power unit is a cylinder.

[0014] Additionally, a method for using a mold to manufacture a gas chamber core with an exhaust channel is provided, comprising the following steps:

[0015] S1. Assemble the mold components, install the cylinder, assemble the movable block body and the air needle, and install asbestos inside the hollow structure of the air needle; connect the assembled movable block to the power end of the cylinder, and adjust the extension and retraction stroke of the power end of the cylinder to adjust the movable block to the installation position in the cavity; after completing the assembly of the mold components, install the mold into the core-making machine.

[0016] S2. During core making, the core making machine first heats the mold to the curing temperature of the coated sand;

[0017] S3. After the mold temperature rises to the curing temperature, use the sand shooting equipment to perform the sand shooting process from the sand shooting port of the mold. After the sand shooting is completed, wait for the surface coating sand of the air chamber core to cure.

[0018] S4. After the surface coating sand of the air chamber core has cured, start the cylinder and drive the power end to pull the movable block out of the air chamber core;

[0019] S5. After the movable block is extracted from the air chamber core, remove the air chamber core from the mold; use an air gun to blow air from the core head into the air chamber core to blow out the uncured raw sand inside the air chamber core to form an internal cavity; use a knife to poke open the cured layer at the air needle position of the air chamber core to form a through hole that communicates with the internal cavity of the air chamber core, thereby forming an exhaust channel for the air chamber core; complete the fabrication of the air chamber core.

[0020] Specifically, in S2, the curing temperature of the coated sand is 260±10℃.

[0021] Specifically, in S3, the curing time for the coating sand on the surface of the air chamber core is 110±10s.

[0022] Compared with the prior art, the beneficial effects of this application are as follows:

[0023] 1. This application uses a cylinder to extract the live block, which solves the problem of manually placing the live block, thereby reducing production difficulty, improving production efficiency and reducing the risk of employees being burned by the live block.

[0024] 2. This application uses a sandblasting method to form the internal cavity of the air chamber core. A separate movable block is used, with the block body and air needles connected by threads, forming a hollow cavity filled with asbestos. Due to the heat insulation properties of asbestos, heat transfer from the movable block body to the air needle position is reduced during core making, thereby reducing the thickness of the cured layer at the air needle position and lowering the hardness and strength of that location. This facilitates direct drilling at that location using a tool, forming a through hole. The through hole connects to the internal cavity of the air chamber core to form an exhaust channel. The thickness of the cured layer is controlled by adjusting the amount of asbestos filling according to the thickness of different parts. The operation is simple, hole formation is convenient, and the finished air chamber core has high quality. Attached Figure Description

[0025] Figure 1This is a schematic diagram of the mold used to fabricate the air chamber core with an exhaust channel in this embodiment;

[0026] Figure 2 This is a schematic diagram of the movable block structure of the mold for making the air chamber core with exhaust channel in this embodiment;

[0027] Figure 3 This is a schematic diagram of the live block body structure in this embodiment;

[0028] Figure 4 This is a schematic diagram of the air needle structure in this embodiment;

[0029] Figure 5 This is a cross-sectional view of the air needle structure in this embodiment;

[0030] Figure 6 This is a schematic diagram of the gas chamber core structure in this embodiment;

[0031] Figure 7 This is a cross-sectional view of the gas chamber core structure in this embodiment.

[0032] In the diagram: 1. Mold body; 2. Air chamber core body cavity; 3. Sand injection port; 4. Connecting side cavity; 5. Movable block; 50. Movable block body; 51. Air needle; 52. Hollow cavity; 6. Cylinder; 7. Air chamber core; 70. Air chamber core head; 71. Through hole; 72. Internal cavity of air chamber core. Detailed Implementation

[0033] To make the objectives and advantages of this invention clearer, the invention will be specifically described below with reference to embodiments. It should be understood that the following text is merely used to describe one or more specific embodiments of the invention and does not strictly limit the scope of protection specifically claimed by the invention.

[0034] This embodiment employs a mold for manufacturing an air chamber core with an exhaust channel, comprising a mold body 1, a movable block, and a power unit; the mold body 1 has an internal cavity for the air chamber core and a sand injection port 3 on its side; the sand injection port 3 is connected to the cavity; the cavity includes an air chamber core body cavity 2 and a connecting side cavity 4; the position of the connecting side cavity 4 corresponds to the position of the connection end between the air chamber core and the flow channel core; the air chamber core body cavity 2 is connected to the connecting side cavity 4; the power unit is fixedly installed on the outside of the mold body 1; the movable block 5 is slidably installed in the connecting side cavity 4, and one end of the movable block is connected to the power end of the power unit, while the other end of the movable block has a hollow cavity 52 inside; a heat insulation component is installed inside the hollow cavity.

[0035] Furthermore, there are two connecting side cavities 4; each connecting side cavity 4 is equipped with a movable block 5; the number of power units is the same as the number of movable blocks 5.

[0036] Furthermore, the movable block 5 includes a movable block body 50 and an air needle 51; the air needle 51 is closed at the top, open at the bottom, and has a hollow internal structure; one end of the movable block body 50 is connected to the power end of the power device, and the other end is connected to the bottom opening of the air needle 51, and a hollow cavity 52 is formed between the hollow internal structure of the air needle 51 and the movable block body.

[0037] Furthermore, the outer side of the connection end between the movable block body 50 and the air needle 51 is provided with external threads, and the inner wall of the air needle 51 is provided with internal threads. The movable block body 50 and the air needle 51 are connected as a single unit by the external threads and the internal threads.

[0038] Furthermore, the insulation is made of asbestos.

[0039] Furthermore, in order to improve work efficiency and reduce the energy consumption cost of mold heating, the number of cavities of the air chamber core on the mold body 1 is set to two.

[0040] Furthermore, the power unit is cylinder 6.

[0041] In addition, this embodiment also improves the method of using a mold for manufacturing an air chamber core with an exhaust channel, including the following steps:

[0042] S1. Assemble the mold components, install the cylinder, assemble the movable block body and the air needle, and install asbestos inside the hollow structure of the air needle; connect the assembled movable block to the power end of the cylinder, and adjust the extension and retraction stroke of the power end of the cylinder to adjust the movable block to the installation position in the cavity; after completing the assembly of the mold components, install the mold into the core-making machine.

[0043] S2. During core making, the core making machine first heats the mold to the curing temperature of the coated sand;

[0044] S3. After the mold temperature rises to the curing temperature, use the sand shooting equipment to perform the sand shooting process from the sand shooting port 3 of the mold. After the sand shooting is completed, wait for the surface coating sand of the air chamber core 7 to cure.

[0045] S4. After the surface coating sand of the air chamber core 7 has cured, start the cylinder 6 and drive the power end to pull the movable block 5 out of the air chamber core 7.

[0046] S5. After the movable block 5 is pulled out from the air chamber core 7, remove the air chamber core 7 from the mold; use an air gun to blow air into the air chamber core 7 from the core head 70 to blow out the uncured raw sand inside the air chamber core to form the internal cavity 72 of the air chamber core; use a knife to poke open the cured layer at the air needle position of the air chamber core to form a through hole 71 that communicates with the internal cavity 72 of the air chamber core, thereby forming the air chamber core exhaust channel; complete the production of the air chamber core 7.

[0047] Working Principle: The mold for manufacturing air chamber cores with exhaust channels in this embodiment solves the problem of manually placing the movable block during air chamber core manufacturing. Four cylinders are installed at the bottom of the mold as a power system to drive the movement of the movable block, improving production efficiency and reducing the risk of burns to personnel. This embodiment uses a sandblasting method to create the internal cavity of the air chamber core, reducing the amount of coating sand used. A split movable block is used to solve the problem of manual drilling of the air chamber core. The movable block is divided into two parts: the main body and the air needle, which are spirally connected. Asbestos is placed in the gap between them to reduce heat transfer from the main body to the air needle, thereby reducing the thickness of the cured layer at the corresponding position of the air needle in the air chamber core. This allows employees to directly poke through the hole with a sharp file, forming a through hole. The through hole connects to the inner cavity of the air chamber core, thus forming the air chamber core exhaust channel. The operation is simple and fast, with high production efficiency and good hole quality for the air chamber core exhaust channel.

[0048] The embodiments of the present invention have been described in detail above with reference to the examples. However, the present invention is not limited to the above embodiments. For those skilled in the art, after learning the contents described in the present invention, several equivalent changes and substitutions can be made without departing from the principle of the present invention. These equivalent changes and substitutions should also be considered to fall within the protection scope of the present invention.

Claims

1. A mold for manufacturing a chamber core with an exhaust channel, comprising a mold body, a movable block, and a power unit; characterized in that: The mold body has an internal cavity with an air chamber core and a sand injection port on its side; the sand injection port is connected to the cavity; the cavity includes an air chamber core body cavity and a connecting side cavity; the position of the connecting side cavity corresponds to the position of the connection end between the air chamber core and the flow channel core; the air chamber core body cavity is connected to the connecting side cavity; the power unit is fixedly installed on the outside of the mold body; the movable block is slidably installed in the connecting side cavity, and one end of it is connected to the power end of the power unit, while the other end of the movable block has a hollow cavity inside; a heat insulation component is installed in the hollow cavity; The movable block includes a movable block body and an air needle; the air needle is closed at the top, open at the bottom, and has a hollow internal structure; one end of the movable block body is connected to the power end of the power device, and the other end is connected to the bottom opening of the air needle, and the hollow internal structure of the air needle and the movable block body form the hollow cavity. The outer side of the connecting end between the movable block body and the air needle is provided with external threads, and the inner wall of the air needle is provided with internal threads. The movable block body and the air needle are connected as a whole by the external threads and the internal threads. The insulation component is asbestos.

2. The mold for manufacturing a gas chamber core with an exhaust channel according to claim 1, characterized in that: The number of connecting side cavities is two; each connecting side cavity is equipped with a movable block; the number of power devices is the same as the number of movable blocks.

3. The mold for manufacturing a gas chamber core with an exhaust channel according to claim 1, characterized in that: The power unit is a cylinder.

4. A mold for manufacturing a gas chamber core with an exhaust channel according to claim 1, characterized in that: The number of cavities in the gas chamber core is two.

5. A method of using a mold for manufacturing a gas chamber core with an exhaust channel according to any one of claims 1-4, characterized in that: Includes the following steps: S1. Assemble the mold components, install the cylinder, assemble the movable block body and the air needle, and install asbestos inside the hollow structure of the air needle; connect the assembled movable block to the power end of the cylinder, and adjust the extension and retraction stroke of the power end of the cylinder to adjust the movable block to the installation position in the cavity; after completing the assembly of the mold components, install the mold into the core-making machine. S2. During core making, the core making machine first heats the mold to the curing temperature of the coated sand; S3. After the mold temperature rises to the curing temperature, use the sand shooting equipment to perform the sand shooting process from the sand shooting port of the mold. After the sand shooting is completed, wait for the surface coating sand of the air chamber core to cure. S4. After the surface coating sand of the air chamber core has cured, start the cylinder and drive the power end to pull the movable block out of the air chamber core; S5. After the movable block is extracted from the air chamber core, remove the air chamber core from the mold; use an air gun to blow air from the core head into the air chamber core to blow out the uncured raw sand inside the air chamber core to form an internal cavity; use a knife to poke open the cured layer at the air needle position of the air chamber core to form a through hole that communicates with the internal cavity of the air chamber core, thereby forming an exhaust channel for the air chamber core; complete the fabrication of the air chamber core.

6. The method of using a mold for manufacturing a gas chamber core with an exhaust channel according to claim 5, characterized in that: In S2, the curing temperature of the coated sand is 260±10℃.

7. The method of using a mold for manufacturing a gas chamber core with an exhaust channel according to claim 5, characterized in that: In S3, the curing time for the surface coating sand of the air chamber core is 110±10s.

Images