A low-stress casting method and apparatus for a weak-stiffness aluminum alloy case

Abstract

A low-stiffness aluminum alloy enclosure casting method and apparatus includes: multiple high-energy sound beam transducers; a casting sand mold with a cavity adapted to the enclosure; and a casting platform on which the casting sand mold is placed, and the high-energy sound beam transducers are mounted with their emitting ends facing the cavities. The method involves: acquiring the enclosure's parameters; determining the enclosure's casting process based on these parameters; casting the enclosure according to the casting process; determining a first control parameter based on the enclosure's parameters; and controlling the high-energy sound beam transducers to emit high-energy sound beams after casting, thus performing a first control on the enclosure. This reduces the internal stress of the enclosure during solidification, preventing deformation and cracking due to residual stress after solidification.

Description

Technical Field

[0001] This invention relates to the field of metal casting technology, and in particular to a low-stress casting method and apparatus for weak-rigidity aluminum alloy boxes. Background Technology

[0002] Casting is a method of producing a part or blank by pouring molten metal into a cavity conforming to the shape of the part, allowing it to cool and solidify. As a traditional metal forming method, casting, due to its inherent characteristics, involves temperature gradients during solidification. Furthermore, in sand casting, the good heat retention of the sand mold allows for real-time temperature field changes, leading to stress concentration within the component and causing deformation. Thin-walled, complex components may even crack due to the presence of residual stress.

[0003] Taking armored vehicle transmission boxes and engine blocks as examples, these are typically made of cast aluminum alloy. Manufacturing low-stiffness box-type components using aluminum alloy casting technology not only faces casting defects such as shrinkage cavities, porosity, and cold shuts caused by the casting process, but also suffers from residual stress due to the inability of different parts to cool simultaneously during solidification, leading to severe problems such as casting deformation and even cracking. This seriously affects the performance, product quality, and manufacturing cycle of aluminum alloy castings. Therefore, the forming technology for low-stiffness box-type aluminum alloy castings has become a bottleneck restricting the development of tank and armored vehicle transmission boxes and engines. Consequently, there is an urgent need for a low-stiffness aluminum alloy box-type low-stiffness casting method and apparatus that can reduce the internal stress in the low-stiffness aluminum alloy box-type components, preventing deformation and cracking due to residual stress. Summary of the Invention

[0004] In view of the above problems of the prior art, this application provides a low-stress casting method and apparatus for weak stiffness aluminum alloy boxes, which can reduce the internal stress in the weak stiffness aluminum alloy boxes and prevent the boxes from deforming and cracking due to residual stress.

[0005] The first aspect of this application provides a low-stress casting method for a weak-stiffness aluminum alloy enclosure, comprising: acquiring parameters of the enclosure; determining a casting process for the enclosure based on the parameters of the enclosure; casting the enclosure according to the casting process; determining a first control parameter based on the parameters of the enclosure; and after casting the enclosure, controlling a high-energy sound beam transducer to emit a high-energy sound beam according to the first control parameter to perform a first control on the enclosure.

[0006] Therefore, after the enclosure is cast, a high-energy sound beam emitted by a high-energy sound beam transducer can reduce the internal stress of the enclosure during the solidification process. This prevents the enclosure from deforming and cracking due to residual stress after solidification.

[0007] As one possible implementation of the first aspect, the casting process includes determining the location of at least one of the ingate, vents, and risers.

[0008] By identifying the ingate, pores, and risers, the casting of the box can be guaranteed.

[0009] As one possible implementation of the first aspect, the parameters of the housing include information on areas of the housing that are prone to deformation and cracking.

[0010] Based on the above, the first control parameter can be determined according to the information of the areas of the box that are prone to deformation and cracking. Therefore, when the box is first controlled according to the first control parameter, the internal stress in the areas of the box that are prone to deformation and cracking can be reduced, thereby preventing the box from deforming and cracking due to residual stress after solidification.

[0011] As one possible implementation of the first aspect, the first control parameters include the frequency, power, and amplitude information of the high-energy acoustic beam transducer.

[0012] As described above, high-energy sound beams of different frequencies, powers, and amplitudes can be used to reduce internal stress in different sizes, depths, and regions, thereby preventing the enclosure from deforming and cracking due to residual stress after solidification.

[0013] As one possible implementation of the first aspect, after the first adjustment, the enclosure is removed, residual stress is detected on the enclosure, and detection information is obtained; a second adjustment parameter is determined based on the detection information; and the high-energy sound beam transducer is controlled to emit a high-energy sound beam based on the second adjustment parameter to perform a second adjustment on the enclosure.

[0014] Because internal stress may still exist within the box after it solidifies, residual stress is tested after solidification. Then, based on the test results, a second set of control parameters is determined to adjust the box. This reduces internal stress within the box, preventing deformation and cracking due to residual stress.

[0015] A second aspect of this application provides a low-stiffness aluminum alloy enclosure low-stress casting device, comprising: a high-energy sound beam transducer, wherein multiple high-energy sound beam transducers are provided; a casting sand mold having a cavity adapted to the enclosure; and a casting platform, wherein the casting sand mold is placed on the casting platform, the high-energy sound beam transducers are disposed on the casting platform, and the emitting end of the high-energy sound beam transducer is oriented towards the cavity.

[0016] Therefore, after the enclosure is cast, a high-energy sound beam emitted by a high-energy sound beam transducer can reduce the internal stress of the enclosure during the solidification process. This can prevent the enclosure from deforming and cracking due to residual stress after solidification.

[0017] As a possible implementation of the second aspect, an adjustment hole is provided on the outer surface of the casting sand mold. The adjustment hole is blind-hole shaped, and the high-energy sound beam transducer is disposed at a position corresponding to the adjustment hole.

[0018] As mentioned above, by setting adjustment holes on the casting sand mold, the distance that the high-energy sound beam travels through the casting sand mold to the box can be reduced, thereby reducing the attenuation of the high-energy sound beam when passing through the casting sand mold, improving the propagation efficiency of the high-energy sound beam, and reducing the stress inside the box.

[0019] As a possible implementation of the second aspect, it further includes: a wedge, one end of which is coupled to the transmitting end, and the other end of which extends into the adjustment hole and is coupled to the bottom surface of the adjustment hole.

[0020] As mentioned above, by setting wedges to match the shape of the adjustment holes, the high-energy sound beam transducers can be conveniently deployed.

[0021] As a possible implementation of the second aspect, the other end of the wedge is coated with high-temperature resistant grease.

[0022] As mentioned above, by applying high-temperature resistant grease to the other end of the wedge, the propagation efficiency of the high-energy sound beam between the wedge and the casting sand mold can be improved, thereby enhancing the stress reduction effect inside the box.

[0023] As one possible implementation of the second aspect, the material of the casting sand mold includes a sound-permeable resin.

[0024] Therefore, by adding sound-permeable resin to the material of the casting sand mold, the propagation efficiency of high-energy sound beams can be improved, thereby enhancing the stress reduction effect within the enclosure.

[0025] These and other aspects of the invention will become more apparent from the following description of several embodiments. Attached Figure Description

[0026] The various features of the present invention and the relationships between them are further explained below with reference to the accompanying drawings. The drawings are exemplary; some features are not shown to scale, and some drawings may omit conventional features in the field of this application that are not essential to this application, or additional features that are not essential to this application may be shown. The combination of features shown in the drawings is not intended to limit the present application. Furthermore, throughout this specification, the same reference numerals refer to the same things. Specific descriptions of the drawings are as follows:

[0027] Figure 1 The flowchart of the low-stiffness aluminum alloy box casting method in the embodiments of this application is as follows. Figure 1 ;

[0028] Figure 2 The flowchart of the low-stiffness aluminum alloy box casting method in the embodiments of this application is as follows. Figure 2 ;

[0029] Figure 3 This is a schematic diagram of the low-stiffness aluminum alloy box casting device in the embodiments of this application.

[0030] Figure 4 This is a flowchart of a low-stiffness aluminum alloy box casting method according to this application.

[0031] Explanation of reference numerals in the attached figures

[0032] 200 Low-stiffness aluminum alloy box low-stress casting device; 210 Transducer; 220 Casting sand mold; 230 Casting platform; 231 Tabletop; 232 Support; 233 Connecting part. Detailed Implementation

[0033] The terms "first, second, third, etc." or similar terms such as module A, module B, module C, etc., used in the specification and claims are only used to distinguish similar objects and do not represent a specific ordering of objects. It is understood that a specific order or sequence may be interchanged where permitted so that the embodiments of this application described herein can be implemented in an order other than that illustrated or described herein.

[0034] In the following description, the labels of the steps, such as S110, S120, etc., do not necessarily mean that the steps will be executed in this way. The order of the steps can be interchanged or executed simultaneously if permitted.

[0035] The term "comprising" as used in the specification and claims should not be construed as limiting itself to what follows; it does not exclude other elements or steps. Therefore, it should be interpreted as specifying the presence of the mentioned feature, integral, step, or component, but does not exclude the presence or addition of one or more other features, integrals, steps, or components, or groups thereof. Thus, the statement "device comprising means A and B" should not be limited to a device consisting solely of components A and B.

[0036] The term "an embodiment" or "an embodiment" as used in this specification means that a particular feature, structure, or characteristic described in conjunction with that embodiment is included in at least one embodiment of the invention. Therefore, the terms "in one embodiment" or "in an embodiment" appearing throughout this specification do not necessarily refer to the same embodiment, but may refer to the same embodiment. Furthermore, in one or more embodiments, the particular features, structures, or characteristics can be combined in any suitable manner, as will be apparent to those skilled in the art from this disclosure.

[0037] The following, with reference to the accompanying drawings, provides a detailed description of the low-stiffness aluminum alloy box casting method and apparatus in the embodiments of this application.

[0038] Figure 1 This is the flow chart of the low-stiffness aluminum alloy box casting method 100 in the embodiments of this application. Figure 1 .like Figure 1 As shown, the specific process of the low-stiffness aluminum alloy box casting method 100 in this embodiment includes:

[0039] Step S110: Obtain the box parameters.

[0040] In step S110, the parameters of the box body are acquired, specifically including acquiring information such as the structural parameters and material property parameters of the box body. It also includes acquiring information on areas of the box body prone to deformation and cracking. This area information can be obtained, for example, through stress-strain simulation results of castings using casting-specific simulation software such as Magma Soft or Procast.

[0041] Step S120: Determine the casting process.

[0042] In step S120, the casting process of the box is determined according to the parameters of the box, and the box is cast according to the casting process.

[0043] Specifically, the casting process includes determining at least one location among the ingrate, pores, and risers. By determining the ingrate, pores, and risers, the casting of the housing can be ensured.

[0044] In step S130, the first control parameter is determined.

[0045] In step S130, a first control parameter is determined based on the parameters of the enclosure. Specifically, the first control parameter may include the frequency, power, and amplitude information of the high-energy sound beam transducer 210 determined based on the enclosure parameters. High-energy sound beams of different frequencies, powers, and amplitudes can be used to reduce internal stress in different sizes, depths, and regions, preventing deformation and cracking of the enclosure due to residual stress after solidification.

[0046] In step S140, the first regulation is performed.

[0047] In step S140, the high-energy sound beam transducer 210 is controlled to emit a high-energy sound beam according to the first control parameter, thereby performing the first control on the enclosure. This allows the high-energy sound beam emitted by the high-energy sound beam transducer 210 to reduce the internal stress of the enclosure during the solidification process after casting. This prevents deformation and cracking of the enclosure due to residual stress after solidification.

[0048] Specifically, the first control parameter can be determined based on the information of the areas of the box that are prone to deformation and cracking. Thus, when the box is first controlled according to the first control parameter, the internal stress in the areas of the box that are prone to deformation and cracking can be reduced, thereby preventing the box from deforming and cracking due to residual stress after solidification.

[0049] Figure 2 The flowchart of the low-stiffness aluminum alloy box casting method in the embodiments of this application is as follows. Figure 2 .like Figure 2 As shown, the specific process of the low-stiffness aluminum alloy box casting method in this application embodiment further includes:

[0050] Step S150: Obtain detection information.

[0051] In step S150, after the first adjustment, the enclosure is removed, and residual stress is detected to obtain detection information. Since internal stress may still exist within the enclosure after solidification, residual stress detection is performed after solidification to determine whether the residual stress within the enclosure meets the standards. The detection information may specifically include the magnitude, area, and depth of residual stress within the enclosure.

[0052] Step S160: Determine the second control parameter.

[0053] In step S160, a second control parameter is determined based on the detection information. Specifically, the second control parameter may include the frequency, power, and amplitude information of the high-energy acoustic beam transducer 210 determined based on the detection information.

[0054] Step S170: Perform the second regulation.

[0055] In step S170, the high-energy sound beam transducer 210 is controlled to emit a high-energy sound beam according to the second control parameter, thereby performing a second control on the enclosure. This can reduce the internal stress in the enclosure and prevent the enclosure from deforming and cracking due to residual stress.

[0056] Figure 3 This is a schematic diagram of the low-stiffness aluminum alloy box casting device 200 in an embodiment of this application. Figure 3 As shown, the low-stiffness aluminum alloy enclosure low-stress casting device 200 in this embodiment includes: a high-energy sound beam transducer 210, a casting sand mold 220, and a casting platform 230. Multiple high-energy sound beam transducers 210 are provided. The casting sand mold 220 has a cavity adapted to the enclosure. The casting sand mold 220 is placed on the casting platform 230, and the high-energy sound beam transducers 210 are mounted on the casting platform 230 with their emitting ends facing the cavity. Therefore, after the enclosure is cast, the high-energy sound beam emitted by the high-energy sound beam transducer 210 can reduce the internal stress of the enclosure during the solidification process. This prevents the enclosure from deforming and cracking due to residual stress after solidification.

[0057] Specifically, the structure and shape of the casting sand mold 220 are determined according to the casting process, and the casting sand mold 220 can be manufactured using 3D printing technology. The material of the casting sand mold 220 contains sound-permeable resin. Therefore, by adding sound-permeable resin to the material of the casting sand mold 220, the sound-permeable resin can act as a binder for the casting sand mold 220, thereby improving its strength. Furthermore, the sound-permeable resin can improve the propagation efficiency of high-energy sound beams, thereby enhancing the stress reduction effect within the enclosure.

[0058] Specifically, the casting platform 230 may include a tabletop 231, a support 232, and a connecting part 233. The tabletop 231 is a rectangular flat plate, and the casting sand mold 220 can be placed at the top center of the tabletop 231. The support 232 is used to mount the high-energy acoustic beam transducer 210; two supports 232 are symmetrically arranged, located on the top of the tabletop 231, on either side of the casting sand mold 220. The bottom of the tabletop 231 is provided with a connecting part 233 for fixing to other equipment, thereby improving the stability of the manufacturing platform.

[0059] Furthermore, adjustment holes (not shown) can be provided on the outer surface of the casting sand mold 220. The shape of the adjustment holes can be circular, square, or any other blind hole. The high-energy sound beam transducer 210 is positioned corresponding to the adjustment holes. Specifically, the depth of the adjustment holes can be adjusted according to the structure of the enclosure. When the enclosure thickness is large, the depth of the adjustment holes can be increased to minimize the thickness between the bottom of the adjustment holes and the enclosure, thereby reducing the attenuation of the high-energy sound beam as it passes through the sand mold. When the enclosure thickness is small, the depth of the adjustment holes can be adjusted, leaving a larger margin between the bottom of the adjustment holes and the enclosure. Thus, by providing adjustment holes on the casting sand mold 220, the distance the high-energy sound beam travels through the casting sand mold 220 to the enclosure can be reduced, thereby reducing the attenuation of the high-energy sound beam as it passes through the casting sand mold 220, improving the propagation efficiency of the high-energy sound beam, and reducing stress within the enclosure.

[0060] Furthermore, the low-stiffness aluminum alloy housing low-stress casting device 200 in this embodiment may also include a wedge (not shown). The wedge may be made of titanium alloy or steel, with one end coupled to the transmitting end and the other end extending into the adjustment hole and coupled to the bottom surface of the adjustment hole. Thus, by setting the wedge, the shape of the wedge can be adapted to the adjustment hole, thereby facilitating the placement of the high-energy sound beam transducer 210.

[0061] Furthermore, a high-temperature resistant grease can be applied to the other end of the wedge. This can improve the propagation efficiency of the high-energy sound beam between the wedge and the casting sand mold 220, thereby enhancing the stress reduction effect within the enclosure.

[0062] Figure 4 This is a flowchart of a low-stress casting method 300 for a weak-stiffness aluminum alloy box according to this application, showing a specific embodiment of the low-stiffness aluminum alloy box casting method 300. For example... Figure 4 As shown, the low-stress casting method 300 for weak-stiffness aluminum alloy boxes specifically includes the following steps:

[0063] Step S310: Based on the structure and material properties of the weak stiffness aluminum alloy box, design the corresponding casting process and determine the location of the ingate, pores, risers, etc.

[0064] Step S320: Combining the casting process of the box, the structure of the box, and the areas prone to deformation and cracking found during conventional casting, if necessary, use casting professional simulation software such as Magma Soft or Procast to simulate the stress and strain of the casting and determine the high-energy acoustic beam array excitation scheme.

[0065] Step S330: Use the casting platform 230 to fix the casting sand mold 220 and the high-energy sound beam transducer 210;

[0066] Step S340: Based on the high-energy acoustic beam array excitation scheme determined in step S320, ultrasonic waves emitted by the installed high-energy acoustic beam transducer 210 are used to regulate the residual stress inside the casting sand mold 220.

[0067] Step S350: After the adjustment is completed, the sand mold is demolded, and then residual stress is detected in a place with relatively good surface roughness. If the adjustment effect does not meet the requirements, high-energy sound beam residual stress adjustment is performed.

[0068] In some embodiments, in step S350, if the molded box does not meet the requirements after residual stress non-destructive testing, the high-energy ultrasonic transducer 210 needs to be fixed with a fixture so that the transmitting end of the high-energy ultrasonic transducer 210 is in close contact with the surface of the box, and then the residual stress is adjusted; if the requirements are met, the low-stress casting process ends.

[0069] As described above, the high-energy ultrasonic transducer 210 can excite multiple modes of ultrasonic waves. When these waves pass through the casting sand mold 220 and act on the surface of the enclosure, they can effectively reduce and homogenize the multi-dimensional residual stress at different depths on the surface and inside the enclosure. By changing the start time of the high-energy sound beam, it can, to a certain extent, refine the grains and enhance the performance of the enclosure.

[0070] Optionally, due to the presence of the wedge, the incident method of the high-energy sound beam may be different, including at least one of the vertical box surface incident method and the oblique incident method.

[0071] Optionally, before turning on the high-energy acoustic beam ultrasonic transducer 210, the operating parameters of the transducer 210 need to be adjusted, including: frequency, amplitude, and output power of the transducer 210.

[0072] Note that the above are merely preferred embodiments and the technical principles employed in this application. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present application has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, all of which fall within the scope of protection of the present invention.

Claims

1. A low-stiffness aluminum alloy box casting method, characterized in that, The enclosure is cast using a low-stiffness aluminum alloy enclosure low-stress casting device. This device includes a high-energy acoustic beam transducer, a casting sand mold, a casting platform, and a wedge. Multiple high-energy acoustic beam transducers are provided. The casting sand mold has a cavity adapted to the enclosure. The casting sand mold is placed on the casting platform, and the high-energy acoustic beam transducers are mounted on the platform with their emitting ends facing the cavity. Adjustment holes, which are blind holes, are provided on the outer surface of the casting sand mold. The high-energy acoustic beam transducers are positioned corresponding to the adjustment holes. One end of the wedge is coupled to the emitting end, and the other end extends into the adjustment hole and is coupled to the bottom surface of the adjustment hole. The other end of the wedge is coated with high-temperature resistant grease; The casting sand mold is made of sound-permeable resin; the casting method includes: Obtain the parameters of the enclosure; the parameters of the enclosure include the structural parameters and material property parameters of the enclosure, and information on areas of the enclosure that are prone to deformation and cracking. The casting process of the box body is determined according to the parameters of the box body, and the box body is cast according to the casting process; The first control parameter is determined based on the parameters of the enclosure; the first control parameter includes the frequency, power, and amplitude information of the high-energy acoustic beam transducer. After casting the enclosure, the high-energy sound beam transducer is controlled to emit a high-energy sound beam according to the first control parameter to perform the first control on the enclosure; After the first adjustment, the box is taken out and residual stress is detected to obtain the detection information; The second control parameter is determined based on the detection information; The high-energy sound beam transducer is controlled to emit a high-energy sound beam according to the second control parameter, thereby performing a second control on the enclosure.

2. The low-stiffness aluminum alloy box casting method according to claim 1, characterized in that, The casting process includes determining at least one location among the ingate, vents, and risers.

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