A planetary carrier casting system structure and a casting method

Abstract

The application discloses a kind of planet carrier casting system structure and casting method, planet carrier casting system includes: planet carrier casting mold, riser and gate, planet carrier casting mold includes main body structure and annular plate with central hole, main body structure includes the conical body, circular table and multiple columns connected in sequence from top to bottom, riser includes: open riser and blind riser, open riser is located on the upper end of conical body, blind riser corresponds to column one by one, and is connected to the connecting end surface of column and annular plate;Gate has first port and second port at its upper end, first port is respectively communicated with multiple blind risers, and second port is communicated with open riser;Further include: first sand core and second sand core, first sand core, first sand core is adapted in the cavity defined by multiple columns, and second sand core is adapted in the central hole of annular plate;Wherein, the connecting end surface between column and annular plate is parting surface.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a planetary carrier casting system structure and casting method. Background Technology

[0002] As the most important output component of the gear transmission system of a coal mining machine, the planetary carrier has a complex structure and bears a large torque during operation. Due to the harsh underground working environment, long working hours, and high intensity of the coal mining machine, the planetary carrier is prone to deformation and even breakage during use, leading to machine shutdown and even safety accidents. Therefore, the planetary carrier must have excellent mechanical properties. Planetary carriers are generally produced using casting technology. First, a blank with a structure and dimensions close to the finished product is cast, then machined and heat-treated to obtain a finished product that meets the required microstructure and properties. In existing technologies, planetary carrier castings often have isolated, dispersed, and numerous hot spots, making feeding difficult and resulting in a dense microstructure. The shrinkage resistance at the connection between the lower annular plate and the column is high, making shrinkage difficult to control and ensuring dimensional accuracy. At the junction of the lower annular plate and the column, a casting hot spot is formed. The riser above the cone cannot compensate for this hot spot, easily leading to significant shrinkage porosity and cracks, resulting in substandard casting quality. Therefore, to ensure the safe operation of the coal mining machine, the planetary carrier must have high casting quality. Summary of the Invention

[0003] This solution addresses the problems and needs raised above by proposing a planetary carrier casting system structure and casting method. Due to the adoption of the following technical features, it can achieve the above-mentioned technical objectives and bring about several other technical benefits.

[0004] One object of the present invention is to provide a planetary carrier casting system structure, comprising: a planetary carrier mold, a riser, and a gating system. The planetary carrier mold includes a main structure and an annular plate with a central hole. The main structure includes a cone, a frustum, and multiple columns connected sequentially from top to bottom. The riser includes an open riser and a closed riser. The open riser is located at the upper end of the cone, and the closed riser corresponds one-to-one with the column and is connected to the connection end face of the column and the annular plate. The gate has a first port and a second port located at its upper end. The first port is connected to a plurality of the concealed risers, and the second port is connected to the exposed risers. It also includes: the first sand core and the second sand core. The first sand core is adapted to a cavity defined by a plurality of pillars, and the second sand core is adapted to the central hole of the annular plate; The connection end face between the column and the annular plate is a parting surface.

[0005] In addition, the planetary carrier casting system structure according to the present invention may also have the following technical features: In one example of the present invention, each of the dark risers is provided with a first ingate at its lower end, the first port of which is located near the lower end of the annular plate, and the plurality of the first ingates are connected to the first port of the gating gate.

[0006] In one example of the present invention, two adjacent first ingates are connected by a first sprue, a plurality of first sprues are connected by a second sprue, and the first port is connected to the second sprue.

[0007] In one example of the present invention, a second ingate is provided on the riser, the second ingate being inclined downward and connected to the second port.

[0008] In one example of the invention, the second ingate is located at 1 / 3 to 1 / 2 of the height of the exposed riser.

[0009] In one example of the present invention, both the first sand core and the second sand core are made of a collapsible material, wherein the sand intake of the first sand core is 80mm~100mm and the sand intake of the second sand core is 50mm~80mm.

[0010] In one example of the present invention, a layer of ferroalloy sand is provided at the corner where the first sand core contacts the chamber.

[0011] In one example of the present invention, the dark riser is provided with a first vent hole, and both the first sand core and the second sand core are led into the sand mold by a ventilation rope.

[0012] In one example of the present invention, the dark riser includes: The riser body extends along the vertical direction; The riser neck has one end connected to the riser body and the other end extending horizontally to the connection end face between the column and the annular plate, wherein the riser neck covers its corresponding connection end face.

[0013] Another object of the present invention is to provide a planetary carrier casting process for a planetary carrier casting system structure as described above, comprising the following steps: Molten metal is injected through the gate; The molten metal enters the first ingate through the first port, enters the dark riser through the first ingate, and enters the planetary carrier mold through the dark riser until it fills the entire cavity of the planetary carrier mold. Continue pouring molten metal into the gate. The molten metal rises to the second port and enters the open riser from the second port until the pouring is complete.

[0014] The beneficial effects of this invention are as follows: 1. The hot spot formed at the junction of the feeding ring plate and the column through the dark riser allows the molten metal in the dark riser to smoothly pass through the riser neck and enter the hot spot when the planetary carrier casting solidifies, avoiding shrinkage porosity and thus reducing the generation of cracks.

[0015] 2. The first sand core shrinks under obstructed shrinkage. The planetary carrier casting has dimensional deviations due to the high sand mold strength. By adding a relief material to the first sand core, the planetary carrier casting can be made to shrink smoothly, generate less casting stress, reduce the possibility of cracks, and the planetary carrier casting has relatively high dimensional accuracy.

[0016] 3. Since the first sand core is surrounded by molten metal during the casting process, the gas in the first sand core cannot be smoothly discharged from the sand mold to the atmosphere. By using a ventilation rope, the gas generated during the sand casting process is guided to the outer ring sand mold of the planetary carrier casting, and then the gas is discharged into the air through the sand mold.

[0017] 4. The molten metal enters the first ingate evenly and smoothly from the first and second horizontal runners. During the planetary carrier filling process, the molten metal rises smoothly without causing turbulence, thus reducing the generation of air entrapment and slag inclusion defects.

[0018] The preferred embodiments of the invention will be described in more detail below with reference to the accompanying drawings, so as to facilitate an understanding of the features and advantages of the invention. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention will be briefly described below. The drawings are merely illustrative of some embodiments of the present invention and are not intended to limit the scope of the present invention to all embodiments.

[0020] Figure 1 This is a schematic diagram of the structure of a planetary carrier casting system according to an embodiment of the present invention; Figure 2 This is a front view of a planetary carrier casting system structure according to an embodiment of the present invention; Figure 3 This is a bottom view of a planetary carrier casting system structure according to an embodiment of the present invention; Figure 4 This is a perspective view of a planetary carrier casting system structure according to an embodiment of the present invention; List of reference numerals in the attached diagram: Planetary carrier casting system structure 100; Planetary carrier mold 10; Main structure 11; Cone 111; 112 truncated cones; Column 113; Annular plate 12; 20; Ming Maokou 21; First insulation jacket 211; Insulation material layer 212; Hidden riser 22; Riser body 221; Neck 222; Second insulation sleeve 223; First inner gating 224; First vent 225; Gate 30; Direct pouring channel 31; First port 311; Second port 312; 32mm pouring cup; First core sample 40; Second sand core 50; First horizontal runner 60; Second horizontal runner 70; The third horizontal runner is 80 mm long; Second inner gating runner 90; Chamber A; Parting surface F. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. The same reference numerals in the drawings represent the same components. It should be noted that the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0022] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, “an” or “a” and similar terms do not necessarily indicate a quantity limitation. Terms such as “comprising” or “including” mean that the element or object preceding the word encompasses the element or object listed following the word and its equivalents, without excluding other elements or objects. Terms such as “connected” or “linked” are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as “upper,” “lower,” “left,” and “right” are used only to indicate relative positional relationships; these relative positional relationships may change accordingly when the absolute position of the described object changes.

[0023] According to a first aspect of the present invention, a planetary carrier casting system structure 100 is provided, such as... Figures 1 to 4 As shown, it includes: a planetary carrier mold 10, a riser 20, and a gating system 30. The planetary carrier mold 10 includes a main structure 11 and an annular plate 12 with a central hole. The main structure 11 includes a cone 111, a frustum 112, and multiple columns 113 connected sequentially from top to bottom. The riser 20 includes: an open riser 21 and a closed riser 22. The open riser 21 is located at the upper end of the cone 111, and the closed riser 22 corresponds one-to-one with the column 113 and is connected to the connection end face of the column 113 and the annular plate 12. The gate 30 has a first port 311 and a second port 312 located at its upper end. The first port 311 is connected to a plurality of dark risers 22 respectively, and the second port 312 is connected to the open riser 21. It also includes: the first sand core 40 and the second sand core 50. The first sand core 40 is adapted to a chamber A defined by a plurality of pillars 113, and the second sand core 50 is adapted to a central hole in the annular plate 12. The connection end face between the column 113 and the annular plate 12 is the parting surface F; During casting, molten metal (e.g., molten steel) is injected through gate 30 and enters the first ingate 224 via the first port 311. The molten metal then enters the hidden riser 22 through the first ingate 224 and enters the planetary carrier mold 10 through the hidden riser 22 until it fills the entire cavity of the planetary carrier mold 10. Molten metal continues to be injected into gate 30, and the molten metal rises to the second port 312 and enters the open riser 21 through the second port 312 until the pouring is completed. In the above casting system, the hidden riser 22 can compensate for the hot spot formed at the junction of the annular plate 12 and the column 113, so that when the casting solidifies, the molten metal in the hidden riser 22 can smoothly enter the hot spot through the hidden riser 22, avoiding shrinkage porosity and thus avoiding the generation of cracks. By setting the open riser 21, molten metal can be injected into the open riser 21 after the planetary carrier casting is formed, ensuring that the temperature of the molten metal in the open riser 21 is higher than the temperature of the planetary carrier casting, which can effectively compensate for the hot spot at the upper end of the cone 111.

[0024] Understandably, for example, the planetary carrier mold can be made in a two-box design, that is, the sand mold for the main structure 11 is made in the upper box, and the sand mold for the annular plate is made in the lower box.

[0025] In one example of the present invention, each of the dark risers 22 is provided with a first ingate 224 at its lower end, the first port 311 is provided near the lower end of the annular plate 12, and the plurality of the first ingates 224 are connected to the first port 311 of the gate 30. In other words, the molten metal flows along the gate 30 to the first port 311 at the lower end of the annular plate 12, and then enters the first ingate 224 through the first port 311. The molten metal rises in the first ingate 224 to the dark riser 22, and then enters the mold through the dark riser 22. The above structure ensures that the molten metal does not come into contact with the sand mold during the filling process, which can make the molten metal rise steadily, avoid turbulence, and reduce the generation of air entrapment and slag inclusion defects.

[0026] In one example of the present invention, two adjacent first ingates 224 are connected by a first transverse runner 60, and a plurality of first transverse runners 60 are connected by a second transverse runner 70, and the first port 311 is connected to the second transverse runner 70. For example, in this invention, there are four columns 113, and therefore there are also four corresponding hidden risers 22. Each hidden riser 22 corresponds to a first ingate 224. The two adjacent first ingates 224 are connected by two first horizontal runners 60 respectively, and then the two first horizontal runners 60 are connected by a second horizontal runner 70. The first port 311 of the gate 30 is connected to the second horizontal runner 70. After the molten metal is injected into the gate 30, it flows along the gate 30 to the first port 311 at the lower end of the annular plate 12, and then enters the second transverse runner 70 through the first port 311. The molten metal flows from the second transverse runner 70 into two connected first transverse runners 60, and then from the first transverse runners 60 into two connected first ingates 224. The molten metal rises in the first ingates 224 into the dark riser 22, and then enters the mold through the dark riser 22. By setting the first transverse runners 60 and the second transverse runners 70, the molten metal can enter the first ingates 224 more evenly and smoothly. After the molten metal enters the planetary carrier mold 10, it does not contact the sand mold during the filling process, and rises more smoothly, further reducing the risk of air entrapment and slag inclusion defects.

[0027] Preferably, the inner diameters of the plurality of first transverse runners 60 are the same.

[0028] In one example of the present invention, a second ingate 90 is provided on the riser 21, and the second ingate 90 is inclined downward and connected to the second port 312; In other words, the riser 21 and the gate 30 are connected by a stepped second ingate 90, which allows the molten metal to enter the riser more smoothly and prevents turbulence.

[0029] The above structure allows molten metal to be injected into the open riser 21 through the second ingate 90 after the planetary carrier casting is formed, ensuring that the temperature of the molten metal in the open riser 21 is higher than the temperature of the planetary carrier casting, which is beneficial to improving the feeding efficiency of the open riser 21.

[0030] In one example of the present invention, the second ingate 90 is located at 1 / 3 to 1 / 2 of the height of the riser 21; The optimal height range for the second ingate 90 is 1 / 3 to 1 / 2 of the height of the riser 21. Within this height range, the second ingate 90 can ensure that the temperature of the molten metal in the riser 21 is higher than that of the planetary carrier casting, thus greatly improving the feeding efficiency of the riser 21.

[0031] In one example of the present invention, the exposed riser 21 is formed by covering the upper end of the planetary carrier mold 10 with a first heat-insulating sleeve 211. In this way, during the pouring process, the molten metal in the exposed riser 21 can be kept warm, thereby improving the feeding effect of the exposed riser 21.

[0032] Similar to the exposed riser 21, a second insulating sleeve 223 is provided on one side of each of the columns 113 to form the concealed riser 22; By setting up an insulation sleeve, the temperature of the molten metal in the dark riser 22 can be effectively guaranteed, thereby further improving the feeding effect of the dark riser 22.

[0033] In one example of the present invention, the first sand core 40 and the second sand core 50 are both made of a collapsible material, wherein the sand intake of the first sand core 40 is 80mm~100mm and the sand intake of the second sand core 50 is 50mm~80mm. For example, the middle of the first sand core 40 and the second sand core 50 uses yielding materials such as winding rope and ventilation rope to ensure that the planetary carrier casting is subjected to minimal resistance during solidification, and to minimize stress generation and dimensional deformation. The first sand core 40 is sandwiched between the column 113 and the annular plate 12. When it shrinks, it undergoes obstructed shrinkage. The casting will have dimensional deviations due to the high sand mold strength. Adding a relief material in the middle can ensure that the planetary carrier casting shrinks smoothly, generate less casting stress, avoid the occurrence of cracks, and improve the dimensional accuracy of the casting.

[0034] In one example of the present invention, a layer of ferroalloy sand is provided at the corner where the first sand core 40 contacts the chamber A.

[0035] The first sand core has a layer of iron ore sand at the connection between the column 113 and the annular plate 12 and at the connection between the column 113 and the truncated cone 112. In other words, the surface of the first sand core 40 between the columns 113 needs to be treated with ferroalloy sand. When setting the ferroalloy sand layer, the ferroalloy sand needs to be compacted to avoid sand sticking to the planetary carrier casting.

[0036] In one example of the present invention, the dark riser 22 is provided with a first vent 225, and the first sand core 40 and the second sand core 50 are both led to the sand mold by a ventilation rope; Each dark riser 22 is provided with a first vent hole 225, through which gas in the dark riser 22 can be discharged; since the first sand core 40 is above molten metal during the casting process, this part of the first sand core 40 cannot be smoothly discharged from the sand mold to the atmosphere. The first sand core 40 and the second sand core 50 are led to the sand core for discharge by using a venting rope. For example, the venting rope can be connected to the first vent hole 225, and the gas generated during the casting process is discharged to the air through the first vent hole 225.

[0037] It should be noted that the first sand core 40 may also include an outer structure, that is, the first sand core includes a first part and a second part. The first part has a through hole and a plurality of through holes circumferentially opened along the through hole, wherein the planetary carrier mold is adapted to the through hole, and the dark riser is formed in the through hole. The second part is adapted to a cavity defined by a plurality of columns. The dark riser 22 is provided with a first vent hole, and the first sand core 40 is provided with a second vent hole. The second part of the first sand core 40 between the columns 113 and the second sand core 5 All 0 are connected to the sand mold via venting ropes; a first vent 225 is provided on each dark riser 22, through which the gas in the dark riser 22 can be discharged; a second vent is provided on the first sand core 40, through which the gas in the sand core can be discharged from the mold cavity of the casting; since the second part 42 is above molten metal during the pouring process, the gas in the first sand core 40 of this part cannot be smoothly discharged from the sand mold to the atmosphere; by using venting ropes, the gas generated by the second part 42 and the second sand core 50 during the pouring process is discharged to the air through the second vent.

[0038] In one example of the present invention, the dark riser 22 includes: The riser body 221 extends along the vertical direction; Riser neck 222, one end of which is connected to riser body 221, and the other end extends horizontally to the connection end face of the column 113 and the annular plate 12, wherein the riser neck 222 covers its corresponding connection end face; The molten metal enters the riser body 221 through the first ingate 224, and then enters the cavity of the planetary carrier mold 10 through the dark riser 22. After the casting is formed, the dark riser 22 at the bottom forms a hot joint with the riser neck 222 feeding ring plate 12 and the column 113, so that the molten metal in the dark riser 22 can smoothly pass through the riser neck 222 into the hot joint when the casting solidifies, avoiding shrinkage porosity and thus reducing the generation of cracks.

[0039] In one example of the present invention, the planetary carrier mold 10 is a resin sand molded part, and the shrinkage rate of the planetary carrier casting after casting is 2%.

[0040] In one example of the present invention, the gating 30 includes a sprue 31 and a pouring cup 32, wherein the upper end of the sprue 31 is connected to the pouring cup 32, and the lower end of the sprue 31 is connected to the second runner 70. The pouring cup 32 has a trumpet-shaped structure. By placing the pouring cup 32, the injection efficiency of the molten metal can be improved during pouring, ensuring that the molten metal can smoothly pass through the sprue 31 into the planetary carrier mold 10, thereby improving the forming efficiency of the mold.

[0041] Preferably, in order to facilitate the connection between the second horizontal runner 70 and the straight runner 31, a third horizontal runner 80 is also provided.

[0042] According to a second aspect of the present invention, a planetary carrier casting process for a planetary carrier casting system structure 100 as described above includes the following steps: Molten metal is injected through gate 30; The molten metal enters the first ingate 224 through the first port 311, enters the dark riser 22 through the first ingate 224, and enters the planetary carrier mold 10 through the dark riser 22 until it fills the entire cavity of the planetary carrier mold 10. Continue pouring molten metal into gate 30. The molten metal rises to the second port 312 and enters the open riser 21 from the second port 312 until the pouring is completed. Specifically, when using this casting system structure for pouring, the molten metal enters the sprue 31 through the gating cup 30, and then enters the second sprue 70 through the third sprue 80 connected to the sprue 31. The molten metal flows through the first sprue 60 connected to the second sprue 70 and enters the first ingate 224. During the filling process, the molten metal enters the first ingate 224 and then enters the hidden riser 22, falls back, and enters the casting cavity through the riser neck 222. The molten metal slowly fills the cavity of the planetary carrier mold 10. During this process, the gas in the hidden riser 22 is controlled by a set... The first vent 225 above the dark riser 22 allows the molten metal to smoothly enter the atmosphere. When the molten metal rises to the second ingate 90, it enters the open riser 21 from the stepped second ingate 90, ensuring that the temperature of the molten metal in the open riser 21 is higher than that of the planetary carrier casting. This is beneficial to improving the feeding efficiency of the open riser 21. During solidification, the hot joint formed by the contact between the annular plate 12 and the column 113 solidifies first. The hot molten metal passes through the dark riser 22 and the contact hot joint formed by the riser neck 222 to feed the molten metal, thereby avoiding the generation of shrinkage porosity and cracks.

[0043] In one example of the present invention, the process of molten metal entering the planetary carrier mold 10 from the dark riser 22 until it fills the entire cavity of the planetary carrier mold 10 further includes: The molten metal should be allowed to settle for more than 5 minutes during casting to ensure that the glaze in the molten metal can float to the surface.

[0044] In one example of the present invention, the process from the molten metal entering the riser 21 through the second port 312 until the pouring is completed further includes: laying a layer of thermal insulation material 212 on the upper end of the riser 21. For example, the thermal insulation material is rice straw ash, which is applied after the pouring is completed, and its thickness is 80mm-120mm.

[0045] The foregoing description, with reference to preferred embodiments, details exemplary implementations of the planetary carrier casting system structure 100 and casting method proposed in this invention. However, those skilled in the art will understand that various modifications and alterations can be made to the above specific embodiments without departing from the concept of this invention, and various combinations can be made to the various technical features and structures proposed in this invention without exceeding the protection scope of this invention, which is determined by the appended claims.

Claims

1. A planetary carrier casting system structure, comprising: The planetary carrier mold (10), riser (20), and gating (30) are provided. The planetary carrier mold (10) includes a main structure (11) and an annular plate (12) with a central hole. The main structure (11) includes a cone (111), a frustum (112), and multiple columns (113) connected sequentially from top to bottom. The feature is that... The riser (20) includes: an exposed riser (21) and a concealed riser (22). The exposed riser (21) is located at the upper end of the cone (111). The concealed riser (22) corresponds one-to-one with the column (113) and is connected to the connection end face of the column (113) and the annular plate (12). The concealed riser (22) includes: a riser body (221) extending in the vertical direction; and a riser neck (222), one end of which is connected to the riser body (221) and the other end of which extends horizontally to the connection end face of the column (113) and the annular plate (12). The riser neck (222) covers its corresponding connection end face. The gate (30) has a first port (311) and a second port (312) located at its upper end. The first port (311) is connected to a plurality of dark risers (22) respectively, and the second port (312) is connected to the open riser (21). It also includes: the first sand core (40) and the second sand core (50). The first sand core (40) is adapted in a cavity (A) defined by a plurality of pillars (113), and the second sand core (50) is adapted in the central hole of the annular plate (12); The connection end face between the column (113) and the annular plate (12) is the parting surface (F).

2. The planetary carrier casting system structure according to claim 1, characterized in that, Each of the dark risers (22) has a first ingate (224) at its lower end. The first port (311) is located near the lower end of the annular plate (12). All of the first ingates (224) are connected to the first port (311) of the gate (30).

3. The planetary carrier casting system structure according to claim 2, characterized in that, Two adjacent first ingates (224) are connected by a first sprue (60), and multiple first sprues (60) are connected by a second sprue (70). The first port (311) is connected to the second sprue (70).

4. The planetary carrier casting system structure according to claim 1, characterized in that, A second ingate (90) is provided on the riser (21), and the second ingate (90) is inclined downward and connected to the second port (312).

5. The planetary carrier casting system structure according to claim 4, characterized in that, The second ingate (90) is located at 1 / 3 to 1 / 2 of the height of the riser (21).

6. The planetary carrier casting system structure according to claim 1, characterized in that, The first sand core (40) and the second sand core (50) are made of a yielding material, wherein the sand consumption of the first sand core (40) is 80 mm ~100 mm , and the sand consumption of the second sand core (50) is 50 mm ~80 mm .

7. The planetary carrier casting system structure according to claim 1, characterized in that, A layer of ferroalloy sand is provided at the corner where the first sand core (40) contacts the chamber (A).

8. The planetary carrier casting system structure according to claim 1, characterized in that, The dark riser (22) is provided with a first vent hole (225), and the first sand core (40) and the second sand core (50) are both connected to the sand mold through a ventilation rope.

9. A planetary carrier casting process of the planetary carrier casting system structure according to any one of claims 1 to 8, characterized by, Includes the following steps: Molten metal is injected through the gate (30); The molten metal enters the first ingate (224) through the first port (311), enters the dark riser (22) through the first ingate (224), and enters the planetary carrier mold (10) through the dark riser (22) until it fills the entire cavity of the planetary carrier mold (10); molten metal continues to be injected into the gate (30), the molten metal rises to the second port (312), and enters the open riser (21) through the second port (312) until the pouring is completed.

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