Device and process for straightening castings of heat-resistant steel pipe fittings

Abstract

A device and process for straightening heat-resistant steel pipe castings, comprising the following steps: 1. Placing the pipe casting on a platform, with several positioning blocks tightly connecting it to the platform; electrically heating the cooled and deformed pipe casting to apply pressure for straightening; 2. Turning on the electric heating temperature control device to reach the set temperature, and then turning it off; 3. Moving the pressurizing device to apply the set pressure to the pipe casting; when the pressure reaches the required value, the hydraulic cylinder pushes the casting at the desired straightening position in the preset direction to the position of the limit block on the casting fixing device, and then turning off the pressurizing device; 4. Keeping the casting stationary and waiting for it to cool down; when the temperature reaches the set value, opening the clamping device to remove the casting, completing the casting deformation straightening. This invention not only quickly straightens pipe castings, reducing the defect rate and scrap rate, but also greatly improves the production efficiency and customer satisfaction of pipe castings.

Description

Technical Field

[0001] This invention belongs to the field of mechanical casting, and particularly relates to a device and process for straightening heat-resistant steel pipe castings. Background Technology

[0002] Currently, the world is facing an energy crisis and an environmental crisis, making it imperative to improve energy consumption and reduce environmental pollution. Energy conservation, emission reduction, and emissions reduction have become top priorities for global automakers.

[0003] To reduce energy consumption, the trend towards lightweight automotive products is inevitable. Manufacturers at all levels have shifted their product development towards lighter designs, especially for heat-resistant steel tubing, which accounts for a significant portion of the weight of automotive products due to its large size. To reduce weight and save energy, automotive developers have created products with lower weight and energy efficiency. However, existing products are becoming increasingly thinner in wall thickness and more complex in shape, while their length is increasing. Previously, heat-resistant steel tubing often had six to seven inlets due to its simpler structure, but now it typically requires only three to four inlets, and its length has increased from 300-400mm to 600mm or even over 700mm.

[0004] While lighter products contribute to energy savings, they also bring increasingly prominent problems. The increased size due to thinner walls, especially in heat-resistant steel pipe fittings, leads to casting deformation. Deformation occurs during pouring, solidification, cooling, and subsequent processing. This deformation results in significant dimensional deviations, failing to meet the requirements of subsequent machining and assembly. Furthermore, the deformation trends and magnitudes vary, making the problem unavoidable and difficult to resolve.

[0005] The existing production process involves inspecting the dimensions of castings and scrapping those that fail the inspection. This not only results in low production efficiency and wasted production costs, but also leads to the problem of entire batches failing to meet dimensional standards, requiring the process to be readjusted before production can resume.

[0006] Therefore, the existing production process is not only inefficient and unable to guarantee delivery times, but it also fails to meet customer production needs. Furthermore, in the context of rapid global development, customers are updating and upgrading new products with increasingly shorter R&D cycles, requiring rapid development of prototypes for trial runs. Moreover, due to inconsistent deformation trends in thin-walled heat-resistant steel pipe fittings, the amount of deformation cannot be standardized, and the development cycle is extremely short, resulting in insufficient development and verification time. This makes it impossible to adjust the molds through extensive verification to ensure the castings meet customer requirements. Deformed castings cannot be processed quickly, forcing the company to select qualified castings through mass production, regardless of cost. This leads to significant cost waste, inability to guarantee customer delivery times, decreased customer satisfaction, and delays in new product development and market launch. Summary of the Invention

[0007] The purpose of this invention is to provide a device and process for straightening heat-resistant steel pipe castings, so as to solve the technical problems of deformation of heat-resistant steel pipe castings and meet the needs of customers for use and assembly.

[0008] To achieve the above objectives, the specific technical solution of the device and process for straightening heat-resistant steel pipe castings of the present invention is as follows:

[0009] An apparatus and process for straightening heat-resistant steel pipe castings includes: a workbench, an electric heating straightening device mounted on the workbench, and a pressurizing device disposed next to the electric heating straightening device; wherein, the electric heating straightening device is equipped with: an electric heating temperature control device, and a casting fixing device connected to the electric heating temperature control device via an induction heating coil, the induction heating coil surrounding the body of the pipe casting to be heated.

[0010] The casting fixing device includes: a fixed support block, which is connected to the worktable by several positioning pins and fixing block fastening bolts; the fixed support block and the casting clamping block are connected by a connecting shaft and casting clamping bolts.

[0011] The pressurization device is equipped with a pressure display gauge. The pressure is provided by a hydraulic cylinder. The pressure causes the pipe casting body to deform to the air inlet flange position and move to several limit blocks, thus completing the deformation correction of the pipe casting body.

[0012] Furthermore, the induction heating coil is an induction heating coil made of copper tubing; when the pipe casting body is placed among several positioning blocks, the several positioning blocks are used to fix the position of the pipe casting body.

[0013] Furthermore, the pressurizing device is a manual hydraulic jack; the hydraulic pressure applied by the hydraulic jack to the pipe casting body is 0.8 MPa.

[0014] Furthermore, the workbench is a flat surface used on top, i.e., a platform. The platform is a flat plate made of No. 45 steel, with dimensions of 600mm in length, 400mm in width, and 25mm in thickness. The flat plate is supported by four legs. The workbench is tightly connected to several positioning blocks.

[0015] Furthermore, the plurality of positioning blocks are: a first positioning block, a second positioning block, a third positioning block, and a fourth positioning block; their installation positions are as follows: the first positioning block is installed in front of the casting fixing device at a downward position; the second positioning block is installed in the middle of the casting fixing device at a downward position; the third positioning block is installed in the middle of the casting fixing device, that is, at a position diagonally above the second positioning block; the fourth positioning block is installed directly above the casting fixing device, that is, at a relative position with a set distance from the second positioning block; and is positioned on the casting fixing device; and the first positioning block, the second positioning block, the third positioning block, and the fourth positioning block are Π-shaped to press down on the body of the pipe fitting casting, and the top of the Π-shape is pressed down by a long strip plate, and is a conformal structure that can press down on the body of the pipe fitting casting.

[0016] Furthermore, the electric heating temperature control device is an industrial frequency induction furnace.

[0017] Furthermore, the pressure for correcting the deformation of the pipe fitting casting body is achieved by a pressurizing device; after the pipe fitting casting body completes the deformation correction pressurizing device pressurizes, the hydraulic cylinder generates a pushing force, which pushes the flange position of the pipe fitting casting body to move and deform, and controls the hydraulic cylinder according to the pressure value of the pressure display gauge to push the deformation amount of the pipe fitting casting body, so that the pipe fitting casting body undergoes permanent deformation.

[0018] Furthermore, the limiting block has an arc-shaped structure that mimics the air inlet flange of a casting; the limiting block can fully contact the body of the pipe casting, and the limiting block is located on opposite sides of the air inlet flange of the casting.

[0019] Furthermore, based on the above-described apparatus and process for straightening heat-resistant steel pipe castings, the operating steps are as follows:

[0020] Step 1: Place the pipe fitting casting body on the platform and fix it around the platform with several positioning blocks, namely: the first positioning block, the second positioning block, the third positioning block, and the fourth positioning block, and make the first positioning block, the second positioning block, the third positioning block, and the fourth positioning block tightly connected to the platform; For the pipe fitting casting body that has cooled and deformed, apply electric heating, and within the temperature range that ensures that the metallographic structure of the pipe fitting casting body will not change, apply pressure to the deformed pipe fitting casting body to straighten it;

[0021] Step 2: Turn on the electric heating temperature control device to allow the heating temperature to reach the set value. Once the preset value is reached, turn off the electric heating temperature control device.

[0022] Step 3: Manually move the pressurizing device to apply the set pressure to the body of the pipe fitting casting. When the pressure reaches the required value, the hydraulic cylinder pushes the air inlet flange of the casting that needs to be corrected on the body of the pipe fitting casting to move in the preset direction to the position of the limit block on the casting fixing device, and then closes the pressurizing device.

[0023] Step 4: Keep the casting still and wait for it to cool down. When the temperature reaches the set value of 200℃±10℃, open the casting fixing device and remove the casting. The casting deformation correction process is now complete.

[0024] Furthermore, in the second step, the electric heating temperature control device is turned on to bring the heating temperature to the set temperature range: between 600℃ and 700℃; preferably 650℃.

[0025] The apparatus and process for straightening heat-resistant steel pipe castings of the present invention have the following advantages:

[0026] This invention enables rapid installation of castings;

[0027] 2. The heating temperature can be controlled, and the set pressure can be clearly read;

[0028] 3. It takes less time and yields quick results in correcting deformed castings;

[0029] 4. The straightening device is equipped with a limit device, which is simple, clear and intuitive. Whether the casting is straightened in place can be checked by the contact between the casting and the limit block.

[0030] 5. After the correction, the castings are inspected and verified. If the dimensions are qualified, the finished products will meet the drawings and customer assembly requirements after being transferred to machining.

[0031] 6. It can greatly shorten the new product development time, reduce the defect rate and casting scrap rate, and greatly improve the production efficiency in the new product development stage;

[0032] 7. Providing qualified samples within the time specified by the customer improved customer satisfaction, ensured the launch of new products, and indirectly made a significant contribution to energy conservation, emission reduction, and consumption reduction. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the structure of the present invention;

[0034] Figure 2 This is a schematic diagram of the structural positioning and limiting state of the present invention;

[0035] Figure 3 for Figure 2 AA diagram;

[0036] Figure 4This is a schematic diagram of the structural pressurization device and the electric heating device of the present invention;

[0037] Figure 5 This is a detailed schematic diagram of the structural positioning block of the present invention.

[0038] Explanation of markings in the diagram:

[0039] 1. Workbench; 2. Electric heating temperature control device; 3. Casting fixing device; 3-1. Casting clamping bolt; 3-2. Casting fixing support block; 3-3. Positioning pin; 3-4. Fixing block fastening bolt; 3-5. Casting clamping block; 3-6. Connecting shaft; 4. Pressurizing device; 5. Pipe-type casting body; 6. Limiting block; 7. Casting air inlet flange; 8. Pressure display gauge; 9. Hydraulic cylinder; 10-1. First positioning block; 10-2. Second positioning block; 10-3. Third positioning block; 10-4. Fourth positioning block. Detailed Implementation

[0040] To better understand the purpose, structure, and function of this invention, the following detailed description, in conjunction with the accompanying drawings, provides an apparatus and process for straightening heat-resistant steel pipe castings according to this invention.

[0041] like Figures 1-4 As shown, the present invention includes: a workbench 1, an electric heating straightening device installed on the workbench 1, and a pressurizing device 4 disposed next to the electric heating straightening device; wherein, the electric heating straightening device is provided with: an electric heating temperature control device 2, and a casting fixing device 3 connected to the electric heating temperature control device 2 by bolts through an induction heating coil, the induction heating coil surrounding the pipe casting body 5 that needs to be heated, and after being energized, the temperature of the pipe casting body 5 will rise and soften;

[0042] The casting fixing device 3 mentioned above includes: a fixing support block 3-2, which is connected to the workbench 1 by several positioning pins 3-3 (two in this embodiment) and fixing block fastening bolts 3-4; the fixing support block 3-2 and the casting clamping block 3-5 are connected by a connecting shaft 3-6 and casting clamping bolts 3-1.

[0043] The pressurizing device 4 mentioned above is a manual hydraulic jack. In this implementation case, it is a 5T hydraulic jack with a linear guide rail; the selected model is JRSM-5.

[0044] The aforementioned pressurizing device 4 (i.e., hydraulic jack) applies pressure to the body 5 of the pipe casting. In this example, the hydraulic pressure is 0.2MPa, 0.3MPa, 0.4MPa, 0.5MPa, 0.6MPa, 0.7MPa, 0.8MPa, 0.9MPa, 1.0MPa, or 1.02MPa; 0.8MPa is the preferred hydraulic pressure.

[0045] The pressurizing device 4 is tightly connected to the workbench 1 by bolts or welding. After the pressurizing device 4 pressurizes the hydraulic oil, the cylinder 9 generates a pushing force, which pushes the flange position of the pipe casting body 5 to move and deform. The amount of deformation of the pipe casting body 5 is controlled by the pressure value of the pressure display table 8, so as to achieve the purpose of permanent deformation of the pipe casting body 5.

[0046] The aforementioned induction heating coil is an induction heating coil made of copper tubing. When the pipe casting body 5 is placed among several positioning blocks (in this embodiment, the positioning blocks are: first positioning block 10-1; second positioning block 10-2; third positioning block 10-3; and fourth positioning block 10-4), the positioning blocks are used to fix the position of the pipe casting body 5.

[0047] The aforementioned worktable 1 is tightly connected to several positioning blocks by bolts;

[0048] In this example, the workbench 1 is the flat surface used above, i.e., the platform. The platform is a flat plate made of No. 45 steel, with dimensions of 600mm in length, 400mm in width, and 25mm in thickness. The flat plate is supported by four legs connected by welding.

[0049] like Figure 5 As shown, the positioning blocks are: first positioning block 10-1, second positioning block 10-2, third positioning block 10-3, and fourth positioning block 10-4. The installation positions of the positioning blocks are as follows: the first positioning block 10-1 is installed in front of the casting fixing device 3 at a downward position; the second positioning block 10-2 is installed in the middle of the casting fixing device 3 at a downward position; the third positioning block 10-3 is installed in the middle position of the casting fixing device 3 (i.e., diagonally above the second positioning block 10-2) (i.e., the position where the pipe fitting casting body 5 is fixed); and the fourth positioning block 10-4 is installed directly above the casting fixing device 3 (i.e., at a relative position with a set distance from the second positioning block 10-2).

[0050] The aforementioned pipe fitting casting body 5 is equipped with several positioning blocks, namely: first positioning block 10-1, second positioning block 10-2, third positioning block 10-3, and fourth positioning block 10-4, which are positioned and installed on the casting fixing device 3.

[0051] The first positioning block 10-1, the second positioning block 10-2, the third positioning block 10-3, and the fourth positioning block 10-4 are Π-shaped, which press down on the body 5 of the pipe fitting casting. The top of the Π-shaped block is pressed down by a long strip plate. It is a conformal structure that can press down on the body 5 of the pipe fitting casting, making the body 5 of the pipe fitting casting easy to install, structurally stable, and well positioned.

[0052] The aforementioned electric heating temperature control device 2 is an industrial frequency induction furnace. This induction furnace is connected to the pipe casting body 5 via an induction coil. Temperature control can be ensured by setting the heating time to avoid overheating, which could alter the microstructure of the pipe casting body 5 and cause other problems.

[0053] The pressure for correcting the deformation of the aforementioned pipe fitting casting body 5 is achieved by a pressurizing device 4. This pressurizing device 4 is equipped with a pressure display gauge 8, whose dial can directly read the pressure value. The pressure is provided by a hydraulic cylinder 9. The hydraulic cylinder 9 provides pressure to deform the pipe fitting casting body 5 until the casting air inlet flange 7 moves to the limit block 6, and the pipe fitting casting body 5 completes the deformation correction.

[0054] The aforementioned limiting block 6 is an arc-shaped structure that imitates the casting air inlet flange 7; the limiting block 6 can fully contact the pipe fitting casting body 5, and the limiting block 6 is located on opposite sides of the casting air inlet flange 7.

[0055] The operation steps adopted in this invention are as follows:

[0056] Step 1: Place the pipe fitting casting body 5 on the platform. In this example, the platform used is a flat plate made of 45# steel, with dimensions of 600mm in length, 400mm in width, and 25mm in thickness. It is fixed around the platform using several positioning blocks: first positioning block 10-1, second positioning block 10-2, third positioning block 10-3, and fourth positioning block 10-4. These blocks are tightly connected to the platform using bolts. The cooled and deformed pipe fitting casting body 5 is then electrically heated. Within a temperature range that ensures no change in the metallographic structure of the pipe fitting casting body 5, pressure is applied to the deformed pipe fitting casting body 5 for straightening.

[0057] Step 2: Turn on the electric heating temperature control device 2 to bring the heating temperature to the set value. The set temperature range is 600℃-700℃. In actual experiments, the selected heating temperatures are 600℃, 610℃, 620℃, 630℃, 640℃, 650℃, 660℃, 670℃, 680℃, 690℃, and 700℃. The required set temperature according to process requirements is preferably 650℃. After the predetermined value is reached, turn off the electric heating temperature control device 2.

[0058] Step 3: Manually move the pressurizing device 4 (i.e., hydraulic jack) to apply the set pressure to the pipe fitting casting body 5. The pressurizing device 4 is also equipped with a pressure display gauge 8, which can read the pressure value. When the pressure reaches the required value, the hydraulic cylinder 9 pushes the air inlet flange 7 of the casting that needs to be corrected on the pipe fitting casting body 5, and moves it in the preset direction to the position of the limit block 6 on the casting fixing device 3, and then closes the pressurizing device 4.

[0059] Step 4: Keep the casting still and wait for it to cool down (at this time, it will cool down with the air; do not use methods such as blowing cold air or spraying water to accelerate the cooling). When the temperature reaches the set value (i.e., the temperature is 200℃±10℃), open the clamping device and remove the casting. The casting deformation correction process is now complete.

[0060] The invention is characterized by electrically heating the cooled and deformed pipe casting body 5, applying pressure to the deformed pipe casting body 5 within a temperature range that ensures that the metallographic structure of the pipe casting body 5 will not change, and straightening it so that the pipe casting body 5 changes in the direction of the limiting block 6. Finally, the pipe casting body 5 meets the requirements of the customer's drawings, and the finished product after subsequent processing meets the assembly requirements.

[0061] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0062] The aforementioned workbench; electric heating temperature control device; casting fixing device; pressurizing device; pipe fitting casting body; first positioning block; second positioning block; third positioning block; fourth positioning block; limit block; casting air inlet flange; pressure display gauge; oil cylinder; and positioning blocks are existing technologies. Technologies not described are existing technologies and will not be elaborated further.

[0063] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A device for straightening heat-resistant steel pipe castings, characterized in that, include: The workbench, the electric heating straightening device installed on the workbench, and the pressurizing device set next to the electric heating straightening device; wherein, the electric heating straightening device is equipped with: an electric heating temperature control device, and a casting fixing device connected to the electric heating temperature control device through an induction heating coil, the induction heating coil surrounding the body of the pipe casting that needs to be heated; The casting fixing device includes: a fixed support block, which is connected to the worktable by several positioning pins and fixing block fastening bolts; the fixed support block and the casting clamping block are connected by a connecting shaft and casting clamping bolts. The pressurizing device is equipped with a pressure display gauge. The pressure is provided by the oil cylinder. The pressure is provided to deform the pipe casting body to the air inlet flange position of the pipe casting body, and then move to several limit blocks, thus completing the deformation correction of the pipe casting body. The pressure for correcting the deformation of the pipe fitting casting body is achieved by a pressurizing device. After the pipe fitting casting body completes the deformation correction pressurizing device pressurizes, the oil cylinder generates a pushing force, which pushes the flange position of the pipe fitting casting body to move and deform. The oil cylinder is controlled according to the pressure value of the pressure display gauge to push the deformation amount of the pipe fitting casting body, so that the pipe fitting casting body will undergo permanent deformation. The limiting block has an arc-shaped structure that mimics the air inlet flange of a casting; the limiting block can fully contact the body of the pipe casting, and the limiting block is located on opposite sides of the air inlet flange of the casting.

2. The device for straightening heat-resistant steel pipe castings according to claim 1, characterized in that, The induction heating coil is an induction heating coil made of copper tubing; when the pipe casting body is placed among several positioning blocks, the positioning blocks are used to fix the position of the pipe casting body.

3. The device for straightening heat-resistant steel pipe castings according to claim 1, characterized in that, The pressurizing device is a manual hydraulic jack; the hydraulic pressure applied by the hydraulic jack to the pipe casting body is 0.8 MPa.

4. The device for straightening heat-resistant steel pipe castings according to claim 1, characterized in that, The workbench is a flat surface used on top, i.e., a platform. The platform is a flat plate made of No. 45 steel, with dimensions of 600mm in length, 400mm in width, and 25mm in thickness. The flat plate is supported by four legs. The workbench is tightly connected to several positioning blocks.

5. The device for straightening heat-resistant steel pipe castings according to claim 2, characterized in that, The aforementioned positioning blocks are: a first positioning block, a second positioning block, a third positioning block, and a fourth positioning block; their installation positions are as follows: the first positioning block is installed in front of the casting fixing device at a downward position; the second positioning block is installed in the middle of the casting fixing device at a downward position; the third positioning block is installed in the middle of the casting fixing device, that is, at a position diagonally above the second positioning block; the fourth positioning block is installed directly above the casting fixing device, that is, at a relative position with a set distance from the second positioning block; and they are positioned on the casting fixing device; the first positioning block, the second positioning block, the third positioning block, and the fourth positioning block are Π-shaped to press down on the body of the pipe fitting casting, and the top of the Π-shape is pressed down by a long strip plate, and it is a conformal structure that can press down on the body of the pipe fitting casting.

6. The device for straightening heat-resistant steel pipe castings according to claim 1, characterized in that, The electric heating temperature control device is an industrial frequency induction furnace.

7. A process for straightening heat-resistant steel pipe castings, comprising the apparatus for straightening heat-resistant steel pipe castings as described in any one of claims 1-6, characterized in that, The operation steps are as follows: Step 1: Place the pipe fitting casting body on the platform and fix it around the perimeter with several positioning blocks, namely: the first positioning block, the second positioning block, the third positioning block, and the fourth positioning block, and ensure that the first positioning block, the second positioning block, the third positioning block, and the fourth positioning block are tightly connected to the platform; fix the position of the casting on the worktable using a casting fixing device; apply electric heating to the cooled and deformed pipe fitting casting body, and apply pressure to the deformed pipe fitting casting body within a temperature range that ensures that the metallographic structure of the pipe fitting casting body will not change, in order to straighten it; Step 2: Turn on the electric heating temperature control device to allow the heating temperature to reach the set value. Once the preset value is reached, turn off the electric heating temperature control device. Step 3: Manually move the pressurizing device to apply the set pressure to the body of the pipe fitting casting. When the pressure reaches the required value, the hydraulic cylinder pushes the air inlet flange of the casting that needs to be corrected on the body of the pipe fitting casting to move in the preset direction to the position of the limit block on the casting fixing device, and then closes the pressurizing device. Step 4: Keep the casting still and wait for it to cool down. When the temperature reaches the set value of 200℃±10℃, open the casting fixing device and remove the casting. The casting deformation correction process is now complete.

8. The process for straightening heat-resistant steel pipe castings according to claim 7, characterized in that, In the second step, turn on the electric heating temperature control device to bring the heating temperature to the set temperature range: 600℃-700℃.

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