Split mold for a reducer housing and split casting method

Abstract

The application discloses a split type mold for a reducer shell and a split type casting method. The split type mold is assembled by separate outer mold cores, inner upper mold cores, inner lower mold cores, oil channel cores and differential lock modules. The split type mold and a sand box jointly form a molding cavity for the reducer shell. After casting and cooling, the sand box is opened according to the parting surface of the sand box, the outer mold cores are pulled out, and the separate molding blocks are removed. Then, the inner upper mold cores are removed, the casting is lifted, the casting is separated from the inner lower mold cores, and the oil channel cores and the differential lock modules on the casting are removed. Finally, the casting surface is cleaned, and the casting is sent to a machining workshop for subsequent processing. The components of the split type mold can be manufactured separately, the mold is simple, the error cost is low, the molding speed is fast, the mold assembly is simple and fast, the mold pulling speed is fast, and the efficiency of the large-scale production of the reducer shell is ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of casting, in particular to a split mold for a reducer shell and a split casting method. BACKGROUND

[0002] The reducer shell is a basic component for installing various transmission shafts. Since the reducer works, the torque transmitted by each shaft will generate a relatively large reaction force, which will act on the shell, so the shell is required to have sufficient rigidity to ensure the relative position accuracy of each transmission shaft. A metal structure box can obtain greater strength and rigidity, and the structure is compact. The production process of the reducer shell is generally casting followed by machining. Casting is the most critical step in the production of the reducer shell, which affects the production efficiency and quality of the reducer shell.

[0003] The reducer shell has a complex shape due to the built-in transmission components, which results in a complex geometric shape of the casting, which cannot be directly pulled out of the mold. Only manual resin sand, lost foam and other processes can be used for production. The production efficiency is low, the working hours are long, and it cannot meet the demand of mass production. Therefore, a casting mold is needed to improve the casting speed of the reducer shell, especially the pulling speed. SUMMARY

[0004] The purpose of the present application is to solve the problem of complex geometric shape of the reducer shell casting, which cannot be directly pulled out of the mold, and the production process of manual resin sand, lost foam and other processes, low production efficiency, long working hours, and inability to meet the demand of mass production.

[0005] To solve the above technical problems, the present application adopts the following technical solutions:

[0006] A split mold for a reducer shell, the split mold and the sand box together form a molding cavity for the reducer shell, the split mold and the sand box are divided by the largest outer edge of the reducer shell as the parting surface, the split mold includes an outer mold core, an inner upper mold core, an inner lower mold core, an oil channel core and a differential lock module, the inner wall of the outer mold core is matched with the outer wall of the flange surface to the parting surface on the reducer shell, the oil channel core and the differential lock module are respectively installed in the oil channel groove and the differential lock groove on the inner wall of the outer mold core, the inner upper mold core is installed in the outer mold core from the flange surface, the inner lower mold core is installed in the outer mold core from the parting surface, and the outer mold core is installed in the sand box.

[0007] Further technical solutions are: a plurality of separate molding blocks are installed on the inner wall of the outer mold core by means of core glue, and the separate molding blocks are matched with the inner concave part on the outer wall of the reducer shell.

[0008] Further technical solutions are: the inner upper mold core is provided with a pouring gate.

[0009] Further technical solutions are: a refractory filter screen is provided at the pouring gate.

[0010] A split casting method for a reducer shell, using a split mold, and casting according to the following steps:

[0011] S1, confirm the casting body state: the flange surface of the reducer shell end face is upward;

[0012] S2, determine the parting surface: the parting surface between the split mold and the sand box is the maximum outer edge of the reducer shell;

[0013] S3, make the sand box: the forming cavity for the part below the parting surface of the reducer shell is formed in the sand box;

[0014] S4, make the split mold: according to the outer wall modeling of the part above the parting surface of the reducer shell, the mold shell of the outer mold core is made by the core shooter, and the separated modeling block is adhered to the mold shell to form the outer mold core by the core adhesive, and according to the modeling of the inner step surface above and below the reducer shell, the inner upper mold core and the inner lower mold core are made by the core shooter, and the differential lock module and the oil channel core are made by the core shooter according to the lock hole position and the oil channel position in the reducer shell;

[0015] S5, assemble the split mold: first, place the inner lower mold core in the forming cavity of the sand box, then adhere the oil channel core and the differential lock module to the oil channel groove and the differential lock groove on the inner wall of the outer mold core, then cooperate the outer mold core with the sand box at the parting surface and cover the lower mold core, and finally install the inner upper mold core into the outer mold core, the split mold and the sand box together form the molding cavity for the reducer shell;

[0016] S6, fill sand: fill the sand box, and wrap the outer mold core;

[0017] S7, pouring: the molten iron flows into the molding cavity through the pouring port of the inner upper mold core.

[0018] Further technical solutions are: in S4, the oil channel core and the differential lock module are adhered to the oil channel groove and the differential lock groove on the inner wall of the outer mold core by the core adhesive.

[0019] Further technical solutions are: in S5, the assembled split mold is checked for air tightness, and is subjected to pressure detection.

[0020] Compared with the prior art, the present application can at least achieve one of the following beneficial effects:

[0021] The application provides a split mold for a reducer shell and a split casting method. An outer mold core, an inner upper mold core, an inner lower mold core, an oil passage core and a differential lock module are assembled into a split mold. The split mold and a sand box jointly form a molding cavity for the reducer shell. After casting and cooling, the sand box is opened according to a parting surface of the sand box, the outer mold core is pulled out, and the separated molding blocks are removed. Then, the inner upper mold core is removed, the casting is lifted, the casting is separated from the inner lower mold core, and the oil passage core and the differential lock module on the casting are removed. Finally, the casting surface is cleaned, and the casting is sent to a machining workshop for subsequent processing. The components of the split mold can be manufactured separately, the mold is simple, the error cost is low, the molding speed is fast, the mold assembly is simple and fast, the mold pulling speed is fast, and the large-scale production efficiency of the reducer shell is ensured. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 It is a structure schematic view of the split mold for the reducer shell.

[0023] Figure 2 It is a structure schematic view of the split mold. Figure 1

[0024] Figure 3 It is an explosion view of the split mold. Figure 1

[0025] It is an explosion view of the split mold from another perspective. Figure 4 Figure 1 It is a structure schematic view of the outer mold core.

[0026] Figure 5 Figure 1 It is a structure schematic view of the split mold from another perspective.

[0027] Figure 6 It is a structure schematic view of the inner upper mold core. Figure 5

[0028] Figure 7 Figure 1

[0029] Figure 8 It is a structure schematic view of the split mold from another perspective. Figure 7

[0030] Figure 9 It is a structure schematic view of the inner lower mold core. Figure 1

[0031] Figure 10 It is a structure schematic view of the split mold from another perspective. Figure 9

[0032] ​​​​​​​​​Figure 11 A structure diagram of the oil channel core in the present application Figure 3 A structure diagram of the oil channel core in the present application

[0033] Figure 12 A structure diagram of the differential lock module in the present application Figure 3 A structure diagram of the differential lock module in the present application

[0034] Figure 13 A structure diagram of the differential lock module in the present application

[0035] Figure 14 A structure diagram of the differential lock module in the present application Figure 13 A structure diagram of the differential lock module in the present application

[0036] The reference signs: 1, sand box; 2, outer mold core; 3, inner upper mold core; 4, inner lower mold core; 5, oil channel core; 6, differential lock module; 7, reducer shell; 8, parting surface; 9, flange surface; 10, split mold; 11, pouring gate; 12, refractory filter screen. DETAILED DESCRIPTION

[0037] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. The components of the embodiments of the present application described and shown in the drawings can be arranged and designed in various different configurations.

[0038] Therefore, the following detailed description of the embodiments of the present application provided in the drawings is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work are within the scope of protection of the present application.

[0039] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict.

[0040] It should be noted that: similar reference signs and letters represent similar items in the following drawings, therefore, once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings.

[0041] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship commonly understood by those skilled in the art, or the orientation or positional relationship commonly understood by those skilled in the art, or the orientation or positional relationship commonly understood by those skilled in the art, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second" and the like are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0042] In the description of the present application, it should be noted that unless otherwise specified and limited, the terms "set", "mount", "connected", "connected" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the communication between the two elements inside. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0043] Embodiment one:

[0044] The present embodiment such as Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Figure 9 , Figure 10 , Figure 11 , Figure 12 , Figure 13 and Figure 14As shown, a split mold for a reducer shell, the split mold 10 and the sand box 1 together form a molding cavity for the reducer shell 7, the split mold 10 and the sand box 1 are divided by the maximum outer edge of the reducer shell 7 as the parting surface 8, the split mold 10 includes an outer mold core 2, an inner upper mold core 3, an inner lower mold core 4, an oil channel core 5 and a differential lock module 6, the inner wall of the outer mold core 2 is matched with the outer wall of the flange surface 9 to the parting surface 8 on the reducer shell 7, the oil channel core 5 and the differential lock module 6 are respectively installed in the oil channel groove and the differential lock groove on the inner wall of the outer mold core 2, the inner upper mold core 3 is installed in the outer mold core 2 from the flange surface 9, the inner lower mold core 4 is installed in the outer mold core 2 from the parting surface 8, and the outer mold core 2 is installed in the sand box 1. A plurality of separate molding blocks are installed on the inner wall of the outer mold core 2 by means of core adhesive, and the separate molding blocks are matched with the inner recessed part on the outer wall of the reducer shell 7. The inner upper mold core 3 is provided with a pouring gate 11. The pouring gate 11 is provided with a refractory filter screen 12.

[0045] First, the outer mold core 2 is formed into a core shell and a plurality of separate molding blocks by a core shooting machine, and the separate molding blocks are matched with the structure of the recessed and protruding parts on the outer wall of the reducer shell 7 (these positions cannot be smoothly demolded), then the plurality of separate molding blocks are respectively adhered to the corresponding positions of the outer mold core 2 using core adhesive; then the oil channel core 5 and the differential lock module 6 are also adhered to the oil channel groove and the differential lock groove of the outer mold core 2 by means of core adhesive; then a part of clay sand is first filled into the sand box 1, and a molding cavity below the parting surface 8 of the reducer shell 7 is formed; then the inner lower mold core 4 is placed in the molding cavity, the outer mold core 2 covers the inner lower mold core 4, and the parting surface 8 between the outer mold core 2 and the sand box 1 is matched; finally, the inner upper mold core 3 is placed at the top of the outer mold core 2, the sand box 1 is filled with sand again, the outer mold core 2 and the mating surface of the inner upper mold core 3 and the outer mold core 2 are all coated, and the air tightness of the mold is ensured. At this time, the mold matching and assembly work is completed, and together with the sand box 1, it is sent to the pouring line for casting production of the reducer shell 7. After casting is completed, after cooling, the sand box 1 is opened according to the parting surface, then the outer mold core 2 is pulled out, and the separate molding blocks are removed; then the inner upper mold core 3 is taken out, the casting is lifted, and the casting is separated from the inner lower mold core 4, then the oil channel core 5 and the differential lock module 6 on the casting are removed; finally, the surface of the casting is swept and cleaned, and sent to the machining workshop for subsequent processing. The components of the split mold can be made separately, the module is simple, the error cost is low, the molding speed is fast, and the mold assembly is simple and fast, the demolding speed is fast, and the efficiency of the large-scale production of the reducer shell is ensured.

[0046] Example two:

[0047] On the basis of the above embodiment, the embodiment shows a split casting method for a reducer shell, using a split mold, and the casting is carried out according to the following steps:

[0048] S1, confirm the casting state: make the flange face 9 of the reducer shell 7 end face upward;

[0049] S2, determine the parting surface 8: the parting surface 8 between the split mold 10 and the sand box 1 is determined as the parting surface 8 at the maximum outer edge of the reducer shell 7;

[0050] S3, make the sand box 1: the forming cavity for the part of the reducer shell 7 below the parting surface 8 is made in the sand box 1;

[0051] S4, make the split mold 10: the mold shell of the outer mold core 2 is made by the core shooting machine according to the outer wall modeling of the part of the reducer shell 7 above the parting surface 8, and the separated modeling blocks are adhered to the mold shell to form the outer mold core 2 by the core adhesive, the inner upper mold core 3 and the inner lower mold core 4 are respectively made by the core shooting machine according to the modeling of the part above and below the stepped surface inside the reducer shell 7, and the differential lock module 6 and the oil channel core 5 are respectively made by the core shooting machine according to the lock hole position and the oil channel position inside the reducer shell 7;

[0052] S5, assemble the split mold 10: first, place the inner lower mold core 4 in the forming cavity of the sand box 1, then adhere the oil channel core 5 and the differential lock module 6 in the oil channel groove and the differential lock groove on the inner wall of the outer mold core 2, then cooperate the outer mold core 2 with the sand box 1 at the parting surface 8 and cover the lower mold core 4, and finally install the inner upper mold core 3 into the outer mold core 2, the split mold 10 and the sand box 1 together form the molding cavity for the reducer shell 7;

[0053] S6, fill sand: fill the sand box 1, and wrap the outer mold core 2;

[0054] S7, pouring: the molten iron flows into the molding cavity through the pouring port 11 of the inner upper mold core 3.

[0055] The working process of the present application is as follows: first, according to the geometric shape of the reducer shell 7, the casting state of the reducer shell 7 is confirmed, generally according to the difficulty of opening the mold, the casting state of the reducer shell 7 is the flange surface 9 of the end surface upward; second, according to the maximum outer edge of the reducer shell 7 as the demarcation line, the parting surface 8 is confirmed, which is convenient for opening the box; third, the sand box 1 is made, the sand box 1 is filled with a part of clay sand first, which is used to form the forming cavity of the part below the parting surface 8 of the reducer shell 7; fourth, the split mold 10 is made, according to the geometric shape of the reducer shell 7, the outer mold core 2 is made by the core shooting machine according to the outer wall modeling of the part above the parting surface 8 of the reducer shell 7, and the separated modeling blocks are adhered to the mold shell to form the outer mold core 2 by the core adhesive, the inner upper mold core 3 and the inner lower mold core 4 are made by the core shooting machine according to the modeling of the part above and below the internal stepped surface of the reducer shell 7, and the differential lock module 6 and the oil channel core 5 are made by the core shooting machine according to the lock hole position and the oil channel position in the reducer shell 7; fifth, the split mold 10 is assembled, first, the inner lower mold core 4 is placed in the appropriate position of the forming cavity in the sand box 1, then the oil channel core 5 and the differential lock module 6 are adhered to the oil channel groove and the differential lock groove in the inner wall of the outer mold core 2 respectively by the core adhesive, then the outer mold core 2 is matched with the sand box 1 at the parting surface 8 and covers the lower mold core 4, and finally the inner upper mold core 3 is installed into the outer mold core 2, the split mold 10 and the sand box 1 together form the molding cavity for the reducer shell 7; sixth, the sand is filled, the sand box 1 is filled with sand again, the outer mold core 2, the parting surface and other gaps (matching surface) are wrapped, the assembled split mold 10 is checked for air tightness, and the air pressure test is performed to ensure the air tightness; seventh, pouring, the assembled sand box mold is sent to the pouring line, the molten iron in the ladle flows into the molding cavity through the pouring port 11 of the inner upper mold core 3, the impurities are filtered out by the refractory filter screen 12, and the casting quality is ensured.

[0056] Note the sequence of stripping: after casting is completed, after cooling, first open the box according to the parting surface of the sand box 1, then pull out the outer mold core 2, and then take off the gradually upward separated modeling blocks; then take out the inner upper mold core 3, lift the casting, so that the casting is separated from the inner lower mold core 4, and then remove the oil channel core 5 and the differential lock module 6 on the casting; finally, the surface of the casting is swept and cleaned, and sent to the machining workshop for subsequent processing. The components of the split mold can be made separately, the module is simple, the error cost is low, the molding speed is fast, and the mold assembly is simple and fast, the stripping speed is fast, which ensures the large-scale production efficiency of the reducer shell.

[0057] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can modify the technical solutions described in the foregoing embodiments, or make equivalent replacements to part of the technical features, any modification, equivalent replacement, improvement, etc. within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A split mold for a reducer housing, wherein the split mold (10) and the sand box (1) together form a molding cavity for the reducer housing (7), characterized in that: The split mold (10) and the sand box (1) are separated by a parting surface (8) at the maximum outer edge of the reducer housing (7). The split mold (10) includes an outer mold core (2), an inner upper mold core (3), an inner lower mold core (4), an oil passage core (5), and a differential lock module (6). The inner wall of the outer mold core (2) is adapted to the outer wall of the flange surface (9) on the reducer housing (7) to the parting surface (8). The oil passage core (5) and the differential lock module (6) are respectively installed on the oil passage groove and differential lock on the inner wall of the outer mold core (2). Inside the groove, the inner upper mold core (3) is installed from the flange face (9) inside the outer mold core (2), the inner lower mold core (4) is installed from the parting face (8) inside the outer mold core (2), the outer mold core (2) is installed inside the sand box (1), and multiple separation molding blocks are installed on the inner wall of the outer mold core (2) by adhesive core. The separation molding blocks are adapted to the concave part on the outer wall of the reducer housing (7). The inner upper mold core (3) is provided with a pouring port (11), and a fire-resistant filter screen (12) is provided at the pouring port (11).

2. A method for split casting of a reducer housing, characterized in that, The reducer housing is cast using the split mold as described in claim 1, following these steps: S1. Confirm the casting state: Make the flange face (9) of the end face of the reducer housing (7) face upward; S2. Determine the parting surface (8): The parting surface (8) between the split mold (10) and the sand box (1) is the maximum outer edge of the reducer housing (7). S3. Making sand box (1): The sand box (1) is used to create a molding cavity for the part below the parting surface (8) of the reducer housing (7); S4. Making a split mold (10): Based on the shape of the outer wall above the parting surface (8) of the reducer housing (7), the mold shell of the outer mold core (2) and the separation molding block are made by the core shooting machine. The separation molding block is glued to the mold shell to form the outer mold core (2). Based on the shape above and below the stepped surface inside the reducer housing (7), the inner upper mold core (3) and inner lower mold core (4) are made by the core shooting machine. Based on the locking hole position and oil passage position inside the reducer housing (7), the differential lock module (6) and oil passage core (5) are made by the core shooting machine. S5. Assemble the split mold (10): First, place the inner lower mold core (4) in the molding cavity of the sand box (1), then glue the oil channel core (5) and the differential lock module (6) to the oil channel groove and differential lock groove on the inner wall of the outer mold core (2) respectively. Next, make the outer mold core (2) and the sand box (1) fit together with the parting surface (8) and cover the lower mold core (4). Finally, install the inner upper mold core (3) into the outer mold core (2). The split mold (10) and the sand box (1) together form the molding cavity for the reducer housing (7). S6. Filling with sand: Fill the sand box (1) with sand and wrap the outer mold core (2); S7. Pouring: Molten iron flows into the molding cavity through the pouring port (11) of the inner upper mold core (3); In S4, the oil passage core (5) and the differential lock module (6) are respectively bonded to the oil passage groove and differential lock groove on the inner wall of the outer mold core (2) by the core adhesive; In step S5, the assembled split mold (10) is subjected to an airtightness check and a pressure test.

Images