A hfc casting system capable of on-line preparation of mechanically sampled test blocks

Abstract

The application discloses a HFC pouring system capable of preparing mechanical sampling test blocks on line, which comprises an upper die and a lower die, the lower end surface of the upper die and the upper end surface of the lower die are provided with a corresponding annular extrusion sprue, a mechanical performance sampling test block cavity and an exhaust groove arranged in a matched mode, the annular extrusion sprue, the mechanical performance sampling test block cavity and the exhaust groove are communicated with each other, the mechanical performance sampling test block cavity is a circular truncated cone cavity, the minimum diameter of the mechanical performance sampling test block cavity is d, the maximum diameter of the mechanical performance sampling test block cavity is D=k1*d, the length of the mechanical performance sampling test block cavity is L=k2*d, 1.5<=k1<=2, 12<=k2<=15, and d is a calibration value corresponding to a target mechanical performance sampling test block. The application can form mechanical performance test bars which can represent the mechanical performance of parts in the same batch when the parts are manufactured, and realizes the monitoring of the performance of casting products through the sampling of the mechanical performance test bars.

Description

Technical Field

[0001] This invention discloses an HFC casting system, belonging to the field of casting technology, specifically an HFC casting system capable of preparing mechanical sampling test blocks online. Background Technology

[0002] HFC process is a new type of pressure-extrusion dual-control casting technology. It is a new generation of iterative casting technology that organically combines low-pressure casting technology, extrusion casting technology and high-pressure casting technology. The development and application of this technology has achieved significant breakthroughs in product performance, quality and efficiency.

[0003] The HFC system (Hard Compression Casting System) is an advanced process system for metal casting. This system combines the features of pressure casting and extrusion molding to manufacture metal parts with complex shapes and high precision requirements.

[0004] The HFC system (Hydraulic Fusing and Press Casting) involves placing molten metal in a container and then applying pressure to force the molten metal upwards into a mold cavity. Simultaneously, the movement of extrusion pins compresses the metal billet into its final state, increasing the density of the original molten metal.

[0005] The HFC system (Hydraulic Compression Casting) offers the advantage of manufacturing parts with complex shapes, high precision, and excellent surface quality. By applying pressure, it ensures that the metal fully fills the mold, reducing defects and porosity. Simultaneously, the extrusion process further improves the compactness and structural strength of the parts.

[0006] While existing HFC casting systems have the above advantages, they cannot produce mechanical property test bars. Mechanical property test bars produced by other processes (such as gravity casting and low-pressure casting) cannot reflect the mechanical properties of the formed casting. Therefore, how to produce mechanical property test bars with the same mechanical properties as the casting body under HFC process conditions is a technical problem that urgently needs to be solved. Summary of the Invention

[0007] To address the technical problems existing in the prior art, the present invention provides an HFC casting system capable of online preparation of mechanical property sampling test blocks. This system can form mechanical property test bars of the same batch that can represent the mechanical properties of the parts during the manufacturing process, and monitor the performance of the casting products by sampling these mechanical property test bars.

[0008] This invention discloses an HFC casting system for online preparation of mechanical property sampling blocks, comprising an upper mold and a lower mold. The lower end face of the upper mold and the upper end face of the lower mold are provided with correspondingly arranged annular extrusion runners, mechanical property sampling block cavities, and venting grooves. The annular extrusion runners, the mechanical property sampling block cavities, and the venting grooves are interconnected. The mechanical property sampling block cavities are frustoconical cavities. The minimum diameter of the mechanical property sampling block cavities is d, the maximum diameter of the mechanical property sampling block cavities is D = k1 * d, and the length of the mechanical property sampling block cavities is L = k2 * d, where 1.5 ≤ k1 ≤ 2, 12 ≤ k2 ≤ 15, and d is the calibration value corresponding to the target mechanical property sampling block.

[0009] In a preferred embodiment of the present invention, the cross-sectional shape of the cavity of the mechanical property sampling test block is circular, and the longitudinal cross-sectional shape of the cavity of the mechanical property sampling test block is trapezoidal.

[0010] In a preferred embodiment of the present invention, a removable sealing block is provided at the junction between the annular extrusion runner and the cavity of the mechanical property sampling test block.

[0011] In a preferred embodiment of the present invention, the upper countersunk hole of the sealing block is provided with a threaded connector inside the countersunk hole, and the upper / lower mold is provided with a threaded hole for connecting the threaded connector.

[0012] In a preferred embodiment of the present invention, the upper / lower mold is provided with an assembly groove for cooperating with the sealing block, the assembly groove being located between the annular extrusion runner and the cavity of the mechanical property sampling test block.

[0013] In a preferred embodiment of the present invention, when the sealing block is installed in the assembly groove, the molten metal located in the annular extrusion gating channel cannot flow into the cavity of the mechanical property sampling test block.

[0014] In a preferred embodiment of the present invention, a central extrusion pin is provided inside the upper mold.

[0015] In a preferred embodiment of the present invention, a gate is provided on the lower mold.

[0016] In a preferred embodiment of the present invention, a nitrogen pin is provided inside the lower mold, and the nitrogen pin is located between the lower gate and the annular extrusion runner.

[0017] In a preferred embodiment of the present invention, the exhaust groove is an E-shaped exhaust groove.

[0018] The beneficial effects of this invention are as follows: This invention has a simple structure and is easy to process and manufacture. It can produce sample blocks that represent the mechanical properties of parts and the same batch, suitable for HFC processes. At the same time, these sample blocks are easy to obtain, facilitating production.

[0019] Furthermore, this invention introduces a mechanical property sampling test block cavity and venting groove next to the annular extrusion runner, thereby enabling the formation of mechanical property test bars representing the mechanical properties of the parts during the manufacturing process. Sampling of these mechanical property test bars allows for the monitoring of the casting product's performance, avoiding the presence of gas voids in the samples that could cause the parts to be less dense and affect performance testing. Since the target product is a key component requiring high strength, high toughness, and high quality, the mechanical property test bars cannot be formed using other processes, such as gravity casting or low-pressure casting. They must be sampled from test blocks formed under HFC process conditions to achieve the same mechanical properties as the original component. Therefore, it is necessary to create a physical performance test model to reflect the mechanical property level of the actual product. This invention achieves the above objective by creating a physical performance test model to reflect the mechanical property level of the actual product. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of an HFC casting system for online preparation of mechanical sampling test blocks according to the present invention;

[0021] Figure 2 This is a cross-sectional view of an HFC casting system for online preparation of mechanical sampling test blocks according to the present invention;

[0022] Figure 3 This is a schematic diagram of the lower mold of an HFC casting system for online preparation of mechanical sampling test blocks according to the present invention;

[0023] Figure 4 This is a schematic diagram of a casting formed by an HFC casting system capable of online preparation of mechanical sampling test blocks according to the present invention;

[0024] Figure 5 This is a schematic diagram of a mechanical performance sampling block for an HFC casting system that can prepare mechanical sampling blocks online according to the present invention;

[0025] In the diagram: 1-Center extrusion pin; 2-Annular extrusion runner; 3-Cavity of mechanical property sampling test block; 4-Ventilation groove; 5-Sealing block; 6-Lower gate; 7-Upper mold; 8-Lower mold; 9-Mechanical property sampling test block;

[0026] 10-Casing; 11-Gateway. Detailed Implementation

[0027] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by way of listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0028] like Figure 1 The HFC casting system shown here enables online preparation of mechanically sampled test blocks. This system features unique structural characteristics and process properties. Molten aluminum is pressurized and rises into the mold cavity from the lower gate, flowing sequentially into the annular extrusion runner. After filling, excess molten aluminum falls back into the furnace. Nitrogen gas is introduced through the nitrogen pin at the lower gate to seal it. At this point, the central extrusion pin begins to extrude, transmitting pressure from the middle runner to the annular extrusion runner to form the casting. Castings prepared using this HFC casting system can have complex shapes and require high precision.

[0029] Specifically, this invention discloses an HFC casting system for online preparation of mechanical property sampling blocks, comprising an upper mold 7 and a lower mold 8. The upper end face of the upper mold 7 and the upper end face of the lower mold 8 are provided with correspondingly arranged annular extrusion runners 2, mechanical property sampling block cavities 3, and venting grooves 4. The annular extrusion runners 2, mechanical property sampling block cavities 3, and venting grooves 4 are interconnected. The mechanical property sampling block cavity 3 is a frustum-shaped cavity (which can be understood as a shape formed by rotating a right trapezoid 360° around its right-angled side). The mechanical property sampling block cavity 3... The minimum diameter is d, the maximum diameter of the cavity 3 of the mechanical performance sampling test block is D = k1 * d, the length of the cavity 3 of the mechanical performance sampling test block is L = k2 * d, 1.5 ≤ k1 ≤ 2, 12 ≤ k2 ≤ 15, d is the calibration value corresponding to the target mechanical performance sampling test block, that is, D is the diameter of the connecting gate end, and d is the far end diameter. For example, if a mechanical performance sampling test block with a diameter of 18 mm after processing is required, then the far end diameter d = 18 mm, the length L = 18 * 12 = 216 mm, and the diameter of the connecting gate end D = 18 * 1.5 = 27 mm.

[0030] The HFC casting system of this invention differs from other casting systems by employing a ring-shaped extrusion casting system with unique structural features and process properties. Molten aluminum is pressurized and rises into the mold cavity from the lower gate 6, sequentially forming the annular extrusion runner 2, the mechanical performance sampling test block cavity 3, and the part 8. After filling, excess molten aluminum falls back into the furnace, and nitrogen gas is introduced through the nitrogen pin 5 at the lower gate to seal the gate. At this time, the central extrusion pin 1 begins to extrude, transmitting pressure from the middle runner to the annular extrusion runner, the runner, and the part. The structure formed after the central pin extrudes is the annular pressure runner. The performance test blocks under HFC process conditions need to be prepared simultaneously during the production process.

[0031] Preferably, the mechanical property sampling test block cavity 3 is divided along the centerline, with half of the test block in the upper mold and half in the lower mold. A sealing block 5 is placed near the annular extrusion runner, one in the upper mold and one in the lower mold. This sealing block can be removed during production using screws. When the sealing block is used, the mechanical property test block is blocked and not formed. During production, after 30 batches, the sealing block can be removed to manufacture a conical mechanical property test block. Each batch produces 5-10 blocks; once the quantity is met, this position is sealed, and normal part production resumes, avoiding the waste of molten aluminum caused by carrying sample blocks with each production run. Three venting grooves, 10mm wide, are provided at the far end of the conical sample to prevent gas voids in the sample, which could cause the part to be non-dense and affect performance testing.

[0032] Preferably, the cross-sectional shape of the mechanical performance sampling test block cavity 3 is circular (the upper or lower mold contains a semi-circular mechanical performance sampling test block cavity 3, and two semi-circular mechanical performance sampling test block cavities 3 are joined together to form a circular mechanical performance sampling test block cavity 3), and the longitudinal cross-sectional shape of the mechanical performance sampling test block cavity 3 is trapezoidal.

[0033] Preferably, a removable sealing block 5 is provided at the junction between the annular extrusion runner 2 and the mechanical performance sampling test block cavity 3.

[0034] Preferably, the upper countersunk hole of the sealing block 5 is provided with a threaded connector inside the countersunk hole, and both the upper mold 7 and the lower mold 8 are provided with threaded holes for connecting the threaded connector.

[0035] Preferably, both the upper mold 7 and the lower mold 8 are provided with assembly grooves for cooperating with the sealing block 5, and the assembly grooves are located between the annular extrusion runner 2 and the cavity 3 of the mechanical performance sampling test block.

[0036] Preferably, when the sealing block 5 is installed in the assembly groove, the molten metal located in the annular extrusion runner 2 cannot flow into the mechanical property sampling test block cavity 3. The sealing block 5 is removed using screws, thus controlling the timing and quantity of mechanical property test block manufacturing. Furthermore, an venting structure is provided to ensure the internal quality of the sample. After sample production, according to... Figure 4Cut and sample the bar, and then perform subsequent machining on the effective middle section to complete the preparation of the tensile test bar.

[0037] Preferably, a central extrusion pin 1 is provided inside the upper mold 7. During the extrusion process, the central extrusion pin 1 can transfer the extrusion force to the test block, ensuring that the performance of the conical test block is consistent with the performance of the product.

[0038] Preferably, the lower mold 8 is provided with a gate 6.

[0039] Preferably, a nitrogen pin 5 is provided inside the lower mold 8, and the nitrogen pin 5 is located between the lower gate 6 and the annular extrusion runner 2.

[0040] Preferably, the exhaust groove 4 is an E-shaped exhaust groove.

[0041] This invention specifies the method for cutting the specimen: After the modules containing the attached parts, runners, and mechanical properties have cooled, they can be cut. The cutting position can be determined using a saw as shown in the diagram. When cutting the specimen, 50mm of material should be removed from the far end A (i.e., the d-dimension end) to ensure that the remaining specimen in the middle has a dense internal structure free of pores and defects. The cut mechanical property specimen needs to be processed according to the dimensions of a standard tensile test bar.

[0042] It should be noted that the mechanical property sampling test blocks mentioned in this article are mechanical property test bars. Furthermore, the HFC process borrows the low-pressure filling technology of low-pressure casting, filling from the bottom of the furnace, using a nitrogen atmosphere for protection, and employing a gating system of overall extrusion and local multi-point extrusion to achieve automation. The target product is a key and important part with high strength, high toughness, and high quality. The mechanical property test bars produced cannot be formed using other processes, such as gravity casting or low-pressure casting. They must be sampled from test blocks made under the pressure molding conditions of the HFC process to have the same mechanical properties as the original part. Therefore, it is necessary to make a physical performance test model to reflect the mechanical property level of the actual part.

[0043] Those skilled in the art will readily understand that the above are merely preferred embodiments of the present invention and are not intended to limit the invention. Any modifications, combinations, substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

Claims

1. An HFC casting system capable of online preparation of mechanically sampled test blocks, characterized in that: The system includes an upper mold (7) and a lower mold (8). The lower end face of the upper mold (7) and the upper end face of the lower mold (8) are provided with correspondingly arranged annular extrusion runner (2), mechanical property sampling test block cavity (3), and venting groove (4). The annular extrusion runner (2), the mechanical property sampling test block cavity (3), and the venting groove (4) are interconnected. The mechanical property sampling test block cavity (3) is a frustum-shaped cavity. The minimum diameter of the mechanical property sampling test block cavity (3) is d, the maximum diameter of the mechanical property sampling test block cavity (3) is D = k1 * d, and the length of the mechanical property sampling test block cavity (3) is L = k2 * d. 5≤k1≤2, 12≤k2≤15, d is the calibration value corresponding to the target mechanical property sampling test block; a detachable sealing block (5) is provided at the intersection between the annular extrusion runner (2) and the mechanical property sampling test block cavity (3); the sealing block (5) has a countersunk hole, and a threaded connector is provided in the countersunk hole; the upper mold (7) and the lower mold (8) are both provided with threaded holes for connecting the threaded connector; the upper mold (7) and the lower mold (8) are both provided with assembly grooves for cooperating with the sealing block (5), and the assembly grooves are located between the annular extrusion runner (2) and the mechanical property sampling test block cavity (3).

2. The HFC casting system for online preparation of mechanically sampled test blocks according to claim 1, characterized in that: The cross-sectional shape of the mechanical performance sampling test block cavity (3) is circular, and the longitudinal cross-sectional shape of the mechanical performance sampling test block cavity (3) is trapezoidal.

3. The HFC casting system for online preparation of mechanically sampled test blocks according to claim 1, characterized in that: When the sealing block (5) is installed in the assembly groove, the molten metal located in the annular extrusion gating channel (2) cannot flow into the mechanical property sampling test block cavity (3).

4. The HFC casting system for online preparation of mechanically sampled test blocks according to claim 1, characterized in that: The upper mold (7) is provided with a central extrusion pin (1).

5. The HFC casting system for online preparation of mechanically sampled test blocks according to claim 1, characterized in that: The lower mold (8) is provided with a gate (6).

6. The HFC casting system for online preparation of mechanically sampled test blocks according to claim 5, characterized in that: A nitrogen pin is provided inside the lower mold (8), and the nitrogen pin is located between the lower gate (6) and the annular extrusion runner (2).

7. The HFC casting system for online preparation of mechanically sampled test blocks according to claim 1, characterized in that: The exhaust groove (4) is an E-shaped exhaust groove.

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