Method of integrating sand mold performance chain and process dimension chain with casting quality chain

Abstract

The application discloses a fusion method based on integration of sand mold performance chain, process size chain and casting quality chain, and mainly solves the problems that the processing parameters of each step of the sand mold casting production line cannot be fed back and adjusted in real time, the sand mold performance cannot be observed in time, the size precision of the sand mold deviates and the casting quality is unqualified. The specific steps are as follows: the casting production line is divided into three parts of sand mold blank manufacturing, sand mold processing and casting pouring, and sensors or instruments required for measuring parameters are installed in each production link related to influencing or adjusting the sand mold performance, process size and casting quality of each part, each sensor and instrument feeds back real-time data to the total control system of the production line in real time during the working process of the production line, the total control system analyzes and chooses in real time according to the real-time received data and feeds back to the specific working step of the production line so as to adjust the corresponding production and processing parameters. The application has profound significance for promoting national green casting.

Description

Technical Field

[0001] This invention belongs to the technical field of auxiliary cost reduction and efficiency improvement in frozen sand casting production lines, specifically involving a method for integrating sand mold performance chain, process dimension chain and casting quality chain. Background Technology

[0002] Cryogenic casting is an innovative casting process that uses freezing technology to create molds, achieving green, efficient, and high-quality casting production, aligning with the national trend of developing green casting. The advantages of this process include the use of low-cost, reusable molds and the ability to produce high-quality castings in a short time. Furthermore, the use of freezing technology effectively reduces waste and energy consumption, making it a sustainable manufacturing technology. Due to its low production cost, wide applicability, and ease of operation, casting has been widely used in aerospace, shipbuilding, rail transportation, and automotive industries.

[0003] Cryogenic sand casting technology often employs digital technologies such as 3D modeling and simulation optimization to achieve rapid design and forming of cryogenic sand molds through processes such as turning, milling, negative pressure forming, and 3D printing of sand mold blanks. However, the precision of sand mold forming and freezing, as well as the sand mold forming process, have a crucial impact on the forming effect of the finished casting. If the precision of these steps is not high enough, the quality of the final casting may be affected. Therefore, to ensure high casting quality, how to integrate and couple the sand mold performance chain, process dimension chain, and casting quality chain on the cryogenic sand casting production line, and digitally twinnize them to generate real-time optimization parameters so that each processing link can make optimized responses to achieve cost reduction and efficiency improvement is a problem that urgently needs to be solved on today's cryogenic sand casting production lines. Summary of the Invention

[0004] To address the aforementioned issues, this invention discloses a method for integrating the sand mold performance chain, process dimension chain, and casting quality chain. This method solves the problem of integrating and coupling the sand mold performance chain, process dimension chain, and casting quality chain in a frozen sand casting production line, generating real-time optimization parameters through digital twins, and enabling each processing stage to make optimized responses, thereby reducing costs and increasing efficiency. It also avoids the problems of wasting sand mold materials and reworking sand molds or castings that do not meet requirements.

[0005] A method for integrating sand mold performance chain, process dimension chain, and casting quality chain mainly includes the following steps:

[0006] Step 1: Divide the frozen sand casting production line into three parts: sand mold blank manufacturing, sand mold processing, and casting pouring. Identify the production links in each part that affect or adjust the sand mold performance, process dimensions, and casting quality, and classify them as key links.

[0007] Step 2: Analyze the production and manufacturing parameters in the key links of Step 1 that affect or adjust the sand mold performance, process dimensions and casting quality, and classify them into key parameters.

[0008] Step 3: Analyze the acquisition and response methods of the key parameters in Step 2, and arrange sensors or instruments (meters) to acquire the key parameters in the workpiece, processing device, processing environment and processing space related to the key parameters.

[0009] Step 4: The relevant sensors installed in Step 3 will feed back the measured key parameters to the central control system in real time after the frozen sand casting production line is started.

[0010] Step 5: The central control system performs real-time analysis and decision-making on the key parameters fed back in Step 4, performs coupling mapping and digital twin generation, and generates response instructions. This enables the corresponding key links of the frozen sand casting production line to be optimized and adjusted in real time, thereby achieving the integration of the sand mold performance chain, process dimension chain and casting quality chain of the frozen sand casting production line, improving the yield of the final castings, and achieving the effect of cost reduction and efficiency improvement for the entire production line.

[0011] Furthermore, the integrated sand mold performance chain refers to the relationship between various properties and performance characteristics of different sand molds (such as different moisture content of sand molds, different sand bases used in sand molds, different binders used in sand molds, different external dimensions or shapes of sand molds, different manufacturing methods of sand mold blanks, and different compaction methods of sand molds) under different conditions (such as different freezing temperatures, different ambient temperatures, different ambient humidity, different processing methods of sand molds, different processing parameters of sand molds, and casting temperatures).

[0012] Furthermore, the process dimension chain refers to the relationship between the dimensional performance of the sand mold or sand mold blank after undergoing special forming processes (such as turning, milling, 3D printing, negative pressure molding, mold making, freezing, and temperature change) and the required sand mold shape accuracy, as well as the fit between multiple sand molds.

[0013] Furthermore, the key steps in step 1 refer to: selecting appropriate sand grain size, appropriate sand mold substrate, and suitable binder in the blank manufacturing process to ensure the uniformity of the mixture and determining the optimal processing method based on the characteristics of the casting; in sand mold processing, the sand mold is trimmed, shaped, preheated, cured, turned, and closed; and in casting pouring, the appropriate temperature, flow rate, and cooling rate of the molten metal are ensured to guarantee the internal and external quality of the final casting.

[0014] Furthermore, the key parameters in step 2 refer to the relevant production and processing parameters that influence or respond to the integrated sand mold performance chain, the process dimension chain, and the casting quality chain. These include parameters such as the moisture content of the sand mold, the sand base used in the sand mold, the binder used in the sand mold, the external dimensions or shape of the sand mold, the manufacturing method of the sand mold blank, the compaction method of the sand mold, the freezing temperature of the sand mold, the ambient temperature of the sand mold, the ambient humidity of the sand mold, the processing method of the sand mold, and the processing parameters of the forming tools (equipment / methods) on the sand mold. Number of sand molds, turning sand molds, milling sand molds, sand mold 3D printing, sand mold negative pressure molding, sand mold making, sand mold freezing, sand mold temperature regulation, composition of molten metal, temperature of molten metal, methods of tempering molten metal, ambient temperature of casting cooling, ambient humidity of casting cooling, heat preservation / cooling methods during casting cooling process, cooling rate of molten metal, methods to prevent defects such as porosity / sand holes / shrinkage cavities / sand adhesion / cracks, casting structure, mechanical properties of castings, crystal phase structure of castings, surface smoothness of castings, ease of finishing of castings, dimensional accuracy of castings.

[0015] Furthermore, the overall control system in step 4 refers to a large model database composed of experimental data obtained from experiments on various sand mold blanks, various sand mold forming methods, and various casting cooling processes, as well as human production experience, using a computer server as a medium. Through artificial intelligence, the database is deeply learned and key parameters are collected and analyzed in real time, coupled and mapped, and digital twins are generated to make real-time decisions and generate optimized response instructions, which are fed back to the key links in the sand mold production line, so that the production links in the key links can respond and adjust the manufacturing (processing) parameters in real time.

[0016] Furthermore, the overall control system includes a data collection module, a data processing module, and a response output module. The data collection module includes key parameters for sand mold manufacturing, key parameters for sand mold processing, key parameters for casting, and a manual intervention interface. The data processing module performs operations such as storage, real-time analysis and decision-making, data collision, coupling mapping, and digital twin generation on the collected data and feeds them back to the response output module. The response output module includes response commands for sand mold manufacturing, sand mold processing, and casting.

[0017] In addition to autonomously collecting and analyzing key parameters in real time to create a digital twin and making real-time decisions and generating optimized response commands to feed back to key links in the sand mold production line, enabling the production links in key links to respond and adjust manufacturing (processing) parameters in real time, the central control system also reserves a manual intervention interface for manually correcting system misjudgments and regulating the production efficiency of the entire production line as well as the transfer rate and production cycle of sand molds / workpieces between processing links.

[0018] The beneficial effects of this invention are:

[0019] (1) A method is provided to integrate the performance chain of sand mold, the process dimension chain and the casting quality chain, and establish a mapping relationship from the basic performance of sand mold, the sand mold processing window to the precise solidification and forming of complex castings, which is conducive to achieving excellent control over the precise forming of castings from each key node.

[0020] (2) It improves the efficiency of the frozen sand casting production line, improves the quality of castings, and allows the production line to be manually controlled to achieve on-demand production. Through artificial intelligence and digital twins, the entire production process is tracked and optimized in real time, which reduces inventory pressure to a certain extent, increases production speed, and ultimately enables the production line to achieve the goal of cost reduction and efficiency improvement. Attached Figure Description

[0021] Figure 1 This is a flowchart of the frozen sand casting production line.

[0022] Figure 2 This is a flowchart of the data processing of the central control system. Detailed Implementation

[0023] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, and the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively. Example

[0024] A certain cryogenic sand casting production line requires the integration and coupling of the sand mold performance chain, process dimension chain, and casting quality chain on the production line, and the generation of real-time optimization parameters through digital twinning. This enables each processing stage to make optimized responses, thereby achieving the goal of cost reduction and efficiency improvement. Therefore, if... Figure 1 The following steps are required.

[0025] Step 1: The frozen sand casting production line is divided into three parts: sand mold blank manufacturing, sand mold processing, and casting pouring. The technical means disclosed in this invention within each part are not limited to those disclosed in the above embodiments, but also include any combination of the above technical features and production links that influence or adjust sand mold performance, process dimensions, and casting quality, and are uniformly classified as key links.

[0026] Step 2: Analyze the production and manufacturing parameters in the key links of Step 1 that affect or adjust the sand mold performance, process dimensions and casting quality, and classify them into key parameters.

[0027] Step 3: Analyze the acquisition and response methods of the key parameters in Step 2, and arrange sensors or instruments (meters) to acquire the key parameters in the workpiece, processing device, processing environment and processing space related to the key parameters.

[0028] Step 4: The relevant sensors installed in Step 3 will feed back the measured key parameters to the central control system in real time after the frozen sand casting production line is started.

[0029] Step 5: Central control system, such as Figure 2 The key parameters fed back in step 4 are analyzed in real time, coupled and mapped in decision-making, and digital twinned to generate response instructions. This enables the corresponding key links of the frozen sand casting production line to be optimized and adjusted in real time, thereby achieving the integration of the sand mold performance chain, process dimension chain and casting quality chain of the frozen sand casting production line, improving the yield of the final casting, and achieving the effect of cost reduction and efficiency improvement of the entire production line.

[0030] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims

1. A method for integrating the performance chain of sand molds, the dimensional chain of process technology, and the quality chain of castings, characterized in that, Includes the following steps: Step 1: Divide the frozen sand casting production line into three parts: sand mold blank manufacturing, sand mold processing, and casting pouring. Identify the production links in each part that affect or adjust the sand mold performance, process dimensions, and casting quality, and classify them as key links. Step 2: Analyze the production and manufacturing parameters in the key links of Step 1 that affect or adjust the sand mold performance, process dimensions and casting quality, and classify them into key parameters. Step 3: Analyze the acquisition and response methods of the key parameters in Step 2, and arrange sensors or instruments to acquire the key parameters in the workpiece, processing device, processing environment, and processing space related to the key parameters; Step 4: After the frozen sand casting production line is started, the sensor described in Step 3 feeds back the key parameters measured to the central control system in real time; Step 5: The central control system performs real-time analysis and decision-making on the key parameters fed back in Step 4, performs coupling mapping and digital twinning, and generates response instructions to optimize and adjust the corresponding key links of the frozen sand casting production line in real time. This achieves the integration of the sand mold performance chain, process dimension chain and casting quality chain of the frozen sand casting production line, and improves the yield of the final castings, thereby achieving the effect of cost reduction and efficiency improvement of the entire production line. The integrated sand mold performance chain refers to the relationship between various properties and their performance under different conditions, including different water content of sand molds, different sand bases used in sand molds, different binders used in sand molds, different external dimensions or shapes of sand molds, different manufacturing methods of sand mold blanks, and different compaction methods of sand molds. The process dimension chain refers to the relationship between the dimensional performance of the sand mold or sand mold blank after the forming process, the required sand mold shape accuracy, and the fit of multiple sand molds when they are joined together; the casting quality chain refers to the relationship between the forming of different sand molds with different molten metals in different cooling environments and the quality of the final casting after casting; the key links in step 1 are: selecting appropriate sand grain size, appropriate sand mold substrate, and suitable binder in blank manufacturing to ensure the uniformity of the mixture and determining the optimal processing method according to the characteristics of the casting; sand mold processing, including sand mold trimming, forming, preheating, solidification, mold flipping, and mold joining; and ensuring appropriate temperature, flow rate, and cooling rate of the molten metal during casting pouring to ensure the internal and external quality of the final casting.

2. The method for integrating the performance chain of the sand mold, the process dimension chain, and the casting quality chain according to claim 1, characterized in that, The overall control system in step 4 refers to a large model database composed of experimental data obtained from experiments on various sand mold blanks, various sand mold forming methods, and various casting cooling processes, as well as human production experience, using a computer server as a medium. Through artificial intelligence, the database is deeply learned and key parameters are collected and analyzed in real time. The system performs coupling mapping and digital twinning to make real-time decisions and generate optimized response instructions, which are then fed back to the key links in the sand mold production line. This enables the production links in the key links to respond and adjust manufacturing parameters in real time.

3. The method for integrating the performance chain of the sand mold, the process dimension chain, and the casting quality chain according to claim 1, characterized in that, The overall control system includes a data collection module, a data processing module, and a response output module. The data collection module includes key parameters for sand mold manufacturing, key parameters for sand mold processing, key parameters for casting, and a manual intervention interface. The data processing module stores, analyzes and makes decisions in real time, performs data collision, coupling mapping, and digital twin operations on the collected data and feeds it back to the response output module. The response output module includes response commands for sand mold manufacturing, sand mold processing, and casting.

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