A gating system and a casting molding method

Abstract

Embodiments of the present application provide a pouring system and a casting forming method, and relate to the technical field of casting. The pouring system comprises a straight runner, a first cross runner, a second cross runner, a third cross runner, a fourth cross runner, an inner runner and a slag collecting ladle. By limiting the minimum sectional area ratio of each runner, the filling flow during pouring operation is large and more stable, which can effectively avoid the entry of cold material and oxidized slag into the cavity, prevent filling defects such as slag inclusion, air entrapment, insufficient pouring and cold shut, and meet the internal quality requirements of X-ray required castings. The casting forming method can improve the precision of the sand core, reduce the deformation of the sand core, and thus improve the precision of the casting and ensure the size and wall thickness of the casting.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and more specifically, to a gating system and a casting method. Background Technology

[0002] In the manufacturing process of large thin-walled parts, existing technologies often use lost-wax casting or conventional casting. However, lost-wax casting is prone to problems such as severe product deformation and dimensional deviations, while conventional casting has the problems of cold material and oxide slag easily entering the mold cavity, slow filling, unstable liquid level, large fluctuations, and defects such as slag inclusion, air entrapment, incomplete filling, and cold shut. Summary of the Invention

[0003] This invention provides a gating system and casting method that can effectively prevent cold material and oxide slag from entering the mold cavity while reducing deformation and preventing dimensional deviations. It also improves filling efficiency and makes the process more stable, avoiding conventional filling problems.

[0004] The embodiments of the present invention can be implemented as follows:

[0005] Embodiments of the present invention provide a casting system comprising:

[0006] The straight pouring channel, the first horizontal pouring channel, the second horizontal pouring channel, the third horizontal pouring channel, the fourth horizontal pouring channel, the inner pouring channel, and the slag collection bag;

[0007] The first horizontal runner is connected to both the sprue and the second horizontal runner, the third horizontal runner is connected to both the second horizontal runner and the fourth horizontal runner, the ingate is used to connect the fourth horizontal runner and the casting, and the first horizontal runner, the second horizontal runner, the third horizontal runner and the fourth horizontal runner are all provided with the slag collection bag.

[0008] Minimum cross-sectional area of ​​the ingate: Minimum cross-sectional area of ​​the fourth runner: Minimum cross-sectional area of ​​the third runner: Minimum cross-sectional area of ​​the second runner: Minimum cross-sectional area of ​​the first runner: Minimum cross-sectional area of ​​the sprue = 1:(1.1~1.3):(1.4~1.5):(1.7~1.8):(2~2.1):(2.4~2.5).

[0009] Optionally, a pressure-stabilizing cavity is formed at the end of the direct sprue.

[0010] Optionally, the casting system further includes an overlapping bridge, which is disposed at the connection of each gating channel.

[0011] Optionally, the gating system further includes a riser, which is cylindrical and located in the middle of the reinforcing rib of the casting.

[0012] Embodiments of the present invention also provide a casting system applied to the gating system, comprising: a core-making process, a core-assembly process, a pouring process, a casting process, a casting-out process, and a post-processing process performed sequentially.

[0013] Optionally, the core-making process includes: first placing the core into a mold, and then filling it with sand and solidifying it.

[0014] Optionally, the core assembly process includes: pre-core assembly and fine core assembly performed sequentially.

[0015] Optionally, the casting process includes: first heating the sandbag, and then performing low-pressure casting according to preset parameters.

[0016] Optionally, the unpacking process includes: removing the locking mechanism, removing the outer skin of the sandbag, transferring it to the sand-burning furnace for sand-burning treatment, and removing loose sand from the surface after the sand-burning is completed.

[0017] Optionally, the post-processing includes: first shaping the deformed area, and then transferring the casting.

[0018] The beneficial effects of the gating system and casting method of the present invention include, for example:

[0019] This gating system, by limiting the minimum cross-sectional area ratio of each runner, allows for a larger and more stable filling flow during the pouring process. It also effectively prevents cold material and oxide slag from entering the mold cavity, thus preventing filling defects such as slag inclusions, air entrapment, incomplete filling, and cold shuts, ensuring the internal quality of the casting meets X-ray requirements. This casting method, through its ordered steps, improves sand core accuracy and reduces sand core deformation, thereby improving casting accuracy and guaranteeing the dimensions and wall thickness of the casting. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a schematic diagram of the operation of the casting system provided in an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram showing the positions of each horizontal gating channel provided in an embodiment of the present invention;

[0023] Figure 3 This is a schematic flowchart of the casting method provided in an embodiment of the present invention.

[0024] Icons: 100 - Gating system; 110 - Sprue; 111 - Pressure stabilizing cavity; 120 - First runner; 130 - Second runner; 140 - Third runner; 150 - Fourth runner; 160 - Ingate; 170 - Slag trap; 180 - Overlap bridge; 190 - Riser; 200 - Casting. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0026] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0027] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0028] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0029] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0030] The terms “comprising,” “including,” or any other variations thereof are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0031] Unless otherwise explicitly specified and limited, terms such as "setup" and "connection" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0032] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.

[0033] Please refer to Figures 1-3 The gating system 100 and casting method provided in the embodiments of the present invention can solve the above problems, and will be described in detail below.

[0034] refer to Figure 1 and Figure 2 The casting system 100 includes: a straight pouring channel 110, a first horizontal pouring channel 120, a second horizontal pouring channel 130, a third horizontal pouring channel 140, a fourth horizontal pouring channel 150, an inner pouring channel 160, and a slag collection bag 170.

[0035] The first horizontal runner 120 is connected to both the sprue 110 and the second horizontal runner 130. The third horizontal runner 140 is connected to both the second horizontal runner 130 and the fourth horizontal runner 150. The inner runner 160 is used to connect the fourth horizontal runner 150 and the casting 200. The first horizontal runner 120, the second horizontal runner 130, the third horizontal runner 140, and the fourth horizontal runner 150 are all equipped with slag collection bags 170.

[0036] Minimum cross-sectional area of ​​sprue 160: Minimum cross-sectional area of ​​fourth runner 150: Minimum cross-sectional area of ​​third runner 140: Minimum cross-sectional area of ​​second runner 130: Minimum cross-sectional area of ​​first runner 120: Minimum cross-sectional area of ​​sprue 110 = 1:(1.1~1.3):(1.4~1.5):(1.7~1.8):(2~2.1):(2.4~2.5).

[0037] By limiting the minimum cross-sectional area ratio of each gating channel, the gating system 100 can make the filling flow rate during the casting operation larger and more stable. It can also effectively prevent cold material and oxide slag from entering the mold cavity, and prevent filling defects such as slag inclusion, air entrapment, incomplete filling, and cold shut, so as to meet the internal quality requirements of the casting 200 under X-ray.

[0038] It is worth noting that the above ratio range can be 1:1.1:1.4:1.7:2:2.4 or 1:1.3:1.5:1.8:2.1:2.5. The overall effect of the casting operation is best when the specific ratio is 1:1.2:1.44:1.72:2.07:2.48.

[0039] refer to Figure 1 The end of the sprue 110 has a pressure-stabilizing cavity 111, which is used to stabilize the pressure and flow and prevent molten aluminum from splashing. In this embodiment, the sprue 110 is a cylindrical or square structure.

[0040] refer to Figure 2 The casting system 100 also includes an overlap bridge 180, which is disposed at the connection of each casting channel.

[0041] In this embodiment, the first horizontal sprue 120 has a stepped structure, and its cross-sectional height is 1.2 to 2 times its width. Specifically, this multiple can be 1.2, 1.4, 1.5, 1.6, 1.8, 2, etc. Among all the cross-sections of the first horizontal sprue 120, the cross-sectional area at the position where it connects to the sprue 110 is the smallest. The width of the connection position between the sprue 110 and the first horizontal sprue 120 is not large, and the height is reduced. The angle between the transition slope and the horizontal plane is 30° to 70°, specifically 30°, 45°, 60°, 70°, etc. In addition, the volume of the first horizontal gating 120 is 1.5 to 3 times that of the prior art, and the specific multiple can be 1.5 times, 2 times, 2.5 times, 3 times, etc., which can realize large flow rate filling. During filling, it helps to stabilize the flow and pressure of aluminum liquid, increase heat capacity, and make the aluminum liquid entering the next gating channel more stable and at a higher temperature. A slag collection bag 170 is provided below the end of the first horizontal gating 120 to collect oxides and inclusions in the first stream of aluminum liquid.

[0042] In this embodiment, the cross-section of the second horizontal runner 130 is polygonal or other irregularly shaped, and the height of the cross-section is 1.2 to 1.5 times the width, specifically 1.2, 1.3, 1.4, 1.5, etc.; the cross-sectional area is 1 to 2 times the minimum cross-sectional area, specifically 1, 1.2, 1.4, 1.5, 1.6, 1.8, 2, etc., which helps to increase the heat capacity of the horizontal runner and prevent the aluminum liquid in the flow channel from cooling down too quickly. The end of the second horizontal runner 130 is provided with a slag collection bag 170 for collecting oxide slag and slag inclusions washed away during the flow of aluminum liquid; the front end of the second horizontal runner 130 is connected to the overlapping bridge 180, the bottom surface of the second horizontal runner 130 is flush with the bottom surface of the parallel section on the overlapping bridge 180, and the overlapping area is the minimum cross-sectional area of ​​the second horizontal runner 130. The front end of the lap bridge 180 is connected to the first horizontal gating 120. The bottom surface of the lower parallel section of the lap bridge 180 is 20mm to 40mm away from the bottom surface of the first horizontal gating 120. The specific spacing can be 20mm, 25mm, 30mm, 35mm, or 40mm, so that the first stream of molten aluminum flowing into the first horizontal gating 120 can directly enter the slag collection bag 170. This connection method can prevent a large amount of oxide slag and inclusions from flowing into the next horizontal gating.

[0043] In this embodiment, the cross-section of the third horizontal runner 140 is polygonal or other irregular in shape. The height of the cross-section is 1.2 to 1.5 times, 1.2, 1.3, 1.4, 1.5 times, etc., of the width; the cross-sectional area is 1 to 2 times the minimum cross-sectional area, and the specific multiple can be 1, 1.2, 1.4, 1.5, 1.6, 1.8, 2 times, etc., which is beneficial to increase the heat capacity of the horizontal runner and prevent the aluminum liquid in the flow channel from cooling down too quickly. A slag collection bag 170 is provided at the end of the third horizontal runner 140 to collect oxide slag and slag inclusions washed away during the flow of aluminum liquid; the front section of the third horizontal runner 140 is connected to the overlapping bridge 180, and the bottom surface of the second horizontal runner 130 is flush with the bottom surface of the parallel section on the overlapping bridge 180, and the overlapping area is the minimum cross-sectional area of ​​the third horizontal runner 140. The front end of the lap bridge 180 is connected to the second transverse pouring channel 130. The bottom surface of the lower parallel section of the lap bridge 180 is 10mm to 20mm away from the bottom surface of the second transverse pouring channel 130. The specific distance can be 10mm, 15mm or 20mm, so that the end flowing into the second transverse pouring channel 130 can directly enter the slag collection bag 170, avoiding a large amount of oxide slag and inclusions from flowing into the next level transverse pouring channel.

[0044] In this embodiment, the cross-section of the fourth horizontal runner 150 is polygonal or other irregularly shaped, with equal height and width, and a cross-sectional area that is 1 to 2 times the minimum cross-sectional area. Specifically, this multiple can be 1, 1.2, 1.4, 1.5, 1.6, 1.8, or 2 times, which helps increase the heat capacity of the runner and prevents the molten aluminum in the flow channel from cooling down too quickly. The front section of the fourth horizontal runner 150 is connected to the third horizontal runner 140, with the connection point located at the middle height of the third horizontal runner 140, to prevent a large amount of molten aluminum from flowing into the fourth horizontal runner 150.

[0045] In this embodiment, the ingate 160 is flat, the ingate has the smallest cross-sectional area, and the cross-sectional area connected to the fourth horizontal runner 150 is 1.5 to 3 times the cross-sectional area of ​​the ingate. The specific multiple can be 1.5 times, 2 times, 2.5 times, 3 times, etc. The ingate 160 is connected to the casting 200, and the connection position is at the reinforcing rib of the casting 200. The width of the ingate is 0.5 to 0.9 times the wall thickness of the rib. The specific multiple can be 0.5 times, 0.6 times, 0.7 times, 0.8 times, 0.9 times, etc.

[0046] In this embodiment, the slag collection bag 170 consists of a feed inlet and a slag collection chamber, with the feed inlet having a flat structure. Slag collection bags 170 are formed at the end of the runner and on the casting 200. The feed inlet height of the slag collection bag 170 at the end of the runner is 10mm to 20mm, specifically 10mm, 15mm, 20mm, etc., and is used to collect the first stream of molten aluminum oxide slag. The feed inlet height of the slag collection bag 170 on the casting 200 is 3mm, and its width is 0.3 to 0.8 times the width of the slag collection bag 170 on the runner, specifically 0.3 times, 0.5 times, 0.8 times, etc., and is used to collect the oxide slag during the filling of the casting 200.

[0047] It is worth noting that the overlapping bridge 180 consists of a lower horizontal section, a sloping section, and an upper horizontal section. The lower horizontal section forms an angle of 120° to 150° with the sloping section. The specific angle can be 120°, 135°, 150°, etc. The cross-section of each section is equal, which is the minimum cross-sectional area between the horizontal pouring channels. The upper horizontal section has a triangular structure and the area of ​​overlap with the next level horizontal pouring channel is equal to the minimum cross-section of the overlapping bridge 180. This structure can effectively prevent oxidized slag from flowing into the next level horizontal pouring channel.

[0048] refer to Figure 2 The gating system 100 also includes a riser 190, which is cylindrical and positioned in the middle of the reinforcing ribs of the casting 200. In this embodiment, the draft angle of the riser 190 is 3° to 10°, and its specific draft angle can be 3°, 5°, 8°, 10°, etc. By limiting the position of the riser 190, it is convenient to collect oxides and inclusions at the junction.

[0049] refer to Figure 3Embodiments of the present invention also provide a casting system applied to a gating system 100, comprising:

[0050] S100, chip manufacturing process;

[0051] The core-making process includes: first, placing the core into a mold, and then filling and solidifying it with sand. In particular, for cantilevered sand cores, sand cores with long, suspended sections in the middle, and sand cores with relatively flat sections, it is necessary to add a core to prevent the sand core from twisting and deforming, so that the sand core accuracy can reach ±0.15mm.

[0052] S200, core assembly process; specifically including:

[0053] S210, Pre-assembly of core: Place the sand core that needs to be pre-assembled on the core assembly jig for pre-assembly, check whether the detection points are in place, and adjust the sand core if they are not in place to ensure the accuracy of the pre-assembly of the sand core.

[0054] S220, Precision Core Assembly: The pre-assembled sand cores are assembled in the core assembly sequence. Each pre-assembled core needs to be inspected using a testing jig to ensure the accurate position of each sand core. The jig used is an integrated core assembly jig and testing jig. After the core assembly is completed, the spacing between the sand cores can be measured in time and adjusted promptly to ensure the accuracy between the sand cores and improve work efficiency.

[0055] S300, casting process; specifically including:

[0056] S310. Heating the sandbags: Place the assembled sandbags into an oven for heating. After heating the sand core to 100℃~150℃, lock the oven and prepare for pouring.

[0057] S320. Low-pressure casting is performed according to preset parameters, which specifically include: riser filling time of 2s to 5s, gating system filling time of 4s to 8s, casting 200 filling time of 9s to 13s, riser 190 filling time of 4s to 8s, and solidification holding time of 600s to 900s. Furthermore, the casting pressure for low-pressure casting is 20kPa to 60kPa, which can be 20kPa, 30kPa, 40kPa, 50kPa, or 60kPa, etc., and the specific casting pressure is not limited.

[0058] It is worth noting that the filling time of the riser pipe can be 2s, 3s, 4s, or 5s; the filling time of the gating system can be 4s, 6s, or 8s; the filling time of the 200 casting can be 9s, 10s, 11s, 12s, or 13s; the filling time of the 190 riser can be 4s, 6s, or 8s; and the pressure holding time for solidification can be 600s, 700s, 800s, or 900s.

[0059] S400, Unpacking process: Remove the locking mechanism, remove the outer skin of the sandbag, transfer it to the sand-burning furnace for sand-burning treatment, and remove the loose sand on the surface after the sand-burning is completed.

[0060] It is worth noting that the outer skin of the sandbag is removed manually, and the sand-burning treatment temperature is 400℃~500℃, with a treatment time of 4h~8h. After the first sand-burning, the loose sand on the surface is removed. If there are any unburned sand blocks that cannot be removed, the sand-burning process is repeated until there are no unremovable sand blocks within 200mm of the casting. Furthermore, the specific sand-burning temperature can be 400℃, 450℃, or 500℃, and the specific treatment time can be 4h, 6h, or 8h.

[0061] S500, post-processing technology; specifically including:

[0062] S510. First, the deformed area is shaped and fixed with a shaping fixture, then heat-shaped in the heat treatment furnace. This corrects the deformed area of ​​casting 200, ensuring the dimensions of casting 200 are within acceptable limits.

[0063] S520. Then transfer casting 200. During transfer, casting 200 must be placed on a transfer jig with railings around it to prevent bumps and knocks. Rubber pads should be installed at the contact points between the jig and casting 200 to prevent scratches on casting 200.

[0064] In summary, the gating system 100 and casting method provided by the embodiments of the present invention have at least the following beneficial effects:

[0065] (1) By ensuring the minimum cross-sectional area ratio of each gating channel, the gating system 100 can make the filling flow rate during the casting operation larger and more stable, and can also effectively prevent cold material and oxide slag from entering the mold cavity, prevent filling defects such as slag inclusion, air entrapment, insufficient filling, and cold shut, and meet the internal quality requirements of the casting 200 under X-ray.

[0066] (2) The casting method can improve the accuracy of the sand core and reduce the deformation of the sand core through orderly steps, thereby improving the accuracy of the casting 200 and ensuring the size and wall thickness of the casting 200.

[0067] (3) Through precise core assembly process and the application of integrated design of core assembly fixture and testing fixture, the efficiency and accuracy of core assembly are improved.

[0068] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A casting system, characterized in that, include: The straight pouring channel (110), the first horizontal pouring channel (120), the second horizontal pouring channel (130), the third horizontal pouring channel (140), the fourth horizontal pouring channel (150), the inner pouring channel (160), and the slag collection bag (170); The first horizontal runner (120) is connected to both the sprue (110) and the second horizontal runner (130), the third horizontal runner (140) is connected to both the second horizontal runner (130) and the fourth horizontal runner (150), the ingate (160) is used to connect the fourth horizontal runner (150) and the casting (200), and the first horizontal runner (120), the second horizontal runner (130), the third horizontal runner (140) and the fourth horizontal runner (150) are all provided with the slag collection bag (170); The minimum cross-sectional area of ​​the ingate (160): the minimum cross-sectional area of ​​the fourth runner (150): the minimum cross-sectional area of ​​the third runner (140): the minimum cross-sectional area of ​​the second runner (130): the minimum cross-sectional area of ​​the first runner (120): the minimum cross-sectional area of ​​the sprue (110) = 1:(1.1~1.3):(1.4~1.5):(1.7~1.8):(2~2.1):(2.4~2.5).

2. The casting system according to claim 1, characterized in that, A pressure-stabilizing cavity (111) is formed at the end of the sprue (110).

3. The casting system according to claim 1, characterized in that, The casting system also includes an overlapping bridge (180) which is disposed at the connection of each casting channel.

4. The casting system according to claim 1, characterized in that, The gating system also includes a riser (190), which is cylindrical and is located in the middle of the reinforcing rib of the casting (200).

5. A casting method, characterized in that, Applied to the gating system according to any one of claims 1-4, the casting method includes a core-making process, a core-assembly process, a pouring process, a box-opening process, and a post-processing process performed sequentially.

6. The casting method according to claim 5, characterized in that, The core-making process includes: first, placing the core into a mold, and then filling it with sand and solidifying it.

7. The casting method according to claim 5, characterized in that, The core assembly process includes pre-core assembly and fine core assembly performed sequentially.

8. The casting method according to claim 5, characterized in that, The casting process includes: first heating the sandbag, and then performing low-pressure casting according to preset parameters.

9. The casting method according to claim 5, characterized in that, The unpacking process includes: removing the locking mechanism, removing the outer skin of the sandbag, transferring it to the sand-burning furnace for sand-burning treatment, and removing loose sand from the surface after the sand-burning is completed.

10. The casting method according to claim 5, characterized in that, The post-processing includes: first shaping the deformed area, and then transferring the casting (200).

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