A method of casting a double barrier

Abstract

The application relates to a casting method of a double-layer partition plate, which adopts a 3D printing + wooden mold process, a 3D printing sand core carries out a key part of a casting, namely a runner structure, only a simple mold is used in a modeling process, more live materials are not needed, quality risks caused by instability of the mold are eliminated, a mold manufacturing cycle is shortened, an operation process is simple, size precision is high, and quality defects of key structures of products are eliminated; in the modeling process, the 3D printing sand core is bonded with the sand mold as a whole, key parts of the casting do not need to be assembled, and assembling positioning, core marking and the like do not need to be set, and production efficiency and casting quality are effectively improved; compared with a simple wooden mold manufacturing process or a simple 3D printing process, or even compared with a simple combination process of the 3D printing sand core and the manual modeling sand mold, the 3D printing cooperates with the simple mold modeling mode, and all of the casting cost, the quality, the production efficiency and the like are greatly optimized.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a casting method for a double-layer partition. Background Technology

[0002] Compressor castings using double-layer baffle plates with runners require high-quality runners and face significant challenges in dimensional control. Current technology typically employs traditional wooden molds for production, necessitating the creation of a complete mold set for each baffle, resulting in high mold manufacturing costs and long production cycles. The runner is the most critical component of baffle castings. Due to its negative draft angle, the mold must be modified to achieve a positive draft angle. Furthermore, a single runner tooth requires the fabrication of one or more pieces of loose material, leading to a large quantity of loose material. The runner area is prone to damage during casting, and even with methods such as sandblasting, multiple coats of paint, and post-casting grinding, dimensional control remains difficult, easily resulting in large dimensional errors, sand inclusions, and even missing material. Summary of the Invention

[0003] Therefore, it is necessary to provide a casting method for a double-layer partition to address the aforementioned technical problems.

[0004] To solve the above problems, the present invention adopts the following technical solution:

[0005] This invention discloses a casting method for a double-layer partition, wherein the double-layer partition includes a first wall and a second wall, and a plurality of flow channels are provided between the first wall and the second wall. The casting method includes the following steps:

[0006] Core making: The first sand core is made using 3D printing, and the first sand core brings out the flow channel structure; the second sand core is made using manual core making, and the second sand core brings out the inner cavity structure.

[0007] The lower sand mold is formed by assembling the mold components and the first sand core on the molding platform, then fitting the lower sand box and allowing sand to flow, compact, and solidify to form a lower sand mold that is bonded to the first sand core.

[0008] After the upper sand box is shaped and flipped over, the lower sand box is placed on top of the upper sand box, and sand is poured, compacted, and solidified to form the upper sand mold;

[0009] Demolding: Vertically lift the upper sand box upwards and remove the mold assembly;

[0010] The second sand core is assembled into the lower sand mold, and the upper sand box is placed on top of the lower sand box to form a cavity for pouring molten metal.

[0011] In one embodiment, the mold assembly includes a main mold, a first auxiliary mold, and a second auxiliary mold. The main mold is used to form a cavity structure between the first wall and the second wall, and the first auxiliary mold and the second auxiliary mold are used for positioning the first sand core and forming a partial casting structure.

[0012] In one embodiment, the thickness of the main mold is greater than the distance between the first wall and the second wall.

[0013] In one embodiment, during the mold-removal step, the first auxiliary mold, the main mold, and the second auxiliary mold are removed sequentially.

[0014] In one embodiment, in the core-making step, the second sand core is manually made using a core-making main mold and a core-making auxiliary mold. The core-making main mold is used to form the core head and part of the gating system of the second sand core, and the core-making auxiliary mold is used to form the internal cavity structure.

[0015] In one embodiment, during the core-making step, the core-making auxiliary mold is assembled inside the core-making main mold. After sanding and compaction, the outer ring structure is smoothed along the top surface of the core-making main mold using a first scraper, and the inner ring structure is smoothed along the top surface of the core-making auxiliary mold using a second scraper.

[0016] In one embodiment, during the core assembly box step, a plurality of positioning box cones are further provided between the upper sand mold and the lower sand mold.

[0017] In one embodiment, in the lower box shaping step, a positioning box cone sleeve that matches the lower half of the positioning box cone is placed; in the upper box shaping step, a positioning box cone sleeve that matches the upper half of the positioning box cone is placed.

[0018] In one embodiment, the mold assembly is a wooden mold.

[0019] The technical solution adopted in this invention can achieve the following beneficial effects:

[0020] The casting method for double-layer partitions disclosed in this invention adopts 3D printing + wooden mold process. The 3D printed sand core brings out the key parts of the casting, namely the flow channel structure. Only a simple mold is needed in the molding process, without the need for a lot of raw material. This eliminates the quality risks caused by the instability of molds and raw materials, shortens the mold production cycle, simplifies the operation process, and ensures high dimensional accuracy, thus eliminating quality defects in the key structure of the product.

[0021] The double-layer partition casting method disclosed in this invention integrates the 3D printed sand core with the sand mold during the molding process. Key parts of the casting do not require core assembly, nor do they require core positioning or standard cores, which effectively improves production efficiency and casting quality.

[0022] The double-layer partition casting method disclosed in this invention, which combines 3D printing with a simple mold making method, is significantly optimized in terms of casting cost, quality, and production efficiency compared to simple wooden mold making or simple 3D printing process, or even simple combination of 3D printed sand core and hand-molded sand mold. Attached Figure Description

[0023] Figure 1 This is a sectional view of the lower sand box.

[0024] Figure 2 This is a sectional view of the sand box.

[0025] Figure 3 This is a structural schematic diagram of the main mold;

[0026] Figure 4 This is a schematic diagram of the structure of the first auxiliary mold;

[0027] Figure 5 This is a schematic diagram of the structure of the second auxiliary mold;

[0028] Figure 6 This is a schematic diagram of the structure of the first sand core;

[0029] Figure 7 An assembly diagram of the mold components and the first sand core;

[0030] Figure 8 This is a schematic diagram of the second sand core making process;

[0031] Figure 9 This is a diagram showing the combined container.

[0032] Explanation of reference numerals in the attached figures:

[0033] 110 - First sand core, 120 - Second sand core;

[0034] 210 - Upper sand mold, 220 - Lower sand mold;

[0035] 310 - Main mold, 320 - First auxiliary mold, 330 - Second auxiliary mold;

[0036] 410 - Core making main mold, 420 - Core making auxiliary mold, 430 - First scraper, 440 - Second scraper;

[0037] 510-Box cone sleeve;

[0038] 610 - Positioning component. Detailed Implementation

[0039] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0040] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," "top," "bottom," "end," "top," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0042] This invention discloses a casting method for a double-layer partition plate. The double-layer partition plate is a double-layer structure composed of a first wall and a second wall, with multiple flow channels provided between the first and second walls. These flow channels are a key structure of the double-layer partition plate. The casting method of this invention utilizes 3D printing combined with manual molding to create sand molds. The sand core forming the key structure of the casting is created using 3D printing. During molding, a simple mold and the 3D-printed sand core work together, bonding the 3D-printed sand core to the sand mold. After the mold is removed, the 3D-printed sand core remains within the sand mold and is integrated with it. This 3D printing combined with manual molding method effectively simplifies the casting process, reduces operational difficulty, and eliminates the need for large amounts of raw material to create sand cores that form the key flow channel structure. The sand core and sand mold are reliably connected, ensuring casting accuracy of the flow channel structure without the need for positioning cores or standard cores, thus improving the casting quality of the double-layer partition plate. The mold structure is simple and few in number, significantly optimizing casting quality, production efficiency, and casting cost.

[0043] like Figures 1 to 9 As shown, the casting method disclosed in the embodiments of the present invention may include the following steps:

[0044] Design includes sand core design, sand mold design, mold design, and gating system design.

[0045] The sand core design includes a first sand core 110 and a second sand core 120, wherein the first sand core 110 brings out the flow channel structure, and the second sand core 120 brings out the internal cavity structure other than the flow channel structure.

[0046] The sand mold design consists of an upper sand mold 210 and a lower sand mold 220, with most of the casting structure located within the lower sand mold 220.

[0047] The molding die design uses a simple die assembly to work with the first sand core 110 to create upper and lower sand molds. The die assembly may include a main die 310, a first auxiliary die 320, and a second auxiliary die 330. The main die 310 is used to form the cavity structure between the first wall and the second wall. The thickness of the main die 310 is preferably greater than the distance between the first and second walls to ensure that the cavity structure between the two walls is within the lower sand mold 220. The main die 310 can also bring out the positioning structure between the lower sand mold 220 and the second sand core 120. The first auxiliary die 320 and the second auxiliary die 330 bring out the positioning structure of the first sand core 110 and part of the casting structure.

[0048] The design of the core-making mold includes a main core mold 410 and an auxiliary core mold 420 for making the second sand core 120. The main core mold 410 provides the matching and positioning structure between the second sand core 120 and the sand mold, while the auxiliary core mold 420 provides the internal cavity structure of the casting.

[0049] The gating system is designed such that a portion of the gating system is set inside the upper and lower sand molds, and a portion of the gating system can be brought out by both the main mold 310 and the core-making main mold 410.

[0050] Core making involves fabricating a first sand core 110 and a second sand core 120 according to the sand core design. The first sand core 110 is fabricated using 3D printing, while the second sand core 120 is fabricated by hand.

[0051] The specific method for making the second sand core (120) is as follows: Figure 8 As shown, the core-making auxiliary mold 420 is assembled at the corresponding position of the core-making main mold 410. Resin sand is filled and compacted into the cavity between the core-making main mold 410 and the core-making auxiliary mold 420, as well as into the recessed structure of the core-making auxiliary mold 420. The outer ring structure is smoothed along the top surface of the core-making main mold 410 using a first scraper 430, and the inner ring structure is smoothed along the top surface of the core-making auxiliary mold 420 using a second scraper 440. After the resin sand has cured, the core-making main mold 410 and the core-making auxiliary mold 420 are removed, thus forming a second sand core 120 with an inner ring structure and an outer ring structure. The outer ring structure is used to fit and position with the sand mold, and the inner ring structure is used to form the internal cavity structure of the casting.

[0052] It should be noted that in this application, resin sand is foundry sand that has been mixed with resin and curing agent in advance according to the specified ratio.

[0053] For the shaping process, first shape the lower box to form the lower sand mold 220, then flip the lower sand box over and shape the upper box to form the upper sand mold 210.

[0054] Specifically, the first auxiliary mold 320, the main mold 310, and the second auxiliary mold 330 can be sequentially assembled on the molding platform, wherein the first auxiliary mold 320 is assembled at the arc segment of the semicircular inner ring of the main mold 310, and the second auxiliary mold 330 is assembled at the straight segment of the semicircular inner ring of the main mold 310. Then, as... Figure 7 As shown, the first sand core 110 is assembled onto the mold assembly, with the flow channel structure of the first sand core 110 facing the mold assembly; and at least three cone sleeves 510 are spaced apart around the mold assembly, with the openings of the cone sleeves 510 facing downwards. The lower sand box is inverted on the molding platform, and the assembled mold assembly, cone sleeves 510, and first sand core 110 are all inside the lower sand box. Sand is poured into the lower sand box and compacted for molding. After solidification, the lower sand mold 220 is formed. The structure of the lower mold after molding is as follows. Figure 1 As shown, the first sand core 110 is bonded to the lower sand mold 220 as a whole during the curing process of the lower sand mold 220, and no additional core is required in the subsequent process, nor are positioning cores or standard cores required between the two.

[0055] like Figure 2 As shown, the lower sand box is flipped 180° so that its opening faces upward. Each box cone sleeve 510 is inserted into its matching box cone, and the other half of the box cone sleeve 510 is then fitted on. The upper sand box is placed on the lower sand box, and sand is poured into it and compacted. After the resin sand cures, the upper sand mold 210 is formed. It should be noted that if the first auxiliary mold 320 remains on the molding platform during the flipping process, it should be reassembled into the semi-circular inner ring of the main mold 310 before molding the upper box.

[0056] After molding, the upper sand box is lifted vertically upwards first, followed by the mold assembly and the cone. Specifically, the first auxiliary mold 320, the main mold 310, and the second auxiliary mold 330 should be lifted out in sequence, while the first sand core 110 remains in the lower sand mold 220 and does not need to be lifted out.

[0057] Core assembly, such as Figure 9 As shown, the positioning structure of the lower sand mold 220 incorporates the positioning component 610, and the second sand core 120 is assembled into the lower sand mold 220 according to the positioning reference of the positioning component 610.

[0058] The mold is assembled by placing the mold cone inside the mold cone sleeve 510. Based on the positioning reference of the three mold cones, the upper sand mold is assembled on the lower sand mold, and a cavity for containing molten metal is formed between the upper and lower sand molds and inside the first sand core 110 and the second sand core 120.

[0059] Casting involves injecting molten metal into the mold cavity through a gating system, which solidifies to form a double-layer partition casting.

[0060] In the embodiments disclosed in this invention, the mold can be a wooden mold, that is, the mold components and the core-making main mold 410 and core-making auxiliary mold 420 can all be wooden molds.

[0061] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A casting method of a double-layer separator including a first wall and a second wall with a plurality of flow channels provided between the first wall and the second wall, characterized by, The casting method The method comprises the following steps: core making, a first sand core is made by 3D printing, the first sand core brings out a runner structure; a second sand core is made by manual core making, the second sand core brings out an internal cavity structure; lower box molding, the mold assembly and the first sand core are assembled on a molding platform, a lower sand box is sleeved, and after sand flowing, compacting and solidifying, a lower sand mold which is integrated with the first sand core is formed; upper box molding, after turning over the box, an upper sand box is placed on the lower sand box and after sand flowing, compacting and solidifying, an upper sand mold is formed; mold stripping, the upper sand box is vertically lifted up, and the mold assembly is taken out; core assembling and box closing, the second sand core is assembled into the lower sand mold, and the upper sand box is closed on the lower sand box, thereby forming a mold cavity for pouring metal liquid; the mold assembly comprises a main mold, a first auxiliary mold and a second auxiliary mold, the main mold is used for forming a cavity structure between the first wall and the second wall, and the first auxiliary mold and the second auxiliary mold are used for first sand core positioning and forming part of a casting structure.

2. The casting method of a double-layer separator according to claim 1, characterized by, The thickness of the main mold is greater than the spacing between the first wall and the second wall.

3. The dual barrier casting method of claim 1, wherein, In the mold stripping step, the first auxiliary mold, the main mold and the second auxiliary mold are sequentially taken out.

4. The dual barrier casting method of claim 1, wherein In the core making step, the second sand core is manually made by using a core making main mold and a core making auxiliary mold, the core making main mold is used for forming a core head and part of a pouring system of the second sand core, and the core making auxiliary mold is used for forming an internal cavity structure.

5. The dual barrier casting method of claim 4, wherein, In the core making step, the core making auxiliary mold is assembled in the core making main mold, after sand flowing and compacting, a first scraper is used to scrape a flat outer ring structure along a top surface of the core making main mold, and a second scraper is used to scrape a flat inner ring structure along a top surface of the core making auxiliary mold.

6. The dual barrier casting method of claim 1, wherein, In the core assembling and box closing step, a plurality of positioning box cones are further arranged between the upper sand mold and the lower sand mold.

7. The dual barrier casting method of claim 6, wherein, In the lower box molding step, a positioning box cone sleeve which matches a lower half of the positioning box cone is placed; in the upper box molding step, a positioning box cone sleeve which matches an upper half of the positioning box cone is placed.

8. The method of casting a bi-layer separator according to any one of claims 1-7, wherein, The mold assembly is a wooden mold.

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