Casting device and casting process of water-cooled compressor body

Abstract

The invention discloses a casting device and a casting process for a water-cooled compressor body, which belong to the technical field of mechanical casting, and are characterized in that blind holes are formed in positioning core heads of a water jacket core, the water jacket core is in a transverse 8 shape, the positioning core heads are arranged on the upper end surface and the lower end surface of the water jacket core, and a riser I and a riser II are connected in series through a runner; v-shaped grooves are formed in the tops of the riser I and the riser II. The casting mold has the beneficial effects that the pressure-buffering water inlet device is arranged on the outer side of the casting outer mold on the crankcase flange side of the casting, the sand tire is used for preparing the outer pouring gate cavity, the problems of uneven pressure, uneven temperature, turbulent flow, splashing and the like generated by molten iron in a mold filling state in a horizontal casting mode are solved, and therefore the problems of slag inclusion of the crankcase of the engine body casting, high casting quality and the like are solved. And casting defects such as cold shut are overcome.

Description

Technical field:

[0001] The invention belongs to the technical field of mechanical casting, and more specifically relates to a casting device and a casting process for a water-cooled compressor body. Background technology:

[0002] Air compressors for vehicles are core components of commercial vehicles and are mainly used in braking, door and window opening, air suspension, and vehicle body roll. Most commercial vehicle air compressors are reciprocating piston air compressors, including air-cooled and water-cooled types. Water-cooled compressors are much superior to air-cooled compressors in terms of service life, high pressure resistance, low energy consumption, and high adaptability.

[0003] The water-cooled compressors for commercial vehicles have low casting yield and high casting costs, which makes it difficult for water-cooled compressors to replace air-cooled compressors in the market. Therefore, it is necessary to design a casting device and casting process for the water-cooled compressors for commercial vehicles to meet market demand. Summary of the invention:

[0004] In order to solve the above problems and overcome the shortcomings of the prior art, the present invention provides a casting device and a casting process for a water-cooled compressor body, which can effectively solve the casting defects of the water-cooled compressor body. The water-cooled compressor body is a thin-walled complex casting. There is a water circulation cooling chamber structure in the piston cylinder part. This structure requires a water jacket core to be arranged in the casting cavity. When the molten iron fills the casting cavity, the surface of the casting quickly crusts and solidifies. The gas generated by the water jacket core is not enough to escape before the crust forms on the surface of the casting, resulting in the problem of pores in the piston cylinder area.

[0005] The specific technical solution of the present invention to solve the above technical problems is: a casting device for a water-cooled compressor body, characterized by comprising:

[0006] Using sand tires to prepare the casting outer mold and pouring system of the outer runner cavity; arranging two casting outer molds in a centrally symmetrical manner, and arranging the pouring system between the two casting outer molds;

[0007] The casting outer mold comprises an upper mold plate and a lower mold plate, a casting cavity is formed between the upper mold plate and the lower mold plate of the casting outer mold, and a sand core is arranged in the casting cavity.

[0008] The sand tire and the sand core enclose a casting cavity for casting a water-cooled compressor body;

[0009] The sand core includes a body core, an end face core, a water jacket core, and a top plate core; the water jacket core is adapted to the structure of the water circulation cooling chamber of the casting.

[0010] The pouring system includes a pouring cup, a sprue, a filter, a runner I, a pressure-relief water inlet, a slag collecting bag, a runner II, a runner III and an exhaust needle. The pressure-relief water inlet counter-pressures the runner I. A slag collecting bag is provided at the junction of the runner I and the runner II. The runner III counter-pressures the runner II. The runner III connects the riser I and the riser II.

[0011] Furthermore, the water jacket core, the body core and the top plate core are fixedly connected to the sand tire via a positioning core head.

[0012] Furthermore, a blind hole is arranged on the positioning core head of the water jacket core, the water jacket core is in a horizontal figure 8 shape, positioning core heads are arranged on both upper and lower end surfaces of the water jacket core, and a positioning core head is arranged on one side of the water jacket core.

[0013] Furthermore, the riser I and the riser II are connected in series through a flow channel.

[0014] Furthermore, V-shaped grooves are provided on the tops of the risers I and II.

[0015] Furthermore, the riser I and the riser II are arranged opposite to the middle depression and the bottom of the water jacket core, and no positioning core head is arranged at the bottom of the water jacket core.

[0016] Furthermore, the body core is configured as a stealing core structure.

[0017] Furthermore, the pressure-relief water inlet device is a U-shaped structure, including a back-pressure plate, and both ends of the back-pressure plate form a preset device belly, and the two device bellies are respectively provided with water inlet ends.

[0018] A casting process for a water-cooled compressor body, using the casting device for the water-cooled compressor body, comprises the following steps:

[0019] Step 1: Drill a blind hole in the center of the core head of the water jacket core of the prefabricated sand core by using a pistol drill;

[0020] Step 2: Place the casting outer mold and pouring system on the molding equipment, put a sand box in it and fill it with molding sand to form a sand mold;

[0021] Step 3: Remove the casting outer mold and the pouring system. The pouring cup, sprue, filter, runner I, pressure relief water inlet, slag bag, runner II, runner III and exhaust needle of the pouring system form an outer pouring cavity in the sand tire.

[0022] Step 4: The water jacket core is placed in the piston cylinder area of ​​the body core, and the top plate core is placed on the body core through the positioning core head to form a sand core assembly. The sand core assembly is placed on the sand tire with the sand core positioning core head, and the filter is installed in the outer runner cavity where the filter is installed;

[0023] Step 5: The molten cast iron flows through the pouring cup, the sprue, the filter sheet, the runner, and the sand mold to form an outer runner cavity and enter the slag collecting bag cavity by gravity;

[0024] In step 6, the molten cast iron is poured into the pouring cavity through the external runner cavity formed by the slow-pressure water inlet device under pressure, and is poured into the pouring cavity through the external runner cavity formed by riser I and riser II and the sand mold, and solidifies in the pouring cavity.

[0025] Step 7: Remove the sand box and sand core to obtain the solidified water-cooled compressor body.

[0026] The beneficial effects of the present invention are:

[0027] The present invention creatively adopts a water jacket core casting device with a horizontal figure 8 shape to obtain a water-cooled compressor body with a water circulation cooling cavity structure by casting, thereby solving the problem that the water-cooled compressor body is difficult to replace the air-cooled compressor market due to low casting yield and high casting cost.

[0028] The present invention creatively arranges a pressure-relief water inlet device on the outer side of the casting outer mold located on the crankcase flange side of the casting, and uses a sand mold to prepare the outer runner cavity, thereby solving the problems of uneven pressure, uneven temperature, turbulence, splashing, etc. generated by molten iron in the horizontal casting mode when the mold is filled, thereby solving the casting defects such as slag inclusion and cold shut of the crankcase of the body casting;

[0029] The present invention adopts sand core drilling and exhaust, thus solving the problems that the surface area of ​​the water circulation cooling chamber is large and in a horizontal 8 shape, the temperature drops quickly during filling, and there are dead corners, which are easy to produce defects such as sand slag eyes, cold shuts, and air holes.

[0030] The present invention adopts a special riser design, and the bottom of the riser is penetrated by a horizontal runner to make the riser liquid inlet height balanced. Since the gas flows from bottom to top in the molten iron and transfers from high pressure to low pressure, the body casting is quickly crusted after the filling is completed. The design of the V-shaped groove of the riser solves the problem of rapid crusting on the top of the riser. Description of the drawings:

[0031] Figure 1 It is a schematic diagram of the use structure of the casting device of the water-cooled compressor body of the present invention;

[0032] Figure 2 It is a cross-sectional structural schematic diagram of a casting device for a water-cooled compressor body of the present invention;

[0033] Figure 3 It is a schematic diagram of the structure of the pouring cavity and the outer runner cavity enclosed by the sand tire and sand core assembly of the present invention;

[0034] Figure 4 It is a schematic diagram of the water jacket core and riser space structure of the casting device of the water-cooled compressor body of the present invention;

[0035] Figure 5 It is a schematic structural diagram of riser I and riser II of a casting device for a water-cooled compressor body of the present invention;

[0036] Figure 6 It is a schematic diagram of the structure of the pressure-relief water inlet device of the casting device of the water-cooled compressor body of the present invention;

[0037] Figure 7 It is a schematic diagram of the top view of the water-cooled compressor body of the invented product casting;

[0038] Figure 8 This is a cross-sectional view of the water circulation cooling chamber BB of the water-cooled compressor body of the invention product casting;

[0039] Fig. 9 This is the AA cross-sectional view of the piston cylinder of the water-cooled compressor body of the invention product casting; in the accompanying drawings:

[0040] 1. pouring cup, 2. sprue, 3. filter, 4. runner I, 5. slow pressure water inlet, 6. slag collecting bag, 7. runner II, 8. runner III, 9. riser I, 10. riser II, 11. body core, 12. top plate core, 13. end face core, 14. water jacket core, 15. exhaust needle, 16. V-groove, 17. pouring cavity, 18. external runner cavity, 51. back pressure plate, 52. vessel belly, 53. water inlet end. Specific implementation method:

[0041] In the description of the present invention, specific details are only for a full understanding of the embodiments of the present invention, but those skilled in the art should know that the implementation of the present invention is not limited to these details. In addition, well-known structures and functions are not described or shown in detail to avoid blurring the key points of the embodiments of the present invention. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] Specific implementation of the present invention:

[0043] In order to better understand the present invention, a specific embodiment is used for illustration. It is worth emphasizing that the effect of this embodiment is not substantially different from the various embodiments within the protection scope of the present invention, including the respective reagents and the content ratio of the reagents, and all of them can achieve the effects described in the present invention and solve the above-mentioned problems. Other combinations are not described here.

[0044] A casting device for a water-cooled compressor body, characterized in that it comprises:

[0045] Using sand tires to prepare the casting outer mold and pouring system of the outer runner cavity 18; arranging two casting outer molds in a centrally symmetrical manner, and arranging the pouring system between the two casting outer molds;

[0046] The casting outer mold comprises an upper mold plate and a lower mold plate, a casting cavity is formed between the upper mold plate and the lower mold plate of the casting outer mold, and a sand core can be arranged in the casting cavity.

[0047] The sand tire and the sand core enclose a casting cavity 17 for casting a water-cooled compressor body;

[0048] The sand core comprises a body core 11, an end face core 13, a water jacket core 14, and a top plate core 12; the water jacket core 14 is adapted to the structure of the water circulation cooling chamber of the casting.

[0049] The pouring system includes a pouring cup 1, a sprue 2, a filter plate 3, a runner Ⅰ4, a pressure-relief water inlet 5, a slag collecting bag 6, a runner Ⅱ7, a runner Ⅲ8 and an exhaust needle 15. The pressure-relief water inlet 5 counter-pressures the runner Ⅰ4. A slag collecting bag 6 is provided at the junction of the runner Ⅰ4 and the runner Ⅱ7. The runner Ⅲ8 counter-pressures the runner Ⅱ7. The runner Ⅲ8 connects the riser Ⅰ9 and the riser Ⅱ10.

[0050] Furthermore, the water jacket core 14, the body core 11 and the top plate core 12 are fixedly connected to the sand tire via a positioning core head.

[0051] Furthermore, a blind hole is arranged on the positioning core head of the water jacket core 14 . The water jacket core 14 is in a horizontal 8 shape. Positioning core heads are arranged on both upper and lower end surfaces of the water jacket core 14 , and a positioning core head is arranged on one side of the water jacket core 14 .

[0052] Furthermore, the riser I9 and the riser II10 are connected in series via a flow channel.

[0053] Furthermore, a V-shaped groove 16 is provided on the top of the riser I9 and the riser II10.

[0054] Furthermore, the riser I9 and the riser II10 are arranged opposite to the middle depression and the bottom of the water jacket core 14 , and no positioning core head is arranged at the bottom of the water jacket core 14 .

[0055] Furthermore, the body core 11 is configured as a stealing core structure.

[0056] Furthermore, the pressure-relief water inlet 5 is a U-shaped structure, including a back-pressure plate 51, two ends of the back-pressure plate form a preset device belly 52, and the two device bellies are respectively provided with water inlet ends 53.

[0057] A casting process for a water-cooled compressor body, using a casting device for a water-cooled compressor body, comprises the following steps:

[0058] Step 1: Drill a blind hole in the center of the core head of the water jacket core 14 of the prefabricated sand core by using a pistol drill;

[0059] Step 2: Place the casting outer mold and pouring system on the molding equipment, put a sand box in it and fill it with molding sand to form a sand mold;

[0060] Step 3: Remove the casting outer mold and the pouring system. The pouring cup 1, sprue 2, filter 3, runner I 4, slow pressure water inlet 5, slag collection bag 6, runner II 7, runner III 8 and exhaust needle 15 of the pouring system form an outer pouring cavity 18 on the sand tire.

[0061] Step 4: The water jacket core 14 is placed on the piston cylinder area of ​​the body core, and the top plate core 12 is placed on the body core 11 through the positioning core head to form a sand core assembly. The sand core assembly is placed on the sand tire with the sand core positioning core head, and the filter disc 3 is installed in the outer runner cavity 18;

[0062] Step 5: The molten cast iron is passed through the pouring cup 1, the sprue 2, and the runner 4 in sequence by gravity to form an outer pouring channel cavity 18 in the sand mold and enter the cavity of the slag collecting bag 6;

[0063] In step 6, the molten cast iron is poured into the pouring cavity 17 through the outer runner cavity 18 formed by the slow-pressure water inlet 5 by pressure, and poured into the pouring cavity 17 through the outer runner cavity 18 formed by the riser Ⅰ9 and the riser Ⅱ10 and the sand mold, and solidified in the pouring cavity 17.

[0064] Step 7: Remove the sand box and sand core to obtain the solidified water-cooled compressor body.

[0065] In order to more intuitively demonstrate the product advantages of the present invention, a comparison is made.

[0066] Comparative Example 1:

[0067] For example, application publication number CN113426957 discloses a low-gassing water jacket core structure and a core assembly method thereof, wherein the casting is a water-cooled compressor body with a water circulation cooling cavity structure; the device can realize the casting of a water-cooled compressor body with a water circulation cooling cavity structure, but the device adopts a full-core vertical casting method, the water jacket core adopts pearl sand as the raw material, and has a multi-core bone design, which is costly and difficult to operate, and pores are easily generated at the core bone position, resulting in a high rate of defective products;

[0068] Comparative Example 2:

[0069] The difference is that the slow-pressure water inlet before the casting is replaced by a conventional thin-sheet water inlet. After the outer runner cavity 18 is prepared by using a sand tire, the filling speed of the conventional thin-sheet water inlet at this position reaches 1.5-2m / s, and the iron liquid splashes significantly, and the air rolls are formed, resulting in the appearance of irregular air holes in the casting.

[0070] The applicant also tried to reduce the filling speed to 1.5-2m / s. Generally, the method of adding risers is adopted. However, it is impossible to reduce the filling speed by adding risers here. The reason is that the casting water-cooled compressor body is a one-mold two-cavity structure, which results in no position for adding risers.

[0071] The design of the pressure-relief water inlet of the present invention controls the liquid flow rate of the water inlet of the external runner cavity 18 to be 0.8m / S, which can achieve the easy cutting effect of a thin-film water inlet and meet the demand for reducing the filling speed. It solves the problem of obvious iron liquid splashing and irregular air holes in the casting caused by the formation of air rolls due to the filling speed reaching 1.5-2m / s, and makes the liquid inlet time difference at the front and rear ends of the casting consistent, achieving constant pressure and equal flow under the ideal effect, and the organization of each position of the body is more uniform.

[0072] Comparative Example 3;

[0073] The design of the riser is the same as that of the present invention, except that the bottom of the riser I9 and the riser II10 is penetrated by the cross runner, and the top of the riser is not provided with a V-shaped groove 16. After the outer runner cavity 18 is prepared by using a sand mold, the crust on the top of the riser of the outer runner cavity 18 is aggravated, and the riser necks of the two outer runner cavities 18 are unevenly filled with water, and the gas has nowhere to escape;

[0074] The principle is as follows: the bottoms of risers Ⅰ9 and Ⅱ10 are connected by a cross runner, so that the liquid inlet heights of the two risers of the outer runner cavity 18 are balanced, and the temperature is continuously kept at a high temperature. Since the gas flows from bottom to top in the molten iron, it transfers from high pressure to low pressure. The body casting quickly forms a shell after the filling is completed. The solidification time of the riser neck of the outer runner cavity 18 lags by 5-10 minutes, and the gas generation time of the low gas generation sand core is 60-80s. There is a gas transfer channel.

[0075] Comparative Example 4;

[0076] The design of the riser is the same as that of the present invention, except that the riser I9 and the riser II10 are not through-going, and a V-shaped groove 16 is provided on the top of the riser, which will cause the bottom top of the outer runner cavity 18 at one end to rapidly form a crust;

[0077] The principle is as follows: a V-shaped groove 16 is provided at the top of the riser. The design of the V-shaped groove 16 is adapted to the delayed solidification of the V-shaped bottom area, thereby solving the problem of rapid crusting of the riser top of the external runner cavity 18, forming a high-pressure riser, and secondarily eliminating the pores formed in the blind area of ​​the sand core.

[0078] In summary, the present invention creatively adopts a water jacket core casting device with a horizontal figure 8 shape to obtain a water-cooled compressor body with a water circulation cooling cavity structure by casting, thereby solving the problem that the water-cooled compressor body is difficult to replace the air-cooled compressor market due to the low casting yield and high casting cost.

[0079] The present invention creatively arranges a pressure-relief water inlet on the outer side of the casting outer mold located on the crankcase flange side of the casting, thereby solving the problems of uneven pressure, uneven temperature, turbulence, splashing, etc. generated by molten iron in the horizontal casting mode when the mold is filled, thereby solving the casting defects such as slag inclusion and cold shut of the crankcase of the engine casting;

[0080] The present invention adopts sand core punching and exhaust, thus solving the problems that the water-cooled compressor body has thin wall, large surface area and horizontal 8 shape, and the temperature drops very fast during filling and dead corners, which easily cause sand slag eyes, cold shut and other defects.

[0081] The present invention adopts a special riser design, and the bottom of the riser is penetrated by a horizontal runner to make the riser liquid inlet height balanced. Since the gas flows from bottom to top in the molten iron and transfers from high pressure to low pressure, the body casting is quickly crusted after the filling is completed. The design of the V-shaped groove 16 of the riser solves the problem of rapid crusting on the top of the riser.

Claims

1. A casting device for a water-cooled compressor body, characterized in that include: Using a sand mold to prepare a casting outer mold and a pouring system of an outer runner cavity (18); arranging two casting outer molds in a centrally symmetrical manner, and arranging a pouring system between the two casting outer molds; The casting outer mold comprises an upper mold plate and a lower mold plate, a casting cavity is formed between the upper mold plate and the lower mold plate of the casting outer mold, and a sand core is arranged in the casting cavity. A casting cavity (17) for casting a water-cooled compressor body is enclosed between the sand tire and the sand core; The sand core comprises a body core (11), an end face core (13), a water jacket core (14), and a top plate core (12); the water jacket core (14) is adapted to the structure of a water circulation cooling chamber of a casting. The pouring system comprises a pouring cup (1), a sprue (2), a filter (3), a runner I (4), a pressure-relief water inlet (5), a slag collecting bag (6), a runner II (7), a runner III (8) and an exhaust needle (15). The pressure-relief water inlet (5) applies counter pressure to the runner I (4). A slag collecting bag (6) is provided at the junction of the runner I (4) and the runner II (7). The runner III (8) applies counter pressure to the runner II (7). The runner III (8) is connected to the riser I (9) and the riser II (10).

2. The casting device for a water-cooled compressor body according to claim 1, characterized in that The water jacket core (14), the machine body core (11) and the top plate core (12) are fixedly connected to the sand tire via a positioning core head.

3. The casting device for a water-cooled compressor body according to claim 2, characterized in that A blind hole is arranged on the positioning core head of the water jacket core (14); the water jacket core (14) is in a horizontal 8-shape; positioning core heads are arranged on both upper and lower end surfaces of the water jacket core (14); and a positioning core head is arranged on one side of the water jacket core (14).

4. The casting device for a water-cooled compressor body according to claim 3, characterized in that The riser I (9) and the riser II (10) are connected in series via a flow channel.

5. The casting device for a water-cooled compressor body according to claim 4, characterized in that The tops of the riser I (9) and the riser II (10) are both provided with V-shaped grooves (16).

6. The casting device for a water-cooled compressor body according to claim 5, characterized in that The riser I (9) and the riser II (10) are arranged opposite to the middle depression and the bottom of the water jacket core (14), and no positioning core head is arranged at the bottom of the water jacket core (14).

7. The casting device for a water-cooled compressor body according to claim 1, characterized in that The machine body core (11) is configured as a stealing core structure.

8. The casting device for a water-cooled compressor body according to claim 1, characterized in that The slow-pressure water inlet (5) is a U-shaped structure, comprising a back-pressure plate (51), the two ends of the back-pressure plate forming a preset device belly (52), and the two device bellies are respectively provided with water inlet ends (53).

9. A casting process for a water-cooled compressor body, using the casting device for a water-cooled compressor body according to any one of claims 1 to 8, comprising the following steps: Step 1: Drill a blind hole at the center of the core head of the water jacket core (14) of the prefabricated sand core by using a pistol drill; Step 2: Place the casting outer mold and pouring system on the molding equipment, put a sand box in it and fill it with molding sand to form a sand mold; Step 3, remove the casting outer mold and the pouring system, and the pouring cup (1), the sprue (2), the filter (3), the runner I (4), the slow pressure water inlet (5), the slag collecting bag (6), the runner II (7), the runner III (8) and the exhaust needle (15) of the pouring system form an outer runner cavity (18) on the sand tire; Step 4: The water jacket core (14) is sleeved on the piston cylinder area of ​​the body core, and the top plate core (12) is placed on the body core (11) through the positioning core head to form a sand core assembly. The sand core assembly is placed on the sand tire with the sand core positioning core head, and the filter disc (3) is installed in the outer runner cavity (18); Step 5, the molten cast iron flows through the pouring cup (1), the sprue (2), the filter plate (3) in sequence by gravity, flows through the runner (4), forms an outer pouring cavity (18) in the sand mold, and enters the cavity of the slag collecting bag (6); In step 6, the molten cast iron is poured into the pouring cavity (17) by pressure through the external pouring cavity (18) formed by the slow pressure water inlet (5), and poured into the pouring cavity (17) through the external pouring cavity (18) formed by the riser I (9) and the riser II (10) and the sand mold, and solidified in the pouring cavity (17); Step 7: Remove the sand box and sand core to obtain the solidified water-cooled compressor body.

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