Stepped casting system for engine cylinder block

Abstract

The invention discloses a stepped casting system for an engine cylinder block, and belongs to the field of casting. According to the technical scheme, the stepped casting system for the engine cylinder block comprises a main pouring gate part, the main pouring gate part comprises a transverse main pouring gate, a plurality of branch pouring gate parts are arranged below the transverse main pouring gate, each branch pouring gate part comprises a first vertical pouring gate, the first vertical pouring gates are connected with middle pouring gates, the other ends of the middle pouring gates are connected with branch pouring gates, and the branch pouring gates are connected with the transverse main pouring gate. The shunting pouring gate is vertically arranged, the lower end of the shunting pouring gate is connected with a first inner pouring gate, and the upper end of the shunting pouring gate is connected with a second inner pouring gate. In the casting process, liquid metal is divided into two layers and enters a cavity in a stepped mode, scouring to the cavity is relieved, liquid metal mold filling is stable, exhausting of the cavity is facilitated, after mold filling, the temperature of the liquid metal at different height positions is guaranteed, the liquid metal mold filling speed is high, the liquid metal mold filling is stable, and solidification is balanced; the occurrence of slag holes, air holes, sand holes and shrinkage porosity defects which are not easy to find is greatly reduced, and the casting yield is improved.

Description

Technical Field

[0001] The invention relates to the field of casting, and in particular to a stepped casting system for an engine cylinder block. Background Art

[0002] As the core component of the engine, the quality of the diesel engine cylinder block directly affects the performance and life of the engine. Therefore, it is very important to adopt a reasonable casting process in the casting process of the cylinder block. Sand casting technology has been widely used in the production of diesel engine cylinder blocks due to its good adaptability and high cost-effectiveness. However, in the actual production process, the design of the casting system and casting defects have always plagued production companies.

[0003] In the process of cylinder casting, the pouring of liquid metal is a key link. The three-layer stepped casting method currently used, although it guarantees the fluidity and shrinkage compensation effect of the molten metal to a certain extent, still has many problems. First, the structure of the casting system is relatively complex, including bottom pouring and upper and lower middle pouring, which undoubtedly increases the difficulty of operation in the production process. Secondly, the straight-hole ceramic filter has a certain effect in filtering impurities, but it is still difficult to completely avoid defects in castings.

[0004] In the production process, common casting defects include slag holes, shrinkage, air holes, sand holes, etc. The formation of slag holes is mainly due to the impurities in the cavity or the low melting point substances in the liquid metal entering the cavity, resulting in the formation of holes. These holes are irregular in shape, shallow in depth, and the surface inside the hole is smooth and shiny, colorful, similar to enamel. The existence of slag holes seriously affects the strength and sealing performance of the casting, and may cause oil leakage, air leakage and other problems in the engine during operation.

[0005] Although the three-layer stepped casting system guarantees the molding quality of the castings to a certain extent, it also increases the workload of cleaning and grinding the castings. During the processing, the cylinder castings need to be strictly inspected to ensure that there are no defects such as slag holes and shrinkage. However, due to the existence of casting defects, the castings are often scrapped, which not only increases production costs, but also reduces production efficiency. Summary of the invention

[0006] Aiming at the problem that the current molten metal is cooled in layers and causes casting defects, the present invention provides an engine cylinder body stepped casting system.

[0007] In order to solve the above problems, the technical solution adopted by the present invention is a stepped casting system for an engine cylinder block, including a main runner part, the main runner part includes a transverse main runner, and a plurality of branch runner parts are arranged below the transverse main runner. The branch runner part includes a first vertical runner, the first vertical runner is connected to an intermediate runner, and the other end of the intermediate runner is connected to a diversion runner, the diversion runner is vertically arranged, the lower end of the diversion runner is connected to a first ingrate, the upper end of the diversion runner is connected to a second ingrate, and the first ingrate and the second ingrate are horizontally arranged. The liquid metal is injected into the cavity from the first ingend to the bottom layer and the middle and lower layers of the mold, and is injected into the cavity from the second ingend to the middle layer and the top layer of the mold. During the casting process, the liquid metal is divided into two layers and enters the cavity in a stepped manner, which slows down the scouring of the cavity. The liquid metal fills the mold smoothly, which is beneficial to the exhaust of the cavity. After filling, the temperature of the liquid metal at different heights is guaranteed. The liquid metal fills the mold quickly, steadily and solidifies evenly. The casting has a dense structure, which greatly reduces the occurrence of slag holes, air holes, sand holes and shrinkage defects that are not easy to find, and improves the casting yield.

[0008] As a preferred embodiment of the stepped casting system for an engine cylinder block, the branch runner includes a first branch runner and a second branch runner, and the middle runner is connected to the connection between the first branch runner and the second branch runner.

[0009] As a preferred embodiment of the stepped casting system for an engine block, the middle runner forms an angle of 72° with the first branch runner, and the middle runner forms an angle of 62° with the second branch runner. The middle runner is located outside the angle between the first branch runner and the second branch runner. Through the angle design, it can effectively ensure that the liquid metal enters the branch runner smoothly.

[0010] As a preferred embodiment of the stepped casting system for an engine block, the first ingrate and the first branching runner form an angle of 72°, and the second ingrate and the second branching runner form an angle of 105°. The angle design can effectively ensure that the liquid metal smoothly enters the branching runner.

[0011] As a preferred embodiment of the stepped casting system for an engine block, the connection between the first ingates and the cavity is in a diffused bell-mouth shape, and the connection between the second ingates and the cavity is in a diffused bell-mouth shape, which can effectively reduce the scouring of the interior of the cavity by the molten metal.

[0012] As a preferred embodiment of the stepped casting system of an engine block, the transverse main runner includes a first runner, the two ends of the first runner are respectively connected to the second runner, the ends of the second runners on both sides away from the first runner are connected to the third runner, and the inner cavity cross-sectional areas of the first runner, the second runner and the third runner decrease in sequence, so that the molten metal is more evenly distributed.

[0013] As a preferred embodiment of the stepped casting system for an engine cylinder block, the midpoint of the first horizontal runner is connected to a sprue, and the upper end of the sprue is connected to a pouring cup.

[0014] As a preferred embodiment of the stepped casting system for an engine cylinder block, a filter chamber is provided at the upper end of the first vertical runner, and the filter chamber is connected to the transverse main runner. Impurities in the molten metal can be fully filtered, and the filter chamber is provided in the branch runner part, and each branch runner part is filtered at the same time, which improves the filtering flow efficiency of the molten metal and reduces the temperature drop.

[0015] As a preferred implementation scheme of the stepped casting system for an engine cylinder block, a second vertical runner is provided directly below the straight runner, the upper end of which is not connected to the horizontal main runner, and auxiliary runners are respectively provided on the side walls of the first vertical runner on both sides of the straight runner, the auxiliary runners are connected to the second vertical runner, and the second vertical runner is provided with an intermediate runner, a first branch runner, a second branch runner, a first inner runner, and a second inner runner. A vertical runner connected to the horizontal main runner is not directly provided below the gate and the straight runner, so that the molten metal flows to both sides first, ensuring that the molten metal in each branch runner is evenly distributed.

[0016] As a preferred embodiment of the stepped casting system for an engine block, the inner cavity cross-sectional area of ​​the sprue is The inner cross-sectional area of ​​the first runner is The cross-sectional areas of the first branch runner, the second branch runner, the first ingrate and the second ingrate are equal and are Inside, straight: horizontal: Inner = 1.16:1:1.08. The casting system is a closed-first-open-later casting method, which can ensure the smooth filling of liquid metal.

[0017] It can be seen from the above technical solutions that the advantages of the present invention are as follows: First, the engine cylinder stepped casting system of the present invention realizes the layered filling of liquid metal through its unique stepped design, and this filling method greatly improves the internal quality of the casting. In the traditional casting process, due to the rapid flow and impact of the liquid metal, a large number of defects such as slag holes, air holes, and sand holes are often generated, which seriously affect the performance of the casting. However, the system uses two layers of stepped casting to enable the liquid metal to enter the mold cavity more smoothly, reducing the defects caused by excessive flow rate, thereby significantly improving the casting yield rate. Secondly, while optimizing the liquid metal filling process, the system also takes into account the effectiveness of cavity exhaust. The stepped injection method not only slows down the scouring of the cavity, but also provides a smooth discharge path for the gas in the cavity, ensuring that there are no air holes inside the casting, and improving the density and mechanical properties of the casting. In addition, the filter cavity specially designed in this system has a filtration efficiency much higher than that of the traditional filtration method. This design can fully filter impurities in the molten metal, ensuring the purity of the casting, while improving the filtration flow efficiency of the molten metal, reducing the temperature drop caused by filtration, and further ensuring the quality of the casting. Through precise calculation and design in the angle design and cross-sectional area optimization of the casting system, it is ensured that the molten metal can be evenly distributed in each branch runner, which not only improves the consistency of the casting, but also reduces the casting defects caused by uneven flow of the molten metal.

[0018] In summary, the engine cylinder block stepped casting system provided by the present invention has shown significant advantages in improving casting quality, reducing production costs, and improving production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solution of the present invention, the accompanying drawings required for use in the description will be briefly introduced below. Obviously, the accompanying drawings in the following description are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0020] Figure 1 It is a structural schematic diagram of a specific implementation mode of the present invention.

[0021] Figure 2 It is a side view schematic diagram of a specific embodiment of the present invention.

[0022] Description of main reference numerals 1. pouring cup, 2. straight runner, 3. first horizontal runner, 4. second horizontal runner, 5. third horizontal runner, 6. filter cavity, 7. first vertical runner, 8. second vertical runner, 9. auxiliary runner, 10. middle runner, 11. first branch runner, 12. second branch runner, 13. first inner runner, 14. second inner runner. DETAILED DESCRIPTION

[0023] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical scheme of the present invention will be clearly and completely described below in conjunction with the drawings in this specific embodiment. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of them. Based on the embodiments in this patent, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this patent.

[0024] like Figure 1 , 2 As shown, a stepped casting system for an engine cylinder block includes a main runner part, the main runner part includes a transverse main runner, a plurality of branch runner parts are arranged below the transverse main runner, the branch runner part includes a first vertical runner 7, a filter chamber 6 is arranged at the upper end of the first vertical runner 7, the filter chamber 6 is connected to the transverse main runner, the first vertical runner 7 is connected to an intermediate runner 10, the other end of the intermediate runner 10 is connected to a diversion runner, the diversion runner is vertically arranged, the lower end of the diversion runner is connected to a first entgate 13, the upper end of the diversion runner is connected to a second entgate 14, the first entgate 13 and the second entgate 14 are arranged horizontally.

[0025] Specifically, the diversion runner includes a first branch runner 11 and a second branch runner 12, and the middle runner 10 is connected to the connection between the first branch runner 11 and the second branch runner 12. The middle runner 10 and the first branch runner 11 form an angle of 72°, and the transition portion between the two adopts a fillet of R10mm. The middle runner 10 and the second branch runner 12 form an angle of 62°, and the transition portion between the two adopts a fillet of R30mm. The middle runner 10 is located outside the corner of the first branch runner 11 and the second branch runner 12. The first ingrain 13 and the first branch runner 11 form an angle of 72°, and the connection portion is provided with an outer fillet of R11mm and an inner fillet of R5mm. The second ingrain 14 and the second branch runner 12 form an angle of 105°, and the connection portion is provided with an outer fillet of R15mm and R5mm. The connection between the first ingrate 13 and the cavity is in a diffused bell-mouth shape, and the connection between the second ingrate and the cavity is in a diffused bell-mouth shape, which reduces the scouring of the cavity by the liquid metal.

[0026] The transverse main runner includes a first runner 3, both ends of the first runner 3 are respectively connected to second runners 4, and the ends of the second runners 4 on both sides away from the first runner 3 are connected to third runners 5, and the inner cavity cross-sectional areas of the first runner 3, the second runner 4 and the third runner 5 are reduced successively. Specifically, the widths of the first runner 3, the second runner 4 and the third runner 5 are equal, and the heights are reduced by 22mm and 10mm respectively, which can ensure that the liquid metal quickly enters the main channel and effectively alleviates the situation of liquid metal entrainment when flowing in the runner. The inlet of the first runner 3 is connected to the bottom of the straight runner 2, and the connection between the two is provided with a fillet of R6mm, which can reduce the scouring of the runner by the liquid metal when it flows to the runner.

[0027] The midpoint of the first horizontal runner 3 is connected to the sprue 2, and the upper end of the sprue 2 is connected to the pouring cup 1. A second vertical runner 8 is provided directly below the sprue 2, and the upper end of the second vertical runner 8 is not connected to the horizontal main runner. Auxiliary runners 9 are respectively provided on the side walls of the first vertical runner 7 on both sides of the sprue 2, and the auxiliary runners 9 are connected to the second vertical runner 8. The second vertical runner 8 is provided with an intermediate runner 10, a first branch runner 11, a second branch runner 12, a first inner runner 13, and a second inner runner 14.

[0028] The inner cavity cross-sectional area of ​​the sprue is The inner cross-sectional area of ​​the first runner is The cross-sectional areas of the first branch runner 11, the second branch runner 12, the first ingrate 13 and the second ingrate 14 are equal and are Inside, straight: horizontal: Inner = 1.16:1:1.08.

[0029] During the casting process, the liquid metal enters the straight runner 2 through the pouring cup 1. Before the entire cross runner is filled, the liquid metal enters each filter cavity 6 in sequence through the first cross runner 3, the second cross runner 4, and the third cross runner 5. After the liquid metal is filtered by the filter mesh in the filter cavity 6, it enters the first main channel 7 respectively. Then, part of the liquid metal flows into the second main channel 8 which is not connected to the cross runner through the auxiliary runner 9, and then flows through the main runner 10 to the first branch runner 11 and the second branch runner 12. Finally, the liquid metal enters the mold cavity through the first inner runner 13 and the second inner runner 14 until the casting is completed.

[0030] It can be seen from the above embodiments that the beneficial effect of the present invention is that the engine cylinder stepped casting system of the present invention realizes the layered filling of liquid metal through its unique stepped design, and this filling method greatly improves the internal quality of the casting. In the traditional casting process, due to the rapid flow and impact of the liquid metal, a large number of defects such as slag holes, air holes, sand holes, etc. are often generated, which seriously affect the performance of the casting. However, the present system uses two-layer stepped casting to enable the liquid metal to enter the mold cavity more smoothly, reducing the defects caused by excessive flow rate, thereby significantly improving the casting yield rate. Secondly, while optimizing the liquid metal filling process, the system also takes into account the effectiveness of cavity exhaust. The stepped injection method not only slows down the scouring of the cavity, but also provides a smooth discharge path for the gas in the cavity, ensuring that there are no air holes inside the casting, and improving the density and mechanical properties of the casting. In addition, the filter cavity specially designed in the present system has a filtration efficiency much higher than that of the traditional filtration method. This design can fully filter impurities in the molten metal, ensuring the purity of the casting, while improving the filtration flow efficiency of the molten metal, reducing the temperature drop caused by filtration, and further ensuring the quality of the casting. Through precise calculation and design in the angle design and cross-sectional area optimization of the casting system, it is ensured that the molten metal can be evenly distributed in each branch runner, which not only improves the consistency of the casting, but also reduces the casting defects caused by uneven flow of the molten metal.

[0031] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A stepped casting system for an engine cylinder block, characterized in that: The invention comprises a main runner part, wherein the main runner part comprises a transverse main runner, and a plurality of branch runner parts are arranged below the transverse main runner, wherein the branch runner part comprises a first vertical runner (7), wherein the first vertical runner (7) is connected to an intermediate runner (10), wherein the other end of the intermediate runner (10) is connected to a diversion runner, wherein the diversion runner is arranged vertically, wherein the lower end of the diversion runner is connected to a first entrant (13), and the upper end of the diversion runner is connected to a second entrant (14), and wherein the first entrant (13) and the second entrant (14) are arranged horizontally.

2. The engine cylinder block step casting system according to claim 1, characterized in that: The branch runner comprises a first branch runner (11) and a second branch runner (12), and the middle runner (10) is connected to the connection between the first branch runner (11) and the second branch runner (12).

3. The engine cylinder block stepped casting system according to claim 2, characterized in that: The middle runner (10) forms an angle of 72° with the first branch runner (11), and the middle runner (10) forms an angle of 62° with the second branch runner (12), and the middle runner (10) is located outside the angle between the first branch runner (11) and the second branch runner (12).

4. The engine cylinder block stepped casting system according to claim 3, characterized in that: The first ingrate (13) and the first branching ingrate (11) form an angle of 72°, and the second ingrate (14) and the second branching ingrate (12) form an angle of 105°.

5. The engine cylinder block step casting system according to claim 4, characterized in that: The connection between the first ingrate (13) and the cavity is in a diffused bell-mouth shape, and the connection between the second ingrate and the cavity is in a diffused bell-mouth shape.

6. The engine cylinder block step casting system according to claim 5, characterized in that: The transverse main runner comprises a first runner (3), the two ends of the first runner (3) are respectively connected to the second runner (4), the ends of the second runners (4) on both sides away from the first runner (3) are connected to the third runner (5), the first runner (3), the second runner (4) and the third runner (5) are equal in width, and the heights are reduced by 22 mm and 10 mm respectively.

7. The engine cylinder block step casting system according to claim 6, characterized in that: The midpoint of the first horizontal runner (3) is connected to the sprue (2), and the upper end of the sprue (2) is connected to the pouring cup (1).

8. The engine cylinder block step casting system according to claim 1, characterized in that: A filter cavity (6) is provided at the upper end of the first vertical runner (7), and the filter cavity (6) is connected to the transverse main runner.

9. The engine cylinder block step casting system according to claim 7, characterized in that: A second vertical runner (8) is provided directly below the straight runner (2); the upper end of the second vertical runner (8) is not connected to the transverse main runner; auxiliary runners (9) are provided on the side walls of the first vertical runner (7) located on both sides of the straight runner (2); the auxiliary runners (9) are connected to the second vertical runner (8); and the second vertical runner (8) is provided with an intermediate runner (10), a first branch runner (11), a second branch runner (12), a first inner runner (13) and a second inner runner (14).

10. The engine cylinder block step casting system according to claim 7, characterized in that: The inner cavity cross-sectional area of ​​the sprue is The inner cross-sectional area of ​​the first runner is The cross-sectional areas of the first branch runner (11), the second branch runner (12), the first ingrate (13) and the second ingrate (14) are equal and are Inside, straight: horizontal: Inner = 1.16:1:1.08.

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