A tooling and method for straightening a shell casting

Abstract

This invention relates to the field of casting technology, and more particularly to a straightening fixture and method for shell castings. The straightening fixture includes a base plate, a movable beam, a fixed beam, a column block, and four columns. The movable beam and fixed beam are arranged in a cross shape and inserted into the cross-shaped mounting holes of the column block, with the movable beam located below the fixed beam. Both ends of the movable beam are horizontally inserted into the upper parts of two of the columns. The movable beam slides in contact with the columns and column block. Both ends of the fixed beam are horizontally inserted into the upper parts of the other two columns. The columns are detachably connected to the base plate. A shim is inserted between the top surface of the fixed beam and the upper wall of the cross-shaped mounting hole of the column block; the shim is composed of multiple shims of different thicknesses stacked together. Two protrusions of different thicknesses are spaced apart on the lower surface of the movable beam; the thickness of each protrusion is equal to the thickness of one of the shims, or equal to the sum of the thicknesses of two of the shims. The straightening amount can be precisely controlled by removing the shims.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a correction fixture and method for shell castings. Background Technology

[0002] Combination Figure 1 , Figure 2 The diagram shows a structural schematic of the shell casting. This shell casting has high market demand and is already in mass production. However, due to its unique structure, it is difficult to cast, has a low yield rate, and most of the castings produced are scrapped due to large deformation caused by subsequent processes. Because the casting structure has a suspended inner cavity, an arc-shaped partition 101 is installed near the top of the inner cavity, dividing it into upper and lower chambers. Reinforcing ribs are provided on the arc-shaped partition, and a hollow column 102 is integrally formed in the center of the arc-shaped partition.

[0003] Because the arc-shaped partition 101 is prone to shrinkage and deformation, it can easily cause the position of the hollow column 102 to rise. General correction methods are not easy to operate, are difficult, and cannot be quantified. As a result, the arc-shaped partition 101 is crushed during correction, causing most of the castings to be piled up in the correction process, and production tasks are seriously delayed. Summary of the Invention

[0004] The main objective of this invention is to provide a correction fixture and method for shell castings, aiming to solve the aforementioned technical problems.

[0005] To achieve the above objectives, the present invention proposes a calibration fixture for a shell casting, comprising a base plate, a movable beam, a fixed beam, a column block, and four columns; the movable beam and the fixed beam are arranged in a cross shape and inserted into the cross mounting holes of the column block, with the movable beam located below the fixed beam; both ends of the movable beam are respectively inserted laterally into the upper parts of two of the columns; the movable beam is slidably engaged with the columns and the column block respectively; both ends of the fixed beam are respectively inserted laterally into the upper parts of the other two columns; the lower ends of the columns are detachably connected to the base plate; a pad is inserted between the top surface of the fixed beam and the upper wall of the cross mounting hole of the column block, the pad being composed of multiple pads of different thicknesses stacked together; two protrusions of different thicknesses are spaced apart on the lower surface of the movable beam; the thickness of each protrusion is equal to the thickness of one of the pads, or equal to the sum of the thicknesses of two of the pads.

[0006] Preferably, the thickness of the gasket includes 0.5mm, 1.0mm, 1.5mm, and 2.0mm.

[0007] Preferably, the movable beam has three models; the thickness of the two protrusions on the movable beam of the first model is 0.5mm and 1.0mm respectively; the thickness of the two protrusions on the movable beam of the second model is 1.5mm and 2.0mm respectively; and the thickness of the two protrusions on the movable beam of the third model is 2.5mm and 3.0mm respectively.

[0008] Preferably, a groove is provided at the middle position of the lower surface of the fixed beam, and the movable beam slides in conjunction with the groove.

[0009] Preferably, a vertical scale is provided on the column block; and the scale is located on the side of the movable beam.

[0010] Preferably, the lower end of the column is provided with a flange, and the flange is connected to the base plate with screws.

[0011] On the other hand, the present invention also proposes a method for correcting a shell casting, which uses the above-mentioned correction fixture and includes the following steps:

[0012] S1. Place the shell casting on the base plate;

[0013] S2. Estimate the deformation of the hollow column of the shell casting along its axial direction, and select a suitable moving beam based on the deformation.

[0014] S3. Insert the fixed beam and the movable beam selected in step S2 into the cross mounting hole of the column block, and make the bottom of the groove between the two protrusions on the movable beam abut against the lower hole wall of the cross mounting hole of the column block; and insert a pad block made of multiple shims stacked between the top surface of the fixed beam and the upper hole wall of the cross mounting hole of the column block.

[0015] S4. Install the four columns at the ends of the moving beam and the fixed beam respectively, and connect the lower end of the columns to the base plate, so that the lower end of the column block abuts against the top surface of the hollow column of the shell casting.

[0016] S5. Based on the estimated deformation in step S2, extract one or two shims of the corresponding thickness value so that a gap appears between the top surface of the shim block formed by the remaining shims and the upper wall of the cross mounting hole of the column block.

[0017] S6. Use a press to vertically press down the column block, causing it to move downwards;

[0018] S7. Move the moving beam along the axial direction of the moving beam so that the protrusion on the lower surface of the moving beam abuts against the lower wall of the cross mounting hole of the column block.

[0019] S8. Perform stress-relieving annealing on the entire shell casting and tooling to eliminate thermal stress.

[0020] Preferably, the process also includes step S9, dismantling the fixture: after the stress-relieving annealing in step S8 is completed and the shell casting has cooled, lubricating oil is sprayed on the cross mounting holes of the column block and the connection between the column and the moving beam and the fixed beam. First, the end of the moving beam is tapped to remove the moving beam, and then the end of the fixed beam is tapped to remove the fixed beam.

[0021] Preferably, in step S6, when the column block is pressed vertically down using a press, the descent height of the column block relative to the moving beam is observed using a scale on the column block.

[0022] Preferably, steps S5 to S8 are repeated, and the correction is performed twice.

[0023] Due to the adoption of the above technical solution, the beneficial effects of the present invention are as follows:

[0024] (1) In this invention, the hollow column of the shell casting is pressed down and corrected by using the column block to receive the pressure of the press. The amount of correction can be precisely controlled by using the method of removing the shims, so as to avoid the arc-shaped partition on the shell casting being crushed due to excessive correction amount during correction.

[0025] (2) In this invention, when the column moves downward, the moving beam is pulled along the axial direction of the moving beam so that the protrusion on the lower surface of the moving beam abuts against the lower hole wall of the cross mounting hole of the column, which can restrict the column from moving upward and ensure that the lower end of the column always abuts against the top surface of the hollow column of the shell casting.

[0026] (3) In this invention, when the column block is pressed vertically down using a press, the height of the column block relative to the moving beam can be observed using the scale on the column block, thus achieving the effect of visualizing the correction amount.

[0027] (4) In this invention, the shell casting together with the tooling is subjected to stress-relief annealing to prevent the shell bottom casting from rebounding and reduce thermal stress deformation, thereby completing the precise correction of the casting and meeting the requirements of subsequent assembly. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0029] Figure 1 A three-dimensional structural diagram of the shell casting.

[0030] Figure 2 This is a sectional view of the shell casting;

[0031] Figure 3 A schematic diagram showing the shell casting clamped in the alignment fixture;

[0032] Figure 4 This is a schematic diagram showing the positional relationship between the movable beam, the fixed beam, and the pad block in this invention;

[0033] Figure 5 This is a schematic diagram of the structure of gaskets of different thicknesses in this invention;

[0034] Figure 6 This is a schematic diagram of the fixed beam structure in this invention;

[0035] Figure 7 This is a schematic diagram of different types of movable beams in this invention;

[0036] Figure 8 This is a schematic diagram of the scale on the column block in this invention.

[0037] The following are the reference numerals: 1. Moving beam; 1a. Protruding block; 2. Fixed beam; 2a. Slide groove; 3. Scale; 4. Pad block; 4a. Gasket; 5. Base plate; 6. Column block; 7. Column; 7a. Flange; 101. Arc-shaped partition; 102. Hollow column. Detailed Implementation

[0038] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0039] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0040] Combination Figures 3 to 8As shown, this embodiment provides a calibration fixture for a shell casting. The calibration fixture includes a base plate 5, a movable beam 1, a fixed beam 2, a column block 6, and four columns 7. The movable beam 1 and the fixed beam 2 are arranged in a cross shape and inserted into the cross mounting holes of the column block 6. The movable beam 1 is located below the fixed beam 2. The two ends of the movable beam 1 are respectively inserted laterally into the upper parts of two of the columns 7. The movable beam 1 is slidably engaged with the columns 7 and the column block 6. The two ends of the fixed beam 2 are respectively inserted laterally into the upper parts of the other two columns 7. The lower end of the column 7 is detachably connected to the base plate 1. A pad 4 is inserted between the top surface of the fixed beam 2 and the upper wall of the cross mounting hole of the column block 6. The pad 4 is composed of multiple pads 4a of different thicknesses stacked together. Two protrusions 1a of different thicknesses are spaced apart on the lower surface of the movable beam 1. The thickness of each protrusion 1a is equal to the thickness of one of the pads 4a, or equal to the sum of the thicknesses of the two pads 4a.

[0041] Combination Figure 5 As shown, the thickness specifications of the gasket 4a include 0.5mm, 1.0mm, 1.5mm, and 2.0mm.

[0042] Combination Figure 7 As shown, the movable beam 1 has three models, and the specific model specifications are as follows:

[0043] The thicknesses of the two protrusions 1a on the first type of movable beam 1 are 0.5 mm and 1.0 mm, respectively;

[0044] The thicknesses of the two protrusions 1a on the second type of moving beam 1 are 1.5 mm and 2.0 mm, respectively;

[0045] The thicknesses of the two protrusions 1a on the third type of moving beam 1 are 2.5 mm and 3.0 mm, respectively.

[0046] Combination Figure 4 and Figure 6 As shown, a groove 2a is provided at the middle position of the lower surface of the fixed beam 2, and the movable beam 1 slides in conjunction with the groove 2a.

[0047] Combination Figure 3 and Figure 8 As shown, a vertical scale 3 is provided on the column block 6; and the scale 3 is located on the side of the movable beam 1.

[0048] Combination Figure 3 As shown, a flange 7a is provided at the lower end of the column 7, and the flange 7a is connected to the base plate 5 with screws to form a detachable connection structure.

[0049] On the other hand, this embodiment also provides a method for visual inspection and correction of shell castings, which uses the above-mentioned correction fixture and includes the following steps:

[0050] S1. Place the shell casting on the base plate 5;

[0051] S2. Estimate the axial deformation of the hollow column 102 of the shell casting, and select a suitable type of moving beam 1 based on the deformation.

[0052] S3. Insert the fixed beam 2 and the movable beam 1 selected in step S2 into the cross mounting hole of the column block 6, and make the bottom of the groove between the two protrusions 1a on the movable beam 1 abut against the lower hole wall of the cross mounting hole of the column block 6; and insert a pad block 4 made of multiple shims 4a stacked between the top surface of the fixed beam 2 and the upper hole wall of the cross mounting hole of the column block 6.

[0053] S4. Install the four columns 7 at the ends of the moving beam 1 and the fixed beam 2 respectively, and connect the lower end of the column 7 to the base plate 5, so that the lower end of the column block 6 abuts against the top surface of the hollow column 102 of the shell casting.

[0054] S5. Based on the estimated deformation in step S2, extract one or two shims 4a of the corresponding thickness value so that a gap appears between the top surface of the shim block 4 formed by the remaining shims 4a and the upper wall of the cross mounting hole of the column block 6.

[0055] S6. Use a press to press the column block 6 vertically downwards, causing the column block 6 to move downwards;

[0056] S7. Move the moving beam 1 along the axial direction of the moving beam 1 so that the protrusion 1a on the lower surface of the moving beam 1 abuts against the lower wall of the cross mounting hole of the column block 6.

[0057] S8. Perform stress-relieving annealing on the entire shell casting and tooling to eliminate thermal stress.

[0058] S9. Dismantle the fixture: After the stress-relieving annealing in step S8 is completed and the shell casting has cooled, spray lubricating oil on the cross mounting holes of the column block 6 and the connection between the column 7 and the moving beam 1 and the fixed beam 2. First, knock on the end of the moving beam 1 to remove the moving beam 1. Then, knock on the end of the fixed beam 2 to remove the fixed beam 2.

[0059] In step S6, when the press is used to vertically press down the column block 6, the descending height of the column block 6 relative to the moving beam 1 is observed using the scale 3 on the press block 6.

[0060] Repeat steps S5 to S8, using a two-step correction method.

[0061] Specifically, in step S2, the estimated value of the deformation of the hollow column 102 of the shell casting in the axial position is 3.0 mm. Therefore, a third type of moving beam 1 is selected, and the thicknesses of the two protrusions 1a on the moving beam 1 are 2.5 mm and 3.0 mm, respectively.

[0062] Because the deformation is relatively large, a two-stage correction method is used.

[0063] The first calibration operation is as follows:

[0064] First, remove the two shims 4a with thicknesses of 1.0mm and 1.5mm, so that a 2.5mm gap appears between the top surface of the shim block 4 formed by the remaining shims 4a and the upper wall of the cross mounting hole of the column block 6.

[0065] The press is used to press the column 6 vertically downward, causing the column 6 to move downward until the upper wall of the cross mounting hole of the column 6 abuts against the top surface of the pad 4 formed by the remaining pad 4a.

[0066] Move the moving beam 1 along its axial direction so that the 2.5mm thick protrusion 1a on the moving beam 1 abuts against the lower wall of the cross mounting hole of the column block 6.

[0067] The shell casting, along with the tooling, is subjected to stress-relieving annealing to eliminate thermal stress.

[0068] Based on the first calibration, the second calibration operation is performed as follows:

[0069] Move the moving beam 1 axially so that the bottom of the groove between the two protrusions 1a on the moving beam 1 aligns with the lower wall of the cross-shaped mounting hole of the column block 6; reinsert the two shims 4a, 1.0mm and 1.5mm, that were removed during the first calibration, and then proceed with the operation:

[0070] Remove the two shims 4a with thicknesses of 1.0mm and 2.0mm, so that a gap of 3.0mm appears between the top surface of the shim block 4 formed by the remaining shims 4a and the upper wall of the cross mounting hole of the column block 6.

[0071] The press is used to press the column 6 vertically downward, causing the column 6 to move downward until the upper wall of the cross mounting hole of the column 6 abuts against the top surface of the pad 4 formed by the remaining pad 4a.

[0072] Move the moving beam 1 along its axial direction so that the 3.0mm thick protrusion 1a on the moving beam 1 abuts against the lower wall of the cross mounting hole of the column block 6.

[0073] The shell casting, along with the tooling, is subjected to stress-relieving annealing to eliminate thermal stress.

[0074] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A straightening fixture for a shell casting, characterized in that, It includes a base plate (5), a movable beam (1), a fixed beam (2), a column block (6), and four columns (7); The movable beam (1) and the fixed beam (2) are arranged in a cross shape and inserted into the cross mounting holes of the column block (6). The movable beam (1) is located below the fixed beam (2). The two ends of the movable beam (1) are respectively inserted horizontally into the upper part of two of the columns (7). The movable beam (1) is slidably engaged with the columns (7) and the column block (6). The two ends of the fixed beam (2) are respectively inserted horizontally into the upper part of the other two columns (7). The lower end of the columns (7) is detachably connected to the base plate (5). A pad (4) is inserted between the top surface of the fixed beam (2) and the upper wall of the cross mounting hole of the column block (6). The pad (4) is made of multiple pads (4a) of different thicknesses stacked together. Two protrusions (1a) of different thicknesses are provided at intervals on the lower surface of the movable beam (1); the thickness of each protrusion (1a) is equal to the thickness of one of the gaskets (4a), or equal to the sum of the thicknesses of the two gaskets (4a).

2. The alignment fixture for a shell casting as described in claim 1, characterized in that, The thickness specifications of the gasket (4a) include 0.5mm, 1.0mm, 1.5mm, and 2.0mm.

3. The alignment fixture for a shell casting as described in claim 2, characterized in that, The movable beam (1) has three models; The thicknesses of the two protrusions (1a) on the first type of movable beam (1) are 0.5 mm and 1.0 mm, respectively; The thicknesses of the two protrusions (1a) on the second type of moving beam (1) are 1.5 mm and 2.0 mm, respectively; The thicknesses of the two protrusions (1a) on the third type of moving beam (1) are 2.5 mm and 3.0 mm, respectively.

4. The alignment fixture for a shell casting as described in claim 1, characterized in that, A groove (2a) is provided at the middle position of the lower surface of the fixed beam (2), and the movable beam (1) slides in cooperation with the groove (2a).

5. The alignment fixture for a shell casting as described in claim 1, characterized in that, A vertical scale (3) is provided on the column block (6); and the scale (3) is located on the side of the movable beam (1).

6. The alignment fixture for a shell casting as described in claim 1, characterized in that, The lower end of the column (7) is provided with a flange (7a), and the flange (7a) is connected to the base plate (5) with screws.

7. A method for correcting a shell casting, characterized in that, The calibration fixture described in claim 3 includes the following steps: S1. Place the shell casting on the base plate (5); S2. Estimate the deformation of the axial position of the hollow column (102) of the shell casting, and select a suitable moving beam (1) based on the deformation. S3. Insert the fixed beam (2) and the movable beam (1) selected in step S2 into the cross mounting hole of the column block (6), and make the bottom of the groove between the two protrusions (1a) on the movable beam (1) abut against the lower hole wall of the cross mounting hole of the column block (6); and insert a pad (4) made of multiple shims (4a) stacked between the top surface of the fixed beam (2) and the upper hole wall of the cross mounting hole of the column block (6). S4. Install the four columns (7) at the ends of the moving beam (1) and the fixed beam (2) respectively, and connect the lower end of the column (7) to the base plate (5), so that the lower end of the column block (6) abuts against the top surface of the hollow column (102) of the shell casting. S5. Based on the estimated deformation in step S2, extract one or two shims (4a) of the corresponding thickness value so that a gap appears between the top surface of the shim block (4) formed by the remaining shims (4a) and the upper wall of the cross mounting hole of the column block (6). S6. Use a press to press the column block (6) vertically downwards, so that the column block (6) moves downwards; S7. Move the moving beam (1) along the axial direction of the moving beam (1) so that the protrusion (1a) on the lower surface of the moving beam (1) abuts against the lower hole wall of the cross mounting hole of the column block (6). S8. Perform stress-relieving annealing on the shell casting and the correction fixture as a whole to eliminate thermal stress.

8. The method for visual inspection and correction of shell castings as described in claim 7, characterized in that, It also includes step S9, dismantling the tooling: after the stress-relief annealing in step S8 is completed and the shell casting is cooled, lubricating oil is sprayed on the cross mounting hole of the column block (6) and the connection between the column (7) and the moving beam (1) and the fixed beam (2). First, the end of the moving beam (1) is knocked to remove the moving beam (1), and then the end of the fixed beam (2) is knocked to remove the fixed beam (2).

9. The method for visual inspection and correction of shell castings as described in claim 7, characterized in that, In step S6, when the press is used to press the column block (6) vertically downward, the descending height of the column block (6) relative to the moving beam (1) is observed using the scale (3) on the press block (6).

10. The method for visual inspection and correction of shell castings as claimed in claim 7, characterized in that, Repeat steps S5 to S8, using a two-step correction method.

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