Heavy spindle box casting and casting method thereof

Abstract

The invention discloses a heavy spindle box casting and a casting method thereof.The casting method includes the steps that a casting sand mold and a plurality of casting sand cores are manufactured according to the structural shape of a spindle box, and the multiple casting sand cores are put into the casting sand mold to obtain a casting cavity; a first chilling block assembly, a second chilling block assembly and a third chilling block assembly are arranged on the casting sand core and the assembly sand mold; a pouring system is arranged when the casting sand mold is manufactured, the pouring system comprises a pouring gate channel arranged above a parting surface, the pouring gate channel is connected with a transverse pouring gate, a vertical pouring gate is arranged below the transverse pouring gate, multiple layers of inner pouring gates are arranged on the vertical pouring gate, the inner pouring gates are communicated with the side wall of the casting cavity, and a riser assembly is further arranged above the inner pouring gates; and after molten iron is smelted, pouring is conducted, and a casting is naturally cooled after pouring. And through the chilling block, the dead head and the flow gate designed in a layered mode, molten iron can flow to the whole cavity structure, it is guaranteed that cavity filling is stable and sufficient, and the defects of air holes, inclusions, shrinkage cavities, shrinkage porosity and the like are avoided.

Description

Technical Field

[0001] The invention relates to the technical field of heavy machine tool component casting, and in particular to a heavy spindle box casting and a casting method thereof. Background Art

[0002] The spindle box is a key part of the horizontal lathe, which is used to arrange the working spindle of the machine tool and its transmission parts and corresponding additional mechanism components. There are many shaft holes distributed on the box, which are mainly used to carry the spindle. The dimensional accuracy of the shaft holes directly affects the machining accuracy of the machine tool. The spindle box is usually made of gray cast iron and is made by casting. The production of small spindle boxes is relatively simple, but for large and heavy spindle boxes, the casting defects will also be magnified and multiplied due to the increase in volume and weight; however, this type of box casting is not allowed to have defects such as shrinkage cavities, shrinkage, sand holes, slag holes, etc. after processing. Before the finished product is delivered, it is necessary to use a sample to detect the relevant dimensions of the inner cavity. The inner cavity of the casting is an oil tank and oil leakage is not allowed; therefore, an effective casting method is required to produce qualified large-tonnage spindle box castings. Summary of the invention

[0003] The purpose of the present invention is to provide a heavy-duty spindle housing casting and a casting method thereof in view of the problems existing in the prior art.

[0004] To achieve the above object, the technical solution adopted by the present invention is: On the one hand, the present invention provides a heavy-duty spindle box casting, comprising an integrally formed box bottom plate, a box top plate, a box left side plate, a box right side plate and a box back plate, and a front plate assembly arranged on the front side of the spindle box casting; a first parallel transverse partition plate and a second transverse partition plate are arranged in the spindle box casting, the first transverse partition plate is arranged close to the box bottom plate, a vertical partition plate is arranged between the second transverse partition plate and the box top plate, a large chamber is formed between the vertical partition plate and the box left side plate, and a small chamber is formed between the vertical partition plate and the box right side plate; a spindle installation channel running through from top to bottom is provided on the box top plate, the second transverse partition plate, the first transverse partition plate and the box bottom plate on the side where the large chamber is located, and a secondary shaft installation channel running through from top to bottom is provided on the side where the small chamber is located; the spindle installation channel is provided with a first columnar installation area between the first transverse partition plate and the box bottom plate, and the spindle installation channel is provided with a second columnar installation area in the large chamber.

[0005] The spindle box casting forms a rectangular box structure through the box bottom plate, the box top plate, the box left side plate, the box right side plate, the box back plate and the front panel assembly, which can be used to arrange the working spindle of the machine tool and its transmission parts and components of the corresponding additional mechanisms. The spindle mounting channel on the side where the large chamber is located is mainly used to carry the spindle. In order to improve its bearing capacity and stability, the first cylindrical mounting area and the second cylindrical mounting area are arranged at the spindle mounting channel. The arrangement of these two mounting areas can also improve the dimensional accuracy and installation accuracy of the shaft hole, which is beneficial to improving the machining accuracy of the machine tool.

[0006] The first cylindrical mounting area is close to the end face of the spindle housing, and bearings and other components can be set to support the spindle. Its axial length is smaller than the axial length of the second cylindrical mounting area. The second cylindrical mounting area can better support the spindle in the middle and improve the stability of the spindle installation and transmission.

[0007] Furthermore, the first columnar mounting area includes a first cylinder structure connecting the first transverse partition and the box bottom plate, and the periphery of the first cylinder structure is also provided with a plurality of reinforcing rib plates connected to the first transverse partition and the box bottom plate.

[0008] Furthermore, the large chamber is provided with a pair of third transverse partitions connected to the left side plate of the box, the vertical partition and the back plate of the box, the second columnar mounting area includes a second cylinder structure arranged between the pair of third transverse partitions, and the outer periphery of the second cylinder structure is also provided with a plurality of reinforcing ribs connected to the third transverse partitions.

[0009] Furthermore, the small chamber is also provided with a plurality of fourth transverse partitions connected to the right side plate of the box, the vertical partition and the back plate of the box, and the secondary shaft installation channels are multiple and arranged side by side.

[0010] Furthermore, a plurality of windows are provided on the right side panel of the box body; and the front panel assembly includes a plurality of crisscrossing panels.

[0011] The second aspect of the present invention provides a casting method for a heavy-duty spindle housing casting, the casting method comprising the following steps: selecting a parting surface, taking the surface where the housing top plate is located as the parting surface; using resin sand technology, pit molding or sand box molding; A casting sand mold and a plurality of casting sand cores are manufactured according to the structural shape of the spindle housing, and the plurality of casting sand cores are lowered into the casting sand mold to obtain a casting cavity; the casting sand core comprises at least a first core head and a first sand core corresponding to the first columnar mounting area, and a second core head and a second sand core corresponding to the second columnar mounting area; the first sand core is arranged at the periphery of the first core head and a first chill assembly is arranged thereat, the second sand core is located at the periphery of the second core head and a second chill assembly is arranged thereat, and a third chill assembly is arranged in the region of the casting sand mold corresponding to the first transverse partition and the second transverse partition; When making the casting sand mold, a pouring system is provided, the pouring system comprises a gate channel provided above the parting surface, the gate channel is connected to a horizontal runner, a vertical runner is provided below the horizontal runner, a multi-layer ingates are provided on the vertical runner, and the ingates are connected to the side wall of the casting cavity; a riser assembly is also arranged on the parting surface; Melting molten iron, the molten iron composition is designed to be: C: 2.9%-3.1%, Si: 1.65-1.85%, Mn: 0.65%-0.85%, S: 0.05%-0.07%, P: 0.07%-0.085%, Cr: 0.2%-0.4%, and the rest is Fe; Pouring: the pouring temperature is controlled at 1350-1380°C and the pouring time does not exceed 150s; after pouring, the casting is cooled naturally.

[0012] Furthermore, the first chill assembly includes a plurality of chills embedded in the outer peripheral surface of the first core head, and a plurality of chills embedded in the casting sand mold corresponding to the first sand core and distributed around the first core head.

[0013] Furthermore, the second chill assembly includes a plurality of chills embedded in the outer circumference of the second core head and the inner circumference of the second sand core, and a plurality of chills are also disposed below the second sand core and around the second core head.

[0014] Furthermore, the third chiller assembly is a chiller buried in the casting sand mold corresponding to the first transverse baffle and the second transverse baffle, and a chiller on the left side plate and the right side plate of the box body between the first transverse baffle and the second transverse baffle; the riser assembly includes thermal insulation risers arranged around the outer ring and the shaft hole, and shrinkage compensation risers arranged at different wall thicknesses.

[0015] Furthermore, at least two vertical runners are arranged on each side, and the ingates are distributed in at least three places: upper, middle and lower. The upper ingates correspond to the position where the top plate of the box is formed, the lower ingates correspond to the position where the bottom plate of the box is formed, and the middle ingates correspond to the position where the second transverse partition is formed.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. The spindle box casting forms a rectangular box structure through the box bottom plate, the box top plate, the box left side plate, the box right side plate, the box back plate and the front panel assembly, which can be used to arrange the working spindle of the machine tool and its transmission parts and components of the corresponding additional mechanisms. The spindle mounting channel on the side where the large chamber is located is mainly used to carry the spindle. In order to improve its bearing capacity and stability, the first cylindrical mounting area and the second cylindrical mounting area are arranged at the spindle mounting channel. The arrangement of these two mounting areas can also improve the dimensional accuracy and installation accuracy of the shaft hole, which is beneficial to improving the machining accuracy of the machine tool; 2. In the present casting method, chillers are arranged on both the sand core and the sand mold, and inner and outer chillers are designed at the shaft hole position. According to the position and shape of the shaft hole, the inner and outer chillers are designed to be ring-shaped, which is beneficial to the conduction and dispersion of heat and improves the cooling efficiency and uniformity. Strengthen the chilling effect, balance the cooling speed of the whole casting, and avoid shrinkage and shrinkage defects in the hot joints near the shaft hole; 3. Through the layered design of the gate, it is conducive to the flow of molten iron to the entire cavity structure, ensuring that the cavity is filled smoothly and fully, avoiding the occurrence of defects such as pores and inclusions; calculate the gate area by weight to avoid pouring time that is too long or too short, reduce the solidification time, and prevent excessive internal stress of the casting, thereby reducing deformation and cracks; and the gate is distributed along the rib plate to conform to the shape of the casting itself to ensure that the entire pouring process is filled. Smooth, without turbulence; 4. Design an inner gate along the parting surface, and supplement the molten iron on the parting surface in the later stage of pouring to avoid poor fusion with the core support due to the temperature drop when the molten iron is filled to the parting surface. The core support set on the parting surface is to support the cover box, and it will melt in the molten iron after the molten iron is poured, and finally become a part of the casting; 5. The insulation risers around the outer ring and the shaft hole, as well as the shrinkage feed risers set at different wall thicknesses, are beneficial to the overall shrinkage feed of the casting, especially the shrinkage feed near the shaft hole, to ensure that there are no shrinkage holes or shrinkage defects in the installation channel where the shaft hole is located. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 The overall structure of a heavy-duty spindle housing casting of the present invention is schematically shown. Figure 1 ; Figure 2 The overall structure of a heavy-duty spindle housing casting of the present invention is schematically shown. Figure 2 ; Figure 3 It is a front structural schematic diagram of a heavy-duty spindle housing casting of the present invention; Figure 4 A schematic diagram of a pouring system, chiller and riser arrangement of a heavy-duty spindle housing casting of the present invention; Figure 5 A schematic side view of a pouring system, chiller and riser arrangement of a heavy-duty spindle housing casting of the present invention; Figure 6 is a schematic diagram of a first cold iron assembly of the present invention; Figure 7 is a schematic diagram of a second cold iron assembly of the present invention; Figure 8 It is a front view schematic diagram of the location of the pouring system of the present invention relative to the casting cavity; Fig. 9 It is a side schematic diagram of the location of the pouring system of the present invention relative to the casting cavity; In the figure: 1, box bottom plate; 2, box top plate; 3, box left side plate; 4, box right side plate; 5, box back plate; 6, front panel assembly; 7, second transverse partition plate; 8, first transverse partition plate; 9, main shaft installation channel; 10, secondary shaft installation channel; 11, second columnar installation area; 1101, second cylinder structure; 12, first columnar installation area; 1201, first cylinder structure; 13, reinforcing rib plate; 14, vertical partition plate; 1 5. The third horizontal partition; 16. The window; 17. The first chiller assembly; 1701. The chiller one; 1702. The chiller two; 1703. The chiller three; 18. The second chiller assembly; 1801. The chiller four; 1802. The chiller five; 1803. The chiller six; 1804. The chiller seven; 19. The third chiller assembly; 20. The pouring channel; 21. The horizontal pouring channel; 22. The vertical pouring channel; 23. The inner pouring channel; 24. The insulation riser; 25. The shrinkage-feeding riser. DETAILED DESCRIPTION

[0018] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "middle", "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance. Example 1

[0020] like Figure 1 to Figure 3As shown, a heavy-duty spindle housing casting comprises an integrally formed housing bottom plate 1, a housing top plate 2, a housing left side plate 3, a housing right side plate 4 and a housing back plate 5, and a front plate assembly 6 arranged on the front of the spindle housing casting; a parallel first transverse partition plate 8 and a second transverse partition plate 7 are arranged in the spindle housing casting, the first transverse partition plate 8 is arranged close to the housing bottom plate 1, a vertical partition plate 14 is arranged between the second transverse partition plate 7 and the housing top plate 2, and a large partition plate 14 is formed between the vertical partition plate 14 and the housing left side plate 3. A small chamber is formed between the chamber and the right side plate 4 of the box body; a main shaft installation channel 9 penetrating vertically is provided on the top plate 2 of the box body, the second transverse partition plate 7, the first transverse partition plate 8 and the bottom plate 1 of the box body on the side where the large chamber is located, and a secondary shaft installation channel 10 penetrating vertically is provided on the side where the small chamber is located; the main shaft installation channel 9 is provided with a first columnar installation area 12 between the first transverse partition plate 8 and the bottom plate 1 of the box body, and the main shaft installation channel 9 is provided with a second columnar installation area 11 in the large chamber.

[0021] The spindle box casting forms a rectangular box structure through the box bottom plate 1, the box top plate 2, the box left side plate 3, the box right side plate 4, the box back plate 5 and the front panel assembly 6, which can be used to arrange the working spindle of the machine tool and its transmission parts and components of the corresponding additional mechanisms. The spindle mounting channel on the side where the large chamber is located is mainly used to carry the spindle. In order to improve its bearing capacity and stability, the first cylindrical mounting area and the second cylindrical mounting area are set at the spindle mounting channel. The setting of these two mounting areas can also improve the dimensional accuracy and installation accuracy of the shaft hole, which is beneficial to improving the machining accuracy of the machine tool.

[0022] The first cylindrical mounting area 12 is close to the end face of the spindle housing, and bearings and other components can be set to support the spindle. Its axial length is smaller than the axial length of the second cylindrical mounting area. The second cylindrical mounting area 11 can better support the spindle in the middle, thereby improving the stability of the spindle installation and transmission.

[0023] Due to the importance of the first cylindrical mounting area 12 and the second cylindrical mounting area 11, the dimensional accuracy and shape assurance during their production are also very important. Therefore, during the casting process of the spindle box casting, the molding requirements of these two areas are relatively high, and it is necessary to ensure that there are no defects such as shrinkage cavities, porosity, and sand holes in these areas.

[0024] In addition to dividing the internal area of ​​the entire box into different spaces, the first transverse partition 8, the second transverse partition 7 and the vertical partition 14 also serve to assist the installation of shaft parts and increase the structural strength and stability; the area between the first transverse partition 8 and the second transverse partition 7 can be installed with transmission parts to connect the main shaft and the secondary shaft through a gear set, so that this area is connected; the large chamber and the small chamber separated by the vertical partition are used to arrange the main shaft and the secondary shaft respectively, which can provide better support on the one hand, and separate the two on the other hand to avoid mutual influence during operation.

[0025] Furthermore, the first columnar mounting area 12 includes a first cylinder structure 1201 connecting the first transverse partition 8 and the box bottom plate 1, and the outer periphery of the first cylinder structure 1201 is also provided with a plurality of reinforcing ribs 13 connected to the first transverse partition 8 and the box bottom plate 1. The inner periphery of the first cylinder structure 1201 supports the main shaft by providing bearings, and the reinforcing ribs provided on the outer periphery can improve strength and stability.

[0026] Furthermore, the large chamber is provided with a pair of third transverse partitions 15 connected to the left side plate 3 of the box (or the vertical partition on the left), the vertical partition 14 on the right and the back plate 5 of the box, and the second columnar mounting area 11 includes a second cylinder structure 1101 arranged between the pair of third transverse partitions 15, and the outer periphery of the second cylinder structure 1101 is also provided with a plurality of reinforcing ribs 13 connected to the third transverse partitions.

[0027] The arrangement of a pair of the third transverse partitions 15 can form a structure connecting the second cylindrical structure 1101, and a reinforcing rib plate 13 is also arranged between the two to enhance strength and stability. Bearings can also be arranged on the inner periphery of the second cylindrical structure 1101 to support the main shaft.

[0028] Furthermore, the small chamber is also provided with a plurality of fourth transverse partitions connected to the right side plate 4 of the box, the vertical partition 14 and the back plate 5 of the box, and the secondary shaft installation channels are arranged in four rows, two large and two small.

[0029] Furthermore, a plurality of windows 16 are provided on the right side panel 4 of the box body, which are convenient for the installation of components such as the secondary shaft, as well as subsequent maintenance; the front panel assembly 6 includes a plurality of criss-crossed panels, the box body bottom plate, the box body top plate, the box body left side panel, the box body right side panel, the box body back plate, and the first, second, third, and fourth horizontal partitions and vertical partitions. The panels are all arranged at the front end surface, that is, a slightly wider structure, forming a front panel assembly. This structure can also improve strength and stability, while leaving an open space for subsequent installation and maintenance. Example 2

[0030] A casting method for a heavy spindle housing casting in embodiment 1, combined with Figures 4 to 9 As shown, the above structure is cast in one piece, and the casting method includes the following steps: Select the parting surface, and use the surface where the box top plate 2 is located as the parting surface; adopt resin sand technology, pit molding or sand box molding; in this way, the entire cavity part of the spindle box casting can be arranged in the pit or sand box, which can reduce the casting difficulty and is also beneficial to its overall molding. The pit and the sand box can be equipped with a cover box, and the structure of the cover box will also be simpler.

[0031] The spindle box casting described in Example 1 has a tonnage of more than 50 tons and an outline size of 2824*2689*3126mm. The box has many structures inside and contains multiple layers of cavities. The traditional casting method is used, and the wall thickness at the shaft hole and other locations of the casting is large, which is prone to shrinkage defects.

[0032] A casting sand mold and a plurality of casting sand cores are manufactured according to the structural shape of the spindle housing, and the plurality of casting sand cores are lowered into the casting sand mold to obtain a casting cavity; the casting sand core at least comprises a first core head and a first sand core corresponding to the first columnar mounting area 12, and a second core head and a second sand core corresponding to the second columnar mounting area 11; the first sand core is arranged at the periphery of the first core head and a first chill assembly 17 is arranged thereat, the second sand core is located at the periphery of the second core head and a second chill assembly 18 is arranged thereat, and a third chill assembly 19 is arranged in the region of the casting sand mold corresponding to the first transverse partition 8 and the second transverse partition 7; For the entire spindle box casting, it is necessary to set up a lot of sand cores. From the description of Example 1, it can be seen that the molding of the first cylindrical area and the second cylindrical area where the spindle is installed is more critical, and the wall thickness of these areas is inconsistent, and there are more hot nodes. Therefore, the sand cores and sand molds are treated differently when setting them. The first chiller assembly, the second chiller assembly and the third chiller assembly are set to enhance the chilling effect of these areas, so that the cooling speed of the entire casting can be controlled, and shrinkage defects such as shrinkage cavities and porosity are avoided in thick and large sections.

[0033] In the design of sand core, two main air outlet channels are designed to ensure smooth air outlet and reduce the risk of choking during pouring. First, a φ20 / 30 air outlet rod is designed at the core head of the axial hole of the multi-layer sand core, which is connected from top to bottom to ensure smooth air outlet channels for the lower sand core; second, 6 air outlet grooves are designed at the core head of the sand mold (external mold), and each layer of sand core is led to the air outlet groove with an air outlet rope to assist the sand core in air outlet.

[0034] A hard point is designed at the topmost sand core near the parting surface, and a hard point is also designed at the corresponding position of the cover box (the hard point is for placing refractory bricks) so as to place core supports and prevent core lifting.

[0035] A special core bone is arranged in the sand core to increase the strength of the core bone, enhance the stability and anti-deformation ability of the sand core, and prevent it from moving or breaking during the pouring process. The core bone has multiple layers of annular round steel, and the outer periphery of the annular round steel is provided with axial round steel connected thereto.

[0036] When making the casting sand mold, a pouring system is set up, and the pouring system includes a gate channel 20 arranged above the parting surface, the gate channel 20 is connected to a horizontal runner 21, a vertical runner 22 is arranged below the horizontal runner 21, and a multi-layer ingates 23 are arranged on the vertical runner 22, and the ingates 23 are connected to the side wall of the casting cavity; a riser assembly is also arranged on the parting surface.

[0037] Melting molten iron, the molten iron composition is designed to be (mass percentage): C: 2.9%-3.1%, Si: 1.65%-1.85%, Mn: 0.65%-0.85%, S: 0.05%-0.07%, P: 0.07%-0.085%, Cr: 0.2%-0.4%, and the rest is Fe; Taking the material grade HT300 of the spindle housing casting as an example, the following alloy composition is designed: Table 1: Molten iron composition (%)

[0038] During pouring, the pouring temperature is controlled at 1360°C and the pouring time is about 140s; after pouring, the casting is cooled naturally.

[0039] Before actually making sand cores, sand molds and pouring, a finite element simulation of the molding process of the spindle box casting will be carried out according to the above design and generation, and numerical simulation will be carried out using PROcast software to analyze the large shrinkage tendency in the hot spot of the shaft hole of the casting. According to the analysis results, the process will be improved, and an internal cooling iron will be designed to fit the hot spot to prevent shrinkage defects in key areas.

[0040] Furthermore, the first cold iron assembly 17 includes a plurality of cold irons 1701 buried in the outer peripheral surface of the first core head, and a plurality of cold irons 1702 buried in the casting sand mold corresponding to the first sand core and distributed around the first core head, and cold irons 1703 are provided at the sand cores corresponding to the partitions on both sides.

[0041] The second cold iron assembly 18 includes a plurality of cold irons 1801 and 1802 buried in the outer circumference of the second core head and the inner circumference of the second sand core. A plurality of cold irons 1803 are also provided below the second sand core around the second core head. Cold irons 1804 are provided at the sand cores corresponding to the vertical partitions on both sides.

[0042] This arrangement of chillers is to set chillers on both the sand core and the sand mold at the same time. The chillers in these areas are arranged correspondingly. For castings, inner and outer chillers are set (in the first cylinder structure 1201 and the second cylinder structure 1101), that is, inner and outer chillers are designed at the shaft hole position. According to the position and shape of the shaft hole, the inner and outer chillers are designed to be ring-shaped, which is conducive to the conduction and dispersion of heat, and improves the cooling efficiency and uniformity. Strengthen the chilling effect, balance the cooling speed of the entire casting, and avoid shrinkage defects in the hot node near the shaft hole. Compared with the simple external chiller setting, this arrangement of the present method can achieve better cooling effect.

[0043] Furthermore, the third chiller assembly 19 is a chiller buried in the casting sand mold corresponding to the first transverse baffle and the second transverse baffle, as well as a chiller on the left side plate and the right side plate of the box body between the first transverse baffle and the second transverse baffle. This area is also a relatively important processing surface and is located below the pouring system. The arrangement of these chillers is beneficial to the timely cooling of the molten iron that enters this area later.

[0044] The material grade of the above-mentioned chills is HT250, which is different from the material grade of the casting body. The side facing the casting cavity is also provided with coated sand or refractory coating, so that while it plays a cooling role, it also avoids self-melting and the casting sticking to the chill, ensuring the surface quality of the casting.

[0045] The riser assembly includes a heat-insulating riser 24 arranged around the outer ring and the shaft hole, and a shrinkage-feeding riser 25 arranged at different wall thicknesses. The arrangement of the two risers is beneficial to the shrinkage-feeding of the casting as a whole, especially the shrinkage-feeding near the shaft hole, ensuring that there are no shrinkage cavities or shrinkage defects in the installation channel where the shaft hole is located. The shrinkage-feeding riser and the heat-insulating riser both include a truncated cone-shaped portion with a larger upper portion and a smaller lower portion, and a rectangular connecting portion. The axial length of the truncated cone-shaped portion is about 700 mm, the diameter of the small end is 110-140 mm, the diameter of the large end is 160-190 mm, the side length of the rectangular connecting portion is 50-80 mm, and the height is 30-40 mm.

[0046] Furthermore, at least two vertical runners 22 are arranged on each side, and the ingates are distributed at least in three places: upper, middle and lower. The upper ingates 23 correspond to the position where the top plate of the box is formed, the lower ingates 23 correspond to the position where the bottom plate of the box is formed, and the middle ingates correspond to the position where the second transverse partition is formed.

[0047] The layered design of the gate is conducive to the flow of molten iron to the entire cavity structure, ensuring smooth and full filling of the cavity and avoiding the occurrence of defects such as pores and inclusions.

[0048] The gate area is calculated by weight to avoid pouring time that is too long or too short, reduce solidification time, and prevent excessive internal stress in the casting, thereby reducing deformation and cracks. The gate is distributed along the rib plate to conform to the shape of the casting itself, ensuring that the entire pouring process is filled smoothly without turbulence. An internal gate is designed along the parting surface, and molten iron is added to the parting surface in the later stage of pouring to avoid poor fusion with the core support due to temperature drop when the molten iron is filled to the parting surface. The core support set on the parting surface is to support the cover box, and it will melt in the molten iron after pouring and eventually become a part of the casting.

[0049] Specifically, a horizontal runner 21 is provided at the parting surface on both sides of the casting cavity, and four vertical runners 22 are provided below each horizontal runner 21, two vertical runners 22 form a group and are provided in the front-back direction; four ingates 23 are arranged at intervals from top to bottom on each vertical runner 22. The horizontal runner 21 has a length of 2600-2650 mm and a trapezoidal cross section, the vertical runner 22 has a length of 3100-3150 mm and a circular cross section, and the ingates 23 has a length of 110-115 mm and a rectangular cross section.

[0050] Assuming that the cross-sectional area of ​​the horizontal runner is S1, the cross-sectional area of ​​the vertical runner is S2, and the cross-sectional area of ​​the ingates is S3, then S1>S2>S3; preferably, S1:S2=(2.8-3):1, S2:S3=(4-5):1; specifically, in this embodiment, S1=15000mm 2 , S2=5024mm 2 , S3=1150mm 2 This cross-sectional area setting ensures that the casting cavity is fully filled, allowing multiple molten iron paths from top, middle and bottom to enter the cavity in a stable and orderly manner, avoiding turbulence and insufficient pouring of molten iron in the cavity, and is also conducive to uniform temperature of various parts of the casting.

[0051] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A heavy-duty spindle housing casting, characterized in that: It includes an integrally formed box bottom plate, a box top plate, a box left side plate, a box right side plate and a box back plate, and a front plate assembly arranged on the front side of the spindle box casting; a parallel first transverse partition plate and a second transverse partition plate are arranged in the spindle box casting, the first transverse partition plate is arranged close to the box bottom plate, a vertical partition plate is arranged between the second transverse partition plate and the box top plate, a large chamber is formed between the vertical partition plate and the box left side plate, and a small chamber is formed between the vertical partition plate and the box right side plate; a spindle installation channel that runs through up and down on the side where the large chamber is located is provided on the box top plate, the second transverse partition plate, the first transverse partition plate and the box bottom plate, and a secondary shaft installation channel that runs through up and down on the side where the small chamber is located is provided; the spindle installation channel is provided with a first columnar installation area between the first transverse partition plate and the box bottom plate, and the spindle installation channel is provided with a second columnar installation area in the large chamber.

2. The heavy-duty spindle housing casting according to claim 1, characterized in that: The first columnar mounting area includes a first cylinder structure connecting the first transverse partition and the box bottom plate, and a plurality of reinforcing rib plates connected to the first transverse partition and the box bottom plate are further provided on the periphery of the first cylinder structure.

3. The heavy-duty spindle housing casting according to claim 1, characterized in that: A pair of third transverse partitions connected to the left side plate of the box, the vertical partition and the back plate of the box are provided in the large chamber, and the second columnar mounting area includes a second cylinder structure arranged between the pair of third transverse partitions, and a plurality of reinforcing ribs connected to the third transverse partitions are also provided on the outer periphery of the second cylinder structure.

4. The heavy-duty spindle housing casting according to claim 1, characterized in that: The small chamber is also provided with a plurality of fourth transverse partitions connected to the right side plate of the box, the vertical partition and the back plate of the box, and the secondary shaft installation channels are arranged in a plurality in parallel.

5. The heavy-duty spindle housing casting according to claim 1, characterized in that: The right side panel of the box body is also provided with a plurality of windows; the front panel assembly comprises a plurality of crisscrossing panels.

6. A method for casting a heavy-duty spindle housing casting according to any one of claims 1 to 5, characterized in that: The casting method comprises the following steps: selecting a parting surface, taking the surface where the top plate of the box body is located as the parting surface; adopting resin sand technology, pit molding or sand box molding; A casting sand mold and a plurality of casting sand cores are manufactured according to the structural shape of the spindle housing, and the plurality of casting sand cores are lowered into the casting sand mold to obtain a casting cavity; the casting sand core comprises at least a first core head and a first sand core corresponding to the first columnar mounting area, and a second core head and a second sand core corresponding to the second columnar mounting area; the first sand core is arranged at the periphery of the first core head and a first chill assembly is arranged thereat, the second sand core is located at the periphery of the second core head and a second chill assembly is arranged thereat, and a third chill assembly is arranged in the region of the casting sand mold corresponding to the first transverse partition and the second transverse partition; When making the casting sand mold, a pouring system is provided, the pouring system comprises a gate channel provided above the parting surface, the gate channel is connected to a horizontal runner, a vertical runner is provided below the horizontal runner, a multi-layer ingates are provided on the vertical runner, and the ingates are connected to the side wall of the casting cavity; a riser assembly is also arranged on the parting surface; Melting molten iron, the molten iron composition is designed to be: C: 2.9%-3.1%, Si: 1.65-1.85%, Mn: 0.65%-0.85%, S: 0.05%-0.07%, P: 0.07%-0.085%, Cr: 0.2%-0.4%, and the rest is Fe; Pouring: the pouring temperature is controlled at 1350-1380°C and the pouring time does not exceed 150s; after pouring, the casting is cooled naturally.

7. The casting method of the heavy-duty spindle housing casting according to claim 6, characterized in that: The first chill assembly includes a plurality of chills embedded in the outer peripheral surface of the first core head, and a plurality of chills embedded in the casting sand mold and distributed around the first core head corresponding to the first sand core.

8. The casting method of the heavy-duty spindle housing casting according to claim 6, characterized in that: The second chill assembly includes a plurality of chills embedded in the outer circumference of the second core head and the inner circumference of the second sand core, and a plurality of chills are also arranged around the second core head below the second sand core.

9. The method for casting a heavy-duty spindle housing casting according to claim 6, characterized in that: The third chiller assembly is a chiller buried in the casting sand mold corresponding to the first transverse baffle and the second transverse baffle, and a chiller on the left side plate and the right side plate of the box body between the first transverse baffle and the second transverse baffle; the riser assembly includes an insulating riser arranged around the outer ring and the shaft hole, and a shrinkage feed riser arranged at different wall thicknesses.

10. The method for casting a heavy-duty spindle housing casting according to claim 6, characterized in that: At least two vertical runners are arranged on each side, and the ingates are distributed at least in upper, middle and lower positions. The upper ingates correspond to the position where the top plate of the box is formed, the lower ingates correspond to the position where the bottom plate of the box is formed, and the middle ingates correspond to the position where the second transverse partition is formed.

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