Block casting method of multi-layer casting

Abstract

The invention relates to the technical field of casting, in particular to a method for integrally casting a multi-layer casting. The invention provides an integral casting method of a multi-layer casting. The problems that in the prior art, the integral casting difficulty of the multi-layer casting is large, the welding period is long in the installing and welding forming process, economic benefits are low, and batch production is difficult are solved. The multilayer casting integral casting technology comprises the design of a casting process and a modeling scheme, integral forming of the multilayer casting in a casting mode is achieved, a finished product can be directly obtained by a whole machine manufacturer through purchasing the casting, the manufacturing process of purchasing raw materials for multiple times and then carrying out assembling and welding is avoided, economic benefits are effectively improved, the production period is effectively shortened, and the production cost is reduced. The production cycle is greatly shortened, manpower and material resource consumption is saved, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of casting, and more particularly to a method for integrally casting a multi-layer casting. Background Art

[0002] The existing manufacturing method of multi-layer bracket products is to use steel plates for welding, and finally weld them into a whole. The disadvantages of this manufacturing method are that the production and procurement cycle of raw materials (steel plates) is long, the welding process is complex and the cycle is long, the welding quality is greatly limited by labor and technology, and the welded products inevitably produce a large number of welds, which seriously affect the performance of the bracket. Therefore, the welds need to be finely polished after welding, and the post-processing workload is very large. The traditional welding production method of brackets has problems such as long cycle, high time and labor costs, difficulty in mass production, and unstable product quality.

[0003] If casting is adopted for production, the multi-layer bracket product has multi-layer flanges and horizontal and vertical staggered rib structure, which is extremely complex, so the overall casting is extremely difficult. Even if the casting is completed, the completed multi-layer casting product will still have many quality problems such as shrinkage holes and cracks. Summary of the invention

[0004] The invention provides a method for integrally casting a multi-layer casting, which solves the problems in the prior art of great difficulty in integrally casting a multi-layer casting, long welding cycle during assembly welding, low economic benefits and difficulty in mass production.

[0005] The object of the present invention is achieved in that the monolithic casting method of the multi-layer casting comprises the following steps:

[0006] S1: building a 3D model of a multi-layer casting in a 3D software, and designing a layered through-gating system and a layer-by-layer distributed riser system on the 3D model of the casting;

[0007] S2: Modeling an overall sand mold according to the three-dimensional model, wherein the overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core formed by layered accumulation of several groups of sand molds;

[0008] S3: determining the position of the parting surface of the integral sand mold according to the height of the integral sand mold and the structure of the casting, and printing the integral sand mold by using a 3D printer and assembling the mold;

[0009] S4: Finish pouring.

[0010] In one embodiment, the rib plates include a plurality of inner cavity rib plates, a plurality of wide rib plates, and a plurality of outer rib plates, wherein a plurality of the inner cavity rib plates are close to the inner cavity of the multi-layer casting, a plurality of the wide rib plates are located between adjacent flanges, and a plurality of the outer rib plates are arranged on the outside of the flange.

[0011] In one embodiment, six open risers are designed on the first layer flange of the multi-layer casting.

[0012] In one embodiment, a riser subsidy is provided between the open riser and the center portion of the casting.

[0013] In one embodiment, six blind risers are respectively arranged at corresponding positions of the second-layer flange and the third-layer flange of the multi-layer casting.

[0014] In one embodiment, concealed riser subsidies are provided between the second and third outer ribs and the inner ribs.

[0015] In one embodiment, six large hidden risers are arranged on the bottom flange of the multi-layer casting, and the large hidden risers are evenly distributed between the outer ribs of the bottom layer.

[0016] In one embodiment, an inner gate is arranged below each of the large blind risers.

[0017] In one embodiment, the pouring system forms a layer-by-layer internal flow system in the inner cavity of the casting.

[0018] In one embodiment, each inner cavity rib of the casting is provided with three inner flow inlets.

[0019] The multi-layer casting integral casting technology in the present invention, including the design of the casting process and the modeling scheme, realizes the integral forming of the multi-layer casting by casting. The whole machine manufacturer can directly obtain the finished product by purchasing the casting, avoiding the manufacturing process of purchasing raw materials for many times and then welding. It effectively improves the economic benefits and production cycle, greatly shortens the production cycle, saves manpower and material resources, and reduces manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the multi-layer casting structure;

[0021] Figure 2 This is a schematic diagram of the riser system distribution;

[0022] Figure 3 This is a schematic diagram of the gating system distribution;

[0023] Figure 4 It is a schematic diagram of the overall structure of the sand mold;

[0024] Figure 5 The schematic diagram of the bottom sand mold structure;

[0025] Figure 6 This is a schematic diagram of the first layer of sand mold structure;

[0026] Figure 7This is a schematic diagram of the second layer sand mold structure;

[0027] Figure 8 It is a schematic diagram of the inner cavity sand core structure;

[0028] 100-flange, 200-inner rib plate, 300-outer rib plate, 400-curved lining plate, 110-first layer flange, 111-open riser, 112-riser subsidy, 310-rib plate hot joint, 320-wide rib plate, 120-second layer flange, 121-blind riser, 122-blind riser subsidy, 130-third layer flange, 140-bottom layer flange, 141-large blind riser, 142- Large hidden riser subsidy, 143-bottom layer hot node, 500-pouring system, 510-inner gate, 520-internal inlet, 530-cross runner, 540-sprue, 600-sand mold as a whole, 610-bottom layer sand mold, 620-first layer outer ring sand mold, 621-first layer inner ring sand core, 630-second layer outer ring sand mold, 631-second layer inner ring sand core, 640-inner cavity sand core, 650-upper layer sand mold. DETAILED DESCRIPTION

[0029] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0031] The invention provides a method for integrally casting a multi-layer casting, which solves the problems in the prior art that the multi-layer casting cannot be integrally cast, the welding cycle is long during the assembly welding process, the economic benefit is low, and it is difficult to mass produce.

[0032] The object of the present invention is achieved in this way. The multi-layer casting includes several layers of flanges and several ribs. The several layers of flange structures are connected by several ribs. The multi-layer casting is an elongated structure as a whole. Its shrinkage compensation ability from top to bottom during casting is extremely poor. Therefore, according to the characteristics of the multi-layer staggered rib structure of the casting, the whole casting method of the multi-layer casting proposed by the present invention includes the following steps:

[0033] S1: building a 3D model of a multi-layer casting in a 3D software, and designing a layered through-gating system and a layer-by-layer distributed riser system on the 3D model of the casting;

[0034] S2: Modeling an overall sand mold according to the three-dimensional model, wherein the overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core formed by layered accumulation of several groups of sand molds;

[0035] S3: determining the position of the parting surface of the integral sand mold according to the height of the integral sand mold and the structure of the casting, and printing the integral sand mold by using a 3D printer and assembling the mold;

[0036] S4: Finish pouring.

[0037] The specific implementation process is as follows: first, the riser system and pouring system of the casting are designed in the three-dimensional software, the ribs include a plurality of inner cavity ribs 200, a plurality of wide ribs 320, and a plurality of outer ribs 300, a plurality of the inner cavity ribs 200 are close to the inner cavity of the multilayer casting, a plurality of the wide ribs 320 are located between the adjacent flanges, and a plurality of the outer ribs 300 are arranged outside the flange 100. A plurality of the inner cavity ribs 200, a plurality of the wide ribs 320, and a plurality of the outer ribs 300 are staggered between the flanges 100.

[0038] The distribution structure of the riser system is specifically as follows: six open risers 111 are designed on the first-layer flange 110 of the multi-layer casting, and a riser subsidy 112 is arranged between the open riser 111 and the central part of the casting. The riser subsidy 112 is arranged in accordance with the casting structure, and the riser subsidy 112 opens up a shrinkage compensation channel from the open riser 111 to the center of the casting.

[0039] Six blind risers 121 are respectively arranged at corresponding positions of the second-layer flange 120 and the third-layer flange 130 of the multi-layer casting, and blind riser subsidies 122 are arranged between the second-layer and third-layer outer ribs and inner ribs. The blind riser subsidies 122 extend from the outer rib 300 to the wide rib 320, so as to compensate the blind risers 121 for shrinkage toward the rib hot node 310 and the center of the casting.

[0040] Six large blind risers 141 are arranged on the bottom flange 140 of the multi-layer casting. Since the bottom heat node 143 of the bottom flange 140 is relatively large, the six large blind risers 141 are evenly distributed between the outer ribs 300 of the bottom layer. Meanwhile, an inner gate 510 is arranged below each of the large blind risers 141 so that the molten steel can flow smoothly from the large blind risers 141 during casting. Preferably, the diameter of the inner gate 510 is 60 mm.

[0041] The multi-layered riser system effectively compensates for the shrinkage of each layer of the multi-layer casting, avoiding defects such as shrinkage cavities and shrinkage porosity. At the same time, the risers evenly distributed in each layer help to discharge the gas in the cavity of each layer, preventing the formation of pore defects.

[0042] The gating system is designed as follows: the gating system 500 forms a layer-by-layer internal flow system in the inner cavity of the casting. Each layer of the inner cavity rib plate of the casting is provided with three internal flow inlets 520, preferably, the diameter of each internal flow inlet is 60 mm.

[0043] The pouring system 500 also includes a runner 530 and a straight runner 540. The runner 530 connects the internal inlet system with the internal gate 510 below the large dark riser 141. The straight runner 540 is arranged on the outside of the casting. Preferably, the diameter of the straight runner is 110 mm. Through this multi-layer distributed pouring system, the simultaneous pouring of each layer of the casting is achieved, so that the pouring of each layer is carried out simultaneously, ensuring that the temperature regulation and solidification sequence during the pouring process are consistent, so that the molten metal is evenly distributed and smoothly fills the entire multi-layer casting cavity. The multi-layer distributed pouring system guides the flow of molten metal and also has a certain shrinkage compensation effect, ensuring that the casting can obtain sufficient molten metal supplement during the solidification process, avoiding shrinkage holes and loose defects.

[0044] Modeling an overall sand mold according to the three-dimensional model, wherein the overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core formed by layered accumulation of several groups of sand molds;

[0045] According to the structural characteristics of the casting having multiple layers of staggered ribs, a sand mold structure is designed for each layer. Specifically, the sand mold 600 of the casting includes a bottom layer sand mold 610, a first layer outer ring sand mold 620, a first layer inner ring sand core 621, a second layer outer ring sand mold 630, a second layer inner ring sand core 631, a third layer outer ring sand mold and a third layer inner ring sand core (not drawn in the figure), an inner cavity sand core 640, and an upper layer sand mold 650. The first layer inner ring sand core 621 is nested in the first layer outer ring sand mold 620, the second layer inner ring sand core 631 is nested in the second layer outer ring sand mold 630, and the inner cavity sand core 640 runs through the first layer inner ring sand core 621 and the second layer inner ring sand core 631, and is located in the bottom layer sand mold 610 and the upper layer sand mold 650.

[0046] The bottom layer sand mold 610 is used for laying the inner gate and is provided with a lower core positioning structure. The first layer outer ring sand mold 620 forms six large hidden risers 141 and the bottom flange 140 structure of the casting. The first layer inner ring sand core 621 is composed of six identical inner ring cores, and the six inner ring cores are respectively embedded in the preset positions of the first layer outer ring sand mold 620 to form the inner cavity rib 200 structure of the casting.

[0047] The second layer outer ring sand mold 630 forms the shrinkage compensation channels of the six blind risers 121 of the casting, and the second layer inner ring sand core 631 is composed of six identical inner ring cores, which are respectively embedded in the preset positions of the second layer outer ring sand mold 630 to form the inner cavity rib 200 structure and the third layer flange 130 of the casting.

[0048] The third outer ring sand mold and the third inner ring sand core have the same structure as the second outer ring sand mold and the second inner ring sand core, forming the six blind risers 121 of the casting, the inner cavity rib plate 200 structure and the second flange 120 structure.

[0049] The inner sand core 640 forms the pouring system 500 , and the upper sand mold 650 is an integral structure. The upper sand mold 650 forms the first layer of flange 110 and six open risers 111 on the casting.

[0050] Finally, according to the height of the overall sand mold and the structure of the casting, the position of the overall sand mold parting surface is determined, and the overall sand mold is printed and assembled using a 3D printer; the 3D printed sand mold effectively overcomes the sand mold molding problem of the multi-layer casting of the present invention, and the 3D printing molding method solves the problem that it is difficult to design a real sample model for multi-layer castings.

[0051] The multi-layer casting integral casting technology in the present invention, including the design of the casting process and the modeling scheme, realizes the integral forming of the multi-layer casting by casting. The whole machine manufacturer can directly obtain the finished product by purchasing the casting, avoiding the manufacturing process of purchasing raw materials for many times and then welding. It effectively improves the economic benefits and production cycle, greatly shortens the production cycle, saves manpower and material resources, and reduces manufacturing costs.

[0052] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0053] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A method for integrally casting a multi-layer casting, wherein the multi-layer casting comprises a plurality of flanges and a plurality of ribs, wherein the plurality of flange structures are staggeredly connected by a plurality of the ribs, and wherein: The following steps are involved: S1: building a 3D model of a multi-layer casting in a 3D software, and designing a layered through-gating system and a layer-by-layer distributed riser system on the 3D model of the casting; S2: Modeling an overall sand mold according to the three-dimensional model, wherein the overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core formed by layered accumulation of several groups of sand molds; S3: determining the position of the parting surface of the integral sand mold according to the height of the integral sand mold and the structure of the casting, and printing the integral sand mold by using a 3D printer and assembling the mold; S4: Finish pouring.

2. The method for integrally casting a multi-layer casting according to claim 1, characterized in that: The rib plates include a plurality of inner cavity rib plates, a plurality of wide rib plates, and a plurality of outer rib plates. The plurality of inner cavity rib plates are close to the inner cavity of the multilayer casting, the plurality of wide rib plates are located between adjacent flanges, and the plurality of outer rib plates are arranged on the outer side of the flange.

3. The method for integrally casting a multi-layer casting according to claim 1, characterized in that: Six open risers are designed on the first layer flange of the multi-layer casting.

4. The integral casting method of a multi-layer casting according to claim 3, characterized in that a riser subsidy is provided between the open riser and the central portion of the casting.

5. The method for integrally casting a multi-layer casting according to claim 1, characterized in that: Six blind risers are respectively arranged at corresponding positions of the second layer flange and the third layer flange of the multi-layer casting.

6. The method for integrally casting a multi-layer casting according to claim 5, characterized in that: Concealed riser subsidies are provided between the outer ribs and the inner ribs of the second and third layers.

7. The method for integrally casting a multi-layer casting according to claim 1, characterized in that: Six large hidden risers are arranged on the bottom flange of the multi-layer casting, and the large hidden risers are evenly distributed between the outer ribs of the bottom layer.

8. The method for integrally casting a multi-layer casting according to claim 7, characterized in that: An inner gate is arranged below each of the large dark risers.

9. The method for integrally casting a multi-layer casting according to claim 1, characterized in that: The pouring system forms a layer-by-layer internal flow system in the inner cavity of the casting.

10. The method for integrally casting a multi-layer casting according to claim 9, characterized in that: Each layer of the inner cavity rib plate of the casting is provided with three inner flow inlets.

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