Method for the integral casting of a multilayer casting

Abstract

This invention relates to the field of casting technology, and more specifically, to a method for integral casting of multi-layer castings. This invention provides a method for integral casting of multi-layer castings, solving the problems of high difficulty in integral casting of multi-layer castings, long welding cycles during assembly, low economic efficiency, and difficulty in mass production in existing technologies. The integral casting technology for multi-layer castings in this invention includes the design of the casting process and the molding scheme, realizing the integral forming of multi-layer castings through casting. Complete machine manufacturers can directly obtain finished products by purchasing castings, avoiding the need for multiple purchases of raw materials and subsequent welding processes. This effectively improves economic efficiency and production cycle, significantly shortens the production cycle, saves manpower and material resources, and reduces manufacturing costs.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and more specifically, to a method for integral casting of multi-layer castings. Background Technology

[0002] The current manufacturing method for multi-layer support products involves welding steel plates together to form a single unit. This method has several drawbacks: long production and procurement cycles for raw materials (steel plates), complex and lengthy welding processes, significant limitations in welding quality due to manual labor and technical constraints, and the inevitable presence of numerous weld seams that severely impact the support's performance. Therefore, fine grinding of the weld seams is required after welding, resulting in substantial post-processing work. Traditional assembly and welding methods for support products suffer from long production cycles, high time and labor costs, difficulty in mass production, and inconsistent product quality.

[0003] If casting is used for production, the multi-layer bracket product has a complex structure with multiple flanges and interlaced ribs, making the overall casting extremely difficult. Even after casting is completed, the finished multi-layer casting product still has many quality problems such as shrinkage cavities and cracks. Summary of the Invention

[0004] This invention provides a method for integral casting of multi-layer castings, which solves the problems of high difficulty in integral casting of multi-layer castings, long welding cycle during assembly and welding, low economic efficiency, and difficulty in mass production in the prior art.

[0005] The objective of this invention is achieved by the integral casting method for the multi-layer casting, comprising the following steps:

[0006] S1: Model a three-dimensional model of a multi-layered casting in three-dimensional software, and design a layered, continuous gating system and a layer-by-layer distributed riser system on the three-dimensional model of the casting.

[0007] S2: Model the overall sand mold according to the three-dimensional model. The overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core, which are composed of several sets of sand molds layered and accumulated.

[0008] S3: Based on the height of the integral sand mold and the structure of the casting, determine the position of the parting surface of the integral sand mold, and use a 3D printer to print the integral sand mold and assemble it;

[0009] S4: Pouring complete.

[0010] In one embodiment, the stiffener includes a plurality of inner cavity stiffeners, a plurality of wide stiffeners, and a plurality of outer stiffeners. The plurality of inner cavity stiffeners are located near the inner cavity of the multilayer casting, the plurality of wide stiffeners are located between adjacent flanges, and the plurality of outer stiffeners are disposed on the outer side of the flange.

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

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

[0013] In one embodiment, six concealed risers are provided at corresponding positions on the second and third flanges of the multilayer casting.

[0014] In one embodiment, concealed risers are provided between the outer and inner stiffening plates of the second and third layers.

[0015] In one embodiment, six large concealed risers are provided on the bottom flange of the multi-layer casting, and the large concealed risers are evenly distributed between the outer stiffening plates of the bottom layer.

[0016] In one embodiment, an ingate is provided below each of the large dark risers.

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

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

[0019] The multi-layer casting integral casting technology in this invention, including the design of casting process and molding scheme, realizes the integral forming of multi-layer casting through casting. The whole machine manufacturer can directly obtain the finished product by purchasing castings, avoiding the manufacturing process of purchasing raw materials and then welding them together multiple times. This effectively improves economic efficiency and production cycle, greatly shortens the production cycle, saves manpower and material resources, and reduces manufacturing costs. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of a 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 This is a schematic diagram of the overall structure of the sand mold;

[0024] Figure 5 This is a 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 of sand mold structure;

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

[0028] 100-Flange, 200-Inner cavity stiffener, 300-Outer cavity stiffener, 400-Curved liner, 110-First layer flange, 111-Exposed riser, 112-Riser patch, 310-Stiffener hot joint, 320-Wide stiffener, 120-Second layer flange, 121-Concealed riser, 122-Concealed riser patch, 130-Third layer flange, 140-Bottom layer flange, 141-Large concealed riser, 142- Large dark riser, 143-bottom heat joint, 500-gating system, 510-ingate, 520-inner inlet, 530-sprue, 540-sprue, 600-integral sand mold, 610-bottom sand mold, 620-first outer ring sand mold, 621-first inner ring sand core, 630-second outer ring sand mold, 631-second inner ring sand core, 640-inner cavity sand core, 650-upper sand mold. Detailed Implementation

[0029] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0030] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0031] This invention provides a method for integral casting of multi-layer castings, which solves the problems of existing technologies such as the inability to cast multi-layer castings as a whole, long welding cycle during assembly and welding, low economic efficiency, and difficulty in mass production.

[0032] The objective of this invention is achieved as follows: the multi-layer casting includes several layers of flanges and several stiffening plates, the flange structure is connected by several stiffening plates, and the multi-layer casting has an overall slender structure, which has extremely poor feeding capacity from top to bottom during casting. Therefore, considering the characteristics of the multi-layer staggered stiffening plate structure of the casting, this invention proposes a whole-casting method for the multi-layer casting, which includes the following steps:

[0033] S1: Model a three-dimensional model of a multi-layered casting in three-dimensional software, and design a layered, continuous gating system and a layer-by-layer distributed riser system on the three-dimensional model of the casting.

[0034] S2: Model the overall sand mold according to the three-dimensional model. The overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core, which are composed of several sets of sand molds layered and accumulated.

[0035] S3: Based on the height of the integral sand mold and the structure of the casting, determine the position of the parting surface of the integral sand mold, and use a 3D printer to print the integral sand mold and assemble it;

[0036] S4: Pouring complete.

[0037] The specific implementation process is as follows: First, the riser system and gating system of the casting are designed in 3D software. The stiffening plates include several inner cavity stiffening plates 200, several wide stiffening plates 320, and several outer stiffening plates 300. The inner cavity stiffening plates 200 are located near the inner cavity of the multi-layer casting, the wide stiffening plates 320 are located between adjacent flanges, and the outer stiffening plates 300 are located on the outside of the flange 100. The inner cavity stiffening plates 200, wide stiffening plates 320, and outer stiffening plates 300 are staggered between the flanges 100.

[0038] The distribution structure of the riser system is as follows: six open risers 111 are designed on the first flange 110 of the multi-layer casting. A riser patch 112 is provided between the open riser 111 and the center of the casting. The riser patch 112 is set to conform to the structure of the casting. The riser patch 112 opens up the feeding channel from the open riser 111 to the center of the casting.

[0039] Six concealed risers 121 are provided at corresponding positions on the second-layer flange 120 and the third-layer flange 130 of the multi-layer casting. Concealed riser subsidies 122 are provided between the outer and inner stiffening plates of the second and third layers. The concealed riser subsidies 122 extend from the outer stiffening plate 300 to the wide stiffening plate 320, and serve to compensate for the shrinkage of the concealed risers 121 towards the stiffening plate hot joint 310 and the center of the casting.

[0040] Six large concealed risers 141 are provided on the bottom flange 140 of the multi-layer casting. Because the bottom hot spot 143 of the bottom flange 140 is relatively large, the six large concealed risers 141 are evenly distributed among the outer reinforcing plates 300 of the bottom layer. Simultaneously, an ingate 510 is provided below each large concealed riser 141, allowing molten steel to flow smoothly into the casting process through the large concealed riser 141. Preferably, the diameter of the ingate 510 is 60 mm.

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

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

[0043] The gating system 500 also includes a sprue 530 and a sprue 540. The sprue 530 connects the internal flow system to the ingate 510 below the large dark riser 141. The sprue 540 is located on the outside of the casting, preferably with a diameter of 110 mm. This multi-layered distributed gating system enables simultaneous pouring of each layer of the casting, ensuring consistent temperature control and solidification sequence during the pouring process. This results in uniform metal distribution, smoothly filling the entire cavity of the multi-layered casting. The multi-layered gating system guides the flow of the molten metal and also provides some feeding, ensuring sufficient molten metal replenishment during solidification and preventing shrinkage cavities and porosity defects.

[0044] The overall sand mold is modeled based on the three-dimensional model. The overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core, which are composed of several sets of sand molds layered and accumulated.

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

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

[0047] The second outer ring sand mold 630 forms feeding channels for the six hidden risers 121 of the casting. The second inner ring sand core 631 is composed of six identical inner ring cores. The six inner ring cores are respectively fitted into the preset positions of the second outer ring sand mold 630 to form the inner cavity rib plate 200 structure and the third 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 feeding channels of the six hidden risers 121, the internal cavity rib plate 200 structure, and the second flange 120 structure of the casting.

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

[0050] Finally, based on the height of the integral sand mold and the structure of the casting, the position of the parting surface of the integral sand mold is determined, and the integral sand mold is printed using a 3D printer and assembled. The 3D printed sand mold effectively overcomes the sand mold forming problem of the integral casting of multi-layer castings in this invention, and the 3D printing forming method solves the problem of the difficulty in designing a real model of multi-layer castings.

[0051] The multi-layer casting integral casting technology in this invention, including the design of casting process and molding scheme, realizes the integral forming of multi-layer casting through casting. The whole machine manufacturer can directly obtain the finished product by purchasing castings, avoiding the manufacturing process of purchasing raw materials and then welding them together multiple times. This effectively improves economic efficiency and production cycle, greatly shortens the production cycle, saves manpower and material resources, and reduces manufacturing costs.

[0052] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above 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 embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A method for integral casting of a multi-layered casting, the multi-layered casting comprising several layers of flanges and several stiffening plates, wherein the flange structure is formed by the staggered connection of several said stiffening plates, characterized in that, Includes the following steps: S1: Model a three-dimensional model of a multi-layered casting in three-dimensional software, and design a layered, continuous gating system and a layer-by-layer distributed riser system on the three-dimensional model of the casting. S2: Model the overall sand mold according to the three-dimensional model. The overall sand mold includes an outer cavity contour sand mold and an inner cavity contour sand core, which are composed of several sets of sand molds layered and accumulated. S3: Based on the height of the integral sand mold and the structure of the casting, determine the position of the parting surface of the integral sand mold, and use a 3D printer to print the integral sand mold and assemble it; S4: Pouring complete.

2. The method for integral casting of multi-layer castings according to claim 1, characterized in that, The stiffeners include several inner cavity stiffeners, several wide stiffeners, and several outer stiffeners. Several of the inner cavity stiffeners are located near the inner cavity of the multi-layer casting, several of the wide stiffeners are located between adjacent flanges, and several of the outer stiffeners are located on the outside of the flanges.

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

4. The integral casting method for multi-layer castings according to claim 3, characterized in that a riser supplement is provided between the exposed riser and the center part of the casting.

5. The method for integral casting of multi-layer castings according to claim 1, characterized in that, Six concealed risers are provided at corresponding positions on the second and third flanges of the multi-layer casting.

6. The method for integral casting of multi-layer castings according to claim 5, characterized in that, Hidden risers are provided between the outer and inner stiffening plates of the second and third layers.

7. The method for integral casting of multi-layer castings according to claim 1, characterized in that, Six large concealed risers are provided on the bottom flange of the multi-layer casting, and the large concealed risers are evenly distributed between the outer stiffening plates of the bottom layer.

8. The method for integral casting of multi-layer castings according to claim 7, characterized in that, An ingate is provided below each of the large dark risers.

9. The method for integral casting of multi-layer castings according to claim 1, characterized in that, The gating system forms a layer-by-layer internal flow system within the cavity of the casting.

10. The method for integral casting of multi-layer castings according to claim 9, characterized in that, Each inner cavity rib of the casting is provided with three internal inlets.

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