Vacuum negative pressure casting mold disc

Abstract

The invention discloses a vacuum negative pressure casting mold disc which comprises a mold disc set, a lifting driving frame, a negative pressure assembly and a plurality of crystal heads fixed to the inner side of the mold disc set. The output end of the lifting driving frame is provided with a plurality of dummy bar heads which are arranged in one-to-one correspondence with the crystallization heads; a negative pressure coil pipe, a drainage coil pipe and a cooling liquid pipe are fixedly installed on the surface of the mold disc set. The rotary sealing cover plate motor is adopted to drive rotation to control the casting process, a crystal head is gradually closed during molten aluminum casting, the filling mode is optimized, molten aluminum oxidation is reduced, and the surface quality of a casting is improved. And meanwhile, by combining the sectional aluminum water filling technology and the sectional negative pressure pumping technology, gas inclusion is effectively reduced, the uniformity of the casting is improved, and the air hole defect generated in the casting process is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of negative pressure casting, and specifically to a vacuum negative pressure casting die plate. Background Art

[0002] In the field of metal casting, the casting processes of aluminum alloys and other non-ferrous metals have relatively high requirements for the structural density, surface finish, and mechanical properties of castings. Traditional casting methods, such as gravity casting, low-pressure casting, and ordinary negative pressure casting, still have certain limitations in aspects such as molten aluminum filling, cooling control, and casting quality consistency, resulting in defects such as shrinkage cavities, gas holes, inclusions, and uneven microstructure in castings, which affect the quality of the final product.

[0003] In the existing negative pressure casting technology, a single negative pressure system is usually used to perform overall vacuum pumping on multiple crystallizers, so that the molten aluminum enters the crystallizers under the action of negative pressure. However, in this method, due to the different pipeline lengths and flow channel resistances at different crystallizers, it is difficult to maintain a consistent negative pressure environment in each crystallizer, resulting in uneven filling rates of molten aluminum, and causing shrinkage cavities or segregation phenomena in some castings. When the molten aluminum flows into the crystallizers under the action of negative pressure, the fluidity may be uneven due to too strong or too weak local negative pressure, affecting the quality of the castings.

[0004] In the prior art, the molten aluminum usually fills all the crystallizers in a single continuous pouring manner. In practical applications, when the molten aluminum is exposed to the air during the pouring process, it will react with oxygen to form an oxide film, affecting the surface quality of the castings. And when the molten aluminum is quickly injected into the crystallizers, air may be trapped inside the molten aluminum, resulting in gas hole defects and affecting the mechanical properties of the castings.

[0005] Therefore, how to optimize the negative pressure control method, improve the stability of molten aluminum filling, reduce oxidation and gas holes during the casting process, and improve the dynamic response ability of the cooling system has become an important technical problem in the current casting industry. In view of the defects of the prior art, the present invention proposes an improved vacuum negative pressure casting die plate, which optimizes the casting process, improves the quality of castings, and enhances the production efficiency through innovative technologies such as independent negative pressure control, segmented pouring of molten aluminum, and intelligent cooling regulation. Summary of the Invention

[0006] The present invention aims to solve one of the technical problems existing in the prior art or related technologies.

[0007] The present invention provides a vacuum negative pressure casting die plate, which integrates a vacuum suction system, a cooling system, a casting control system, and an intelligent monitoring system for efficient and precise aluminum rod casting. The present invention realizes efficient molten aluminum filling, dynamic cooling control, and intelligent optimization of casting parameters by integrating an independent and detachable vacuum system on the surface of the crystallizer, effectively improving the casting quality, production efficiency, and equipment maintenance convenience.

[0008] The vacuum negative pressure casting die plate of the present invention mainly includes a die plate group, a lifting drive frame, a negative pressure assembly, a rotary sealing cover plate, a cooling system and an intelligent monitoring system.

[0009] (1) Die plate group

[0010] Crystallization head: It is used to hold molten aluminum and perform negative pressure casting and cooling and forming. A cooling cavity is arranged outside it, a suction cavity is arranged inside it, and it is communicated with the negative pressure system through exhaust holes. A number of independent flow channels communicating with each crystallization head are arranged in the suction cavity and the air intake filter box.

[0011] Negative pressure coil pipe: It is used to provide an independent vacuum negative pressure environment to quickly fill the crystallization head with molten aluminum.

[0012] Drainage coil pipe: It is used to drain the waste water in the cooling system to ensure stable cooling during the casting process.

[0013] Coolant pipe: It is used to convey the coolant to the cooling cavity to accelerate the solidification of molten aluminum and optimize the casting efficiency.

[0014] Liquid discharge hole: It is used to connect the cooling system to realize the cyclic discharge of the coolant.

[0015] (2) Lifting drive frame

[0016] Dummy bar head: Corresponding to each crystallization head, it is used to control the drawing of the aluminum rod, so that the aluminum rod is gradually formed and demolded during the casting process.

[0017] Hydraulic drive unit: It is used to control the lifting of the dummy bar head so that the aluminum rod can be smoothly pulled out and improve the casting precision.

[0018] (3) Negative pressure assembly

[0019] Pump box: It provides negative pressure power to ensure uniform filling of the crystallization head with molten aluminum.

[0020] Spiral roller: Installed inside the pump box and meshed with each other for transmission, it is used to adjust the negative pressure air flow and improve the stability of molten aluminum filling.

[0021] Air intake filter box: Connecting to the negative pressure system, it filters the incoming air to prevent impurities from affecting the vacuum environment and improve the casting quality.

[0022] Waste heat collection device: Installed inside the air intake filter box, it is used to recover the waste heat generated during the casting process and preheat the molten aluminum to improve the energy utilization rate.

[0023] (4) Rotary sealing cover plate

[0024] It is rotatably installed on the top of the die plate group, and its bottom surface is in sliding contact with the crystallization head, so that the molten aluminum is gradually poured and sealed at different casting stages, ensuring the stability of the negative pressure environment. It is provided with a pouring port for injecting molten aluminum into the crystallization head and ensuring uniform filling of the molten aluminum under the action of negative pressure.

[0025] (5) Sensor group

[0026] Temperature sensor: Monitor the temperature of the crystallization head to ensure the cooling effect.

[0027] Vacuum pressure sensor: Monitor the negative pressure state in the suction cavity to ensure uniform filling of the molten aluminum.

[0028] Flow sensor: Monitor the flow rate of the coolant to optimize the stability of the cooling system.

[0029] Data processing unit: Analyze the sensor data and feedback it to the control system to optimize the casting parameters.

[0030] The beneficial effects achieved by the present invention are as follows:

[0031] 1. In the present invention, an independent negative pressure coil is used to connect each crystallization head to ensure uniform negative pressure for each crystallization head, improve the stability of molten aluminum filling, and use an annular vacuum flow channel to optimize the negative pressure suction effect, improve the density of the aluminum rod, and reduce casting defects.

[0032] 2. In the present invention, the rotary sealing cover plate is driven by a motor to rotate and gradually seal the crystallization head during the molten aluminum casting process, optimize the casting process, reduce the oxidation of the molten aluminum, and improve the surface quality of the casting. When the molten aluminum is rapidly injected, air may be trapped inside the molten aluminum, forming pore defects. Using rotary segmented filling can allow the air in each crystallization head to be more fully discharged, reduce gas entrapment, and improve the density of the casting.

[0033] 3. In the present invention, a variable flow rate cooling system is adopted. According to the feedback data of the temperature sensor, the flow rate of the cooling water is adjusted in real time to ensure a stable temperature gradient during the casting process and reduce cracks or thermal deformation caused by stress concentration; a microchannel cooling design is adopted to make the cooling water flow uniformly in the cooling cavity, optimize the heat dissipation effect, and improve the surface finish and tissue density of the casting. Description of the Drawings

[0034] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present invention;

[0035] Figure 2 It is a schematic diagram of the structure of the die plate group and the negative pressure component of an embodiment of the present invention;

[0036] Figure 3 It is a schematic diagram of the exploded structure of the die plate group of an embodiment of the present invention;

[0037] Figure 4 Schematic cross-sectional structure diagram of a die plate group according to an embodiment of the present invention;

[0038] Figure 5 Schematic structure diagram of a die plate group and a dummy bar head according to an embodiment of the present invention;

[0039] Figure 6 Schematic structure diagram of a negative pressure component according to an embodiment of the present invention.

[0040] Reference numerals:

[0041] 100, die plate group; 110, crystallization head; 120, negative pressure coiled pipe; 130, drainage coiled pipe; 140, coolant pipe; 150, rotary seal cover plate; 101, cooling cavity; 102, suction cavity; 103, liquid discharge hole; 111, exhaust hole; 151, filling port;

[0042] 200, lifting drive frame; 210, dummy bar head;

[0043] 300, negative pressure component; 310, pump box; 320, spiral roller; 330, air inlet filter box; 400, sensor group. Detailed implementation manners

[0044] To make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below in conjunction with the specific implementation manners and with reference to the accompanying drawings. It should be noted that, without conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0045] It should be understood that these descriptions are only exemplary and are not intended to limit the scope of the present invention.

[0046] The following combines the attached Figures 1-6 Describes a vacuum negative pressure casting die plate provided by some embodiments of the present invention.

[0047] Embodiment 1: Overall structure and working process

[0048] A vacuum negative pressure casting die plate includes a die plate group 100, a lifting drive frame 200 and a negative pressure component 300, and combines a rotary seal cover plate 150, a cooling system, a vacuum system and an intelligent control system to achieve efficient and precise aluminum rod casting.

[0049] 1. Structural composition

[0050] 1 Die plate group 100

[0051] The mold plate group 100 is used to carry the entire casting process, and its main structure includes: The crystallizer head 110: used to hold molten aluminum and perform negative pressure casting and cooling and solidification. The negative pressure coil pipe 120: used to provide a vacuum negative pressure environment to quickly fill the crystallizer head 110 with molten aluminum. The drain coil pipe 130: connected to the cooling system to discharge the waste water during the cooling process. The coolant pipe 140: used to transport cooling water to the outer wall of the crystallizer head 110 to accelerate the solidification of molten aluminum. The cooling cavity 101: surrounding the outside of the crystallizer head 110 for cooling molten aluminum. The suction cavity 102: used to form a negative pressure environment to ensure uniform filling of molten aluminum into the drain holes 103 of the crystallizer head 110: used to discharge the cooling water to ensure the normal circulation of the cooling system. There are several independent flow channels communicating with each crystallizer head 110 in the suction cavity 102 and the air intake filter box 330.

[0052] 2 Lifting drive frame 200

[0053] The lifting drive frame 200 mainly includes: The dummy bar head 210: corresponding to the crystallizer head 110, playing the role of traction and controlling the shape of the aluminum rod. The lifting frame: supporting the lifting movement of the dummy bar head 210. The hydraulic drive unit: controlling the lifting process of the dummy bar head 210 to realize casting drawing.

[0054] 3 Negative pressure component 300

[0055] The negative pressure component 300 is used to provide a negative pressure environment during the casting process, and mainly includes: The pump box 310: providing the power for vacuum pumping. The spiral roller 320: rotating and controlling the air flow to ensure the stable operation of the vacuum system. The air intake filter box 330: used to filter air to prevent impurities from entering the vacuum system and ensure a clean casting environment.

[0056] 4 Rotary sealing cover plate 150

[0057] Rotating and installed on the top of the mold plate group 100, cooperating with the crystallizer head 110 to realize casting control. The bottom surface is slidably sealed with the crystallizer head 110 to prevent molten aluminum from leaking during casting. It is provided with a pouring port 151, and the crystallizer head 110 is sequentially poured with molten aluminum during the rotation process.

[0058] 5 Sensor group 400

[0059] Including: The temperature sensor monitors the temperature of the crystallizer head 110. The vacuum pressure sensor monitors the negative pressure condition of the suction cavity 102. The flow sensor monitors the flow rate of the cooling water. After the data is collected, it is transmitted to the control system to optimize the casting parameters.

[0060] Embodiment 2: Optimization scheme based on the double-layer vacuum cooling structure

[0061] Based on Embodiment 1, this embodiment further optimizes the layout of the vacuum system and the cooling system, adopts a double-layer vacuum cooling structure to improve the uniformity of molten aluminum filling, optimize the cooling effect and enhance the casting accuracy. The main features of this solution are:

[0062] A double-layer vacuum chamber is adopted, with a primary suction chamber 102A and a secondary suction chamber 102B arranged inside and outside the crystallizer head 110 respectively. The primary suction chamber 102A and the secondary suction chamber 102B are arranged vertically along the crystallizer head 110 to ensure a more uniform filling process of molten aluminum and improve the density of the casting.

[0063] The cooling system adopts a zoning temperature control strategy, with independent cooling circuits established in different cooling regions to improve the temperature control accuracy, reduce the casting stress and improve the quality of the casting.

[0064] The automatic control system is upgraded to optimize the negative pressure regulation, cooling regulation and automatic monitoring of the casting process, improving the degree of intelligence.

[0065] The working principle and usage process of the present invention:

[0066] The present invention provides a vacuum negative pressure casting die plate. Its main principle is to use negative pressure to suck molten aluminum into the crystallizer head 110, quickly solidify it in combination with the cooling system to form an aluminum rod, and control the casting process through the lifting drive frame 200 to achieve efficient and automated casting operations. The structural layout of this system is delicate, optimizing the cooling system, vacuum negative pressure control, casting accuracy and degree of automation, ensuring excellent quality of the aluminum rod, high production efficiency and convenient equipment maintenance.

[0067] 1. The core structure of the present invention includes: Die plate group 100: mainly bearing the entire casting system, including a plurality of crystallizer heads 110, on the surface of which there are negative pressure coiled pipes 120, drainage coiled pipes 130 and coolant pipes 140.

[0068] Crystallizer head 110: used for the forming and cooling of molten aluminum, with a cooling cavity 101 and a suction cavity 102 inside, and communicating with the negative pressure system through an exhaust hole 111.

[0069] Negative pressure assembly 300: including a pump box 310, a spiral roller 320, and an intake filter box 330, used to generate negative pressure and communicate with the suction cavity 102 to achieve negative pressure suction casting of molten aluminum.

[0070] Lifting drive frame 200: drives the dummy bar head 210 to lift synchronously, gradually pulling out the cast aluminum rod from the crystallizer head 110 and controlling the forming process of the aluminum rod.

[0071] Rotary sealing cover plate 150: used to gradually control the casting process of each crystallizer head 110 and ensure the stability of the negative pressure environment.

[0072] Sensor group 400: It includes a temperature sensor, a vacuum pressure sensor, and a flow sensor, which can monitor the key parameters of the casting process in real time and feed back to the control system.

[0073] 2. Working steps

[0074] 1. Foundry preparation stage

[0075] Mold plate heating: Preheat the mold plate group 100 through the heat-insulating mold cover to ensure that the crystallizer head 110 is at an appropriate casting temperature.

[0076] Pre-vacuuming of the crystallizer head 110: The negative pressure assembly 300 is started, and the negative pressure coil 120 is controlled to form a vacuum environment to ensure smooth filling of the molten aluminum.

[0077] Preparation of the rotary seal cover plate 150: The initial position of the rotary seal cover plate 150 covers the top of the crystallizer head 110, and the rotation opening sequence is set.

[0078] 2. Casting process

[0079] Pouring of molten aluminum: The molten aluminum is shunted through the pouring port 151 and enters into multiple crystallizer heads 110. Under the action of negative pressure, the molten aluminum is quickly filled into the entire crystallizer head 110 by the suction force of the suction cavity 102. The rotary seal cover plate 150 rotates synchronously to gradually control the pouring rhythm of the molten aluminum, so that the molten aluminum flows evenly into each crystallizer head 110.

[0080] Rapid cooling of molten aluminum: The cooling cavity 101 outside the crystallizer head 110 continuously circulates cooling water, and the cooling flow rate is adjusted through the coolant pipe 140 to make the molten aluminum solidify gradually from the outside to the inside. The variable flow regulating valve is used to automatically control the cooling water rate to ensure that the aluminum rod is formed uniformly and without cracks.

[0081] Pulling out and forming of aluminum rod: The lifting drive frame 200 drives the dummy bar head 210 to slowly descend, and at the same time the aluminum rod is gradually pulled out from the crystallizer head 110. The molten aluminum in the crystallizer head 110 continues to fill and solidify, making the aluminum rod grow continuously until it reaches the set length.

[0082] Intelligent monitoring: The sensor group 400 monitors the parameters such as the temperature of the crystallizer head 110, the cooling water flow rate, and the vacuum pressure in real time. Through data analysis, the casting process parameters are optimized to ensure casting stability and reduce casting defects such as inclusions and pores.

[0083] 3. Casting completion

[0084] The negative pressure assembly 300 gradually releases the negative pressure and stops sucking the molten aluminum. When the aluminum rod reaches the set length, it is cut by the automatic cutting device and conveyed to the subsequent processing procedures. Through the automatic slag removal device, the residual aluminum slag inside the crystallizer head 110 is removed to avoid affecting the next round of casting.

[0085] In the description of this specification, the descriptions of terms such as "one embodiment", "some embodiments", "specific embodiments", etc. mean that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or instance. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0086] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A vacuum negative pressure casting mold, characterized in that: include: A mold plate assembly (100), a lifting drive frame (200), a negative pressure assembly (300), and a plurality of crystallization heads (110) fixed inside the mold plate assembly (100); Wherein: the output end of the lifting drive frame (200) is provided with a plurality of ingot guide heads (210) arranged one by one corresponding to each crystallization head (110); the surface of the mold plate group (100) is fixedly installed with a negative pressure coil (120), a drainage coil (130) and a cooling liquid pipe (140); the inner side of the mold plate group (100) is provided with a cooling cavity (101) and a suction cavity (102) located at the periphery of each crystallization head (110); the surface of the crystallization head (110) is provided with an exhaust hole (111) connected to the suction cavity (102), and the port of the suction cavity (102) is connected to the negative pressure coil (120); the surface of the mold plate group (100) is provided with a drainage hole (103) for connecting the cooling cavity (101) with the drainage coil (130); A plurality of sensor groups (400) are fixedly mounted on the surface of the mold plate group (100) for detecting the working status of each crystallization head (110); a rotary sealing cover plate (150) is rotatably mounted on the inner side of the mold plate group (100); the bottom surface of the rotary sealing cover plate (150) is in sliding contact with the top surface of the crystallization head (110) for achieving sealing; and a pouring port (151) for casting the surface of the crystallization head (110) is provided on the surface of the rotary sealing cover plate (150).

2. A vacuum negative pressure casting mold according to claim 1, characterized in that: The lifting drive frame (200) comprises: A lifting frame is installed below the die plate assembly (100); A hydraulic drive unit, used for controlling the lifting and lowering of the dummy head (210); The position feedback device is used to monitor the position of the ingot starter (210) in real time and feed back to the control system.

3. A vacuum negative pressure casting mold according to claim 1, characterized in that: The sensor group (400) comprises: A temperature sensor, used to detect the internal temperature of the crystallization head (110); A vacuum pressure sensor, used to monitor the vacuum degree of the suction chamber (102); The flow sensor is used to monitor the cooling water flow in the cooling liquid pipe (140).

4. A vacuum negative pressure casting mold according to claim 1, characterized in that: The negative pressure component (300) comprises: A pump box (310) for providing negative pressure power; Rotating two spiral rollers (320) installed inside the pump box (310), the two spiral rollers (320) mesh with each other for transmission; An air intake filter box (330) is used to filter incoming air to prevent impurities from affecting the negative pressure environment. The suction chamber (102) and the air intake filter box (330) are provided with a plurality of independent flow channels connected to each crystallization head (110); The waste heat collection device is arranged inside the air intake filter box (330) and is used to recover the waste heat generated during the casting process and to preheat the aluminum liquid.

5. A vacuum negative pressure casting mold according to claim 1, characterized in that: The top surface of the mold plate group (100) is provided with a heat-insulating mold cover, and the top surface of the heat-insulating mold cover is installed with a motor for driving the rotary sealing cover plate (150) to rotate.

6. A vacuum negative pressure casting mold according to claim 1, characterized in that: The inner wall of the crystallization head (110) is provided with a replaceable high-temperature resistant coating, which is a ceramic coating or a boron nitride coating, so as to reduce the adhesion of aluminum liquid and improve durability and thermal conductivity efficiency.

7. A vacuum negative pressure casting mold according to claim 1, characterized in that: The inner wall of the suction chamber (102) is provided with an annular vacuum flow channel, which optimizes the uniformity of molten aluminum filling through multi-point suction, reduces gas inclusions, and improves the density of the aluminum rod.

8. A vacuum negative pressure casting mold according to claim 1, characterized in that: The coolant pipe (140) is provided with a variable flow regulating valve inside, which can automatically adjust the coolant flow rate according to the temperature of the crystallization head (110) to optimize the cooling efficiency of the casting process and reduce cracks caused by temperature stress.

9. The vacuum negative pressure casting mold according to claim 1, characterized in that: An automatic slag discharge device is provided at the bottom of the mold plate group (100) for cleaning the aluminum slag in the mold plate after casting is completed, thereby improving casting efficiency and extending the service life of the mold plate.

10. The vacuum negative pressure casting mold according to claim 1, characterized in that: A flexible sealing ring is provided at the bottom of the transfer cover plate (150), and the sealing ring is made of high-temperature resistant silica gel or graphite material, and is used to enhance the sealing effect between the crystallization head (110) and the transfer cover plate (150), so as to improve the stability of the negative pressure environment.

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