Integrated sand core structure for casting molding and manufacturing method thereof

Abstract

The invention relates to an integrated sand core structure for casting molding, which comprises a plurality of core body modules, the plurality of core body modules are spliced into a sand core through a mortise and tenon joint structure according to a preset sequence, and the sand core adopts a vertical pouring process. The technical problems that in the prior art, due to the fact that a plurality of small parts of a sand core are spliced, the precision is reduced, extra supports and consumables are needed, and the cost and the post-processing complexity are increased are solved. The invention also provides a manufacturing method. The manufacturing method comprises the following steps: generating a plurality of core body modules through 3D; the multiple core body modules are spliced into the sand core according to a preset sequence; and vertical pouring is conducted.

Description

Technical Field

[0001] The present invention relates to an integrated core structure for casting molding and a manufacturing method thereof. Background Art

[0002] In the casting industry, 3D printing core technology has been widely used in rapid sample delivery and customization of products. The core advantage of this technology lies in its ability to quickly manufacture cores that meet specific requirements, greatly shortening the product R & D cycle. The traditional 3D printing core manufacturing method is to divide the core required for casting into multiple small parts, and these small parts are assembled into a complete core by means of screws, nails or adhesives. However, this method of segmented printing and assembly, while improving efficiency, also gives rise to multiple technical problems.

[0003] First of all, since the core is assembled from multiple small parts, this leads to a gradual reduction in the accuracy during the core assembly process. The errors of each small part during assembly will be superimposed on each other, thus affecting the positioning accuracy of the final core. Especially in castings with high dimensional accuracy and wall thickness uniformity requirements, the accuracy problem is particularly prominent. In order to ensure the wall thickness uniformity of the core, it is often necessary to additionally increase support structures such as chaplets, which not only further increases the complexity of assembly, but also increases the production cost.

[0004] Secondly, the consumables used in the core assembly process (such as screws, glue, etc.) increase the production cost, and during later cleaning, these assembly consumables may have an adverse impact on the quality of the casting, increasing the difficulty of later cleaning and processing.

[0005] Therefore, the main problems faced by the current technology are: due to the core being assembled from multiple small parts, the accuracy decreases; and in order to ensure the stability of the core structure, additional supports are often required and a large amount of assembly consumables are consumed, thus increasing the production cost and the complexity of later processing.

[0006] These technical problems indicate that the existing core assembly methods still cannot meet the production requirements of high precision, high efficiency and low cost. To solve these problems, a new technical solution is urgently needed, which can improve the core assembly accuracy, reduce manual operation and consumable use, and at the same time reduce the overall production cost. Summary of the Invention

[0007] The purpose of the present invention is to solve the above deficiencies of the prior art, and provide an integrated core structure for casting molding and a manufacturing method thereof.

[0008] An integrated core structure for casting molding includes: a plurality of core modules, and the plurality of core modules are spliced into a core through a mortise and tenon structure in a predetermined order, and the core adopts a vertical pouring process.

[0009] Further, the multiple core modules include an intermediate core module and an external core module, and the intermediate core module is located inside the external core module.

[0010] Further, the intermediate core module includes an integrally formed crankshaft core, a water jacket core for housing the crankshaft core, and two end cores installed at the front and rear ends of the crankshaft core and the water jacket core. The water jacket core is located above the crankshaft core.

[0011] Further, the external core module includes an integrally formed base core located below the intermediate core, a riser top cover core above, side cores on both sides, and a gate core. The side cores are in a semi-surrounding structure and wrap the intermediate core inside.

[0012] Further, the intermediate core module, the side cores, and the gate core are all on the upper end surface of the base core, and the gate core is on the side of the side cores.

[0013] The integrated sand core structure according to claim 5, wherein an oil passage is provided in the side core.

[0014] A manufacturing method of an integrated sand core structure for casting molding, comprising the following steps:

[0015] S1: Generate multiple core modules through 3D;

[0016] S2: Assemble the multiple core modules into a sand core in a predetermined order;

[0017] S3: Perform vertical pouring.

[0018] Further, the core modules in step S1 include an intermediate core module and an external core module. The intermediate core module includes an integrally formed crankshaft core, a water jacket core, and two end cores. The external module includes an integrally formed base core, a riser top cover core, two side cores, and a gate core.

[0019] Further, the specific predetermined order in S2 is as follows:

[0020] First, place the crankshaft core on the base core so that the bottom surface of the crankshaft core is connected to the upper end surface of the base core. Then, place the two end cores at the front and rear ends of the crankshaft core respectively, place the water jacket core on the upper side of the crankshaft core, place the two side cores on the left and right sides of the crankshaft core respectively, wrap the intermediate core inside, place the riser top cover core above the side cores, and place the gate core on one side of the side cores on the base core.

[0021] Further, the core modules are assembled through a mortise and tenon structure.

[0022] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0023] By integrating the heights of multiple sand core modules into functional modules, the number of core assembly, component assembly, and core setting is significantly reduced, the process flow is simplified, and the dimensional accuracy of the casting is effectively improved;

[0024] Avoid using consumables such as screws, bolts, glue, and nails commonly used in traditional assembly, reducing assembly costs and eliminating auxiliary tools such as special fixtures, thereby reducing the overall manufacturing cost;

[0025] Utilize 3D printing technology to precisely construct key structures such as water jacket cores, avoid using traditional core supports, and combine with vertical pouring technology. Only a simple lifting tool is required to complete core assembly, further improving assembly efficiency and reducing manual labor intensity;

[0026] The high integration of the sand core structure not only improves assembly accuracy and product consistency, but also optimizes casting quality, providing reliable technical support for the high-precision, high-efficiency, and low-cost manufacturing of complex castings. Brief Description of the Drawings

[0027] Figure 1 is an exploded view of the integrated sand core structure;

[0028] Figure 2 is a schematic diagram of installing the crankshaft core;

[0029] Figure 3 is a schematic diagram of installing the end core;

[0030] Figure 4 is a schematic diagram of installing the water jacket core;

[0031] Figure 5 is a schematic diagram of installing the side core;

[0032] Figure 6 is a schematic diagram of installing the riser top cover core and the gate core;

[0033] Figure 7 is a flowchart of the manufacturing method;

[0034] In the figure, 1. riser top cover core, 2. water jacket core, 3. end core, 4. gate core, 5. side core, 6. base core, 7. crankshaft core. Detailed Description of the Embodiment

[0035] To deepen the understanding of the present invention, the present invention will be further described in detail below in combination with embodiments and drawings. The embodiments are only used to explain the present invention and do not limit the protection scope of the present invention.

[0036] An integrated sand core structure for casting molding includes: a plurality of core modules, and the plurality of core modules are spliced into a sand core through a mortise and tenon structure in a predetermined order, and the sand core adopts a vertical pouring process.

[0037] Through the combination of multiple core modules, the integrated core structure realizes the modular and detachable design of the core structure. Each core module is connected by a mortise and tenon structure, ensuring the stability and precision of the structural connection, while facilitating assembly and disassembly, and is suitable for the forming requirements of complex castings. The mortise and tenon structure provides a physical mating interface, enabling precise positioning and fixation between modules without relying on external fasteners. Adopting a vertical casting process helps improve the filling efficiency of molten metal and reduces the generation of inclusions and pores, thereby optimizing the organizational structure and mechanical properties of the finished product.

[0038] This embodiment significantly improves the manufacturing flexibility and production efficiency of the core through modular design. The use of the mortise and tenon structure reduces the assembly difficulty, improves the assembly precision and stability, and reduces the dependence on labor. The vertical casting process optimizes the flow path of the molten metal during casting, reduces defects such as cold shuts and pores, and improves the density and mechanical properties of the finished product. The overall structure facilitates standardized production, enhancing the quality consistency and economic benefits of batch manufacturing.

[0039] In a possible embodiment, the multiple core modules include an intermediate core module group and an external core module group, and the intermediate core module group is located inside the external core module group.

[0040] The intermediate core module group is nested in the external core module group as a core structure, presenting an overall nested configuration. Through hierarchical distribution, the structure of the core part of the casting is formed by the intermediate module group, and the peripheral support structure and process channels are completed by the external module group. The two cooperate to meet the forming requirements of complex cavities, enhancing the overall strength and shape retention ability of the core.

[0041] By setting the intermediate core module group and the external core module group, the functional modules are partitioned in terms of structure, enhancing the strength and stability of the core when withstanding the pouring pressure. The nested structure enables natural positioning of each module during splicing, improving the assembly efficiency and precision, and reducing the probability of misalignment and core breakage, which is suitable for the precision manufacturing of complex geometric castings.

[0042] In a possible embodiment, the intermediate core module group includes an integrally formed crankshaft core 7, a water jacket core 2 that houses the crankshaft core 7, and two end cores 3 installed at the front and rear ends of the crankshaft core 7 and the water jacket core 2. The water jacket core 2 is located above the crankshaft core 7.

[0043] The intermediate core module group takes the crankshaft core 7 as the core, the water jacket core 2 is placed on its upper part to wrap and define its position, and the end cores 3 restrict and fix it from the front and rear ends, forming a stable three-dimensional enclosure structure. This structure is suitable for the internal cavity casting of crankshafts or similar shaft parts, and can effectively define the position of the core mold, ensuring the cavity precision and geometric integrity.

[0044] The integrally formed structure improves the overall stiffness and reduces the splicing error. The water jacket core 2 cladding structure helps to ensure uniform stress and cooling effect during pouring, thus preventing the casting from generating thermal cracks and stress concentration. The end core 3 axially restricts the position of the crankshaft core 7, further ensuring the stability of the intermediate module.

[0045] In a possible implementation, the external core module includes a base core 6 integrally formed below the intermediate core, a riser top cover core 1 above, side cores 5 on both sides, and a gate core 4. The side core 5 is a semi-surrounding structure that wraps the intermediate core.

[0046] The external module is configured around the intermediate module, where the base core 6 provides a support platform, the side cores 5 laterally support the intermediate module in a semi-surrounding manner, the riser top cover core 1 is used for capping and guiding the riser position, and the gate core 4 is arranged on the side for the introduction channel of liquid metal. This structure integrates mechanical support, forming positioning, and process channels, improving the degree of process integration.

[0047] The upper and lower clamping structure of the base core 6 and the riser top cover core 1 improves the overall stability and avoids the offset or deformation of the intermediate module during pouring. The semi-surrounding structure of the side core 5 enhances the lateral support force while ensuring convenient installation and disassembly. The overall structure design helps to simplify the mold clamping process and reduce the operation difficulty.

[0048] In a possible implementation, the intermediate core module, side core 5, and gate core 4 are all connected to the upper end face of the base core 6, and the gate core 4 is connected to the side of the side core 5.

[0049] All core modules are rigidly or fittedly connected to the base core 6 to form a unified bearing platform, making the overall force of the sand core more uniform. The gate core 4 is located on the side of the side core 5 and forms a complete pouring path through lateral connection, ensuring that the liquid metal is injected into the cavity along the established path and preventing flow deviation.

[0050] Fixing multiple modules on the base core 6 helps to unify the positioning reference and improve the assembly consistency. The lateral connection of the gate core 4 and the side core 5 provides a flexible channel layout scheme, and at the same time helps to adjust the gate direction to meet the filling requirements of different casting structures, enhancing the structural versatility and flexibility.

[0051] In a possible implementation, an oil passage is provided inside the side core 5.

[0052] Embodiment 2:

[0053] A manufacturing method of an integrated sand core structure for casting forming includes the following steps:

[0054] S1: Module generation

[0055] Manufacture multiple core modules separately using 3D printing technology.

[0056] The core modules specifically include an intermediate core module and an external core module. The intermediate core module is composed of a crankshaft core 7, a water jacket core 2, and two end cores 3 formed integrally; the external core module is composed of a base core 6, a riser top cover core 1, two side cores 5, and a gating core 4 formed integrally. This 3D printing method can efficiently and precisely construct a sand core assembly with a complex structure.

[0057] S2: Module splicing

[0058] Each core module is spliced in a predetermined order to form a complete sand core.

[0059] The specific order is as follows: First, place the crankshaft core 7 on the base core 6 and make the bottom surface of the crankshaft core 7 contact and fix with the upper end surface of the base core 6; then, respectively set the two end cores 3 at the front and rear ends of the crankshaft core 7 to axially limit the crankshaft core 7; then, place the water jacket core 2 above the crankshaft core 7 to complete the wrapping; then, respectively arrange the two side cores 5 on the left and right sides of the crankshaft core 7 to form a semi-surrounding structure and wrap the entire intermediate core therein; subsequently, place the riser top cover core 1 above the side cores 5 to complete the top closure; finally, arrange the gating core 4 on one side of the side core 5 on the base core 6 for constructing the inlet of the molten metal. All the above core modules are fitted and connected through a mortise and tenon structure to ensure the assembly accuracy and structural stability.

[0060] S3: Vertical pouring

[0061] Place the completed spliced sand core structure in the mold and perform vertical pouring process operations.

[0062] This process can optimize the flow path and filling effect of the molten metal by means of gravity, and improve the density and forming quality of the casting.

[0063] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An integrated core structure for casting forming, characterized in that, Including: A plurality of core modules, which are spliced into a sand core by a mortise and tenon structure in a predetermined order, and the sand core adopts a vertical casting process.

2. The integrated core structure according to claim 1, wherein, The plurality of core modules include an intermediate core module group and an external core module group, and the intermediate core module group is located inside the external core module group.

3. The integrated core structure according to claim 2, wherein, The intermediate core module group includes a crankshaft core formed integrally, a water jacket core for receiving the crankshaft core, and two end cores installed at the front and rear ends of the crankshaft core and the water jacket core. The water jacket core is located above the crankshaft core.

4. The integrated core structure according to claim 3, wherein The external core module group includes a base core integrally formed and located below the intermediate core, a riser top cover core above, side cores on both sides, and a gate core. The side cores are in a semi-surrounding structure and wrap the intermediate core inside.

5. The integrated core structure according to claim 4, characterized in that, The intermediate core module group, the side cores, and the gate core are all on the upper end face of the base core, and the gate core is on the side of the side core.

6. The integrated core structure according to claim 5, characterized in that, An oil passage is provided in the side core.

7. A manufacturing method of an integrated core structure for casting forming, characterized in that, Boakuo includes the following steps: S1: Generate a plurality of core modules through 3D; S2: Splice the plurality of core modules into a sand core in a predetermined order; S3: Perform vertical casting.

8. The manufacturing method according to claim 7, characterized in that, The core modules in step S1 include an intermediate core module group and an external core module group. The intermediate core module group includes a crankshaft core, a water jacket core, and two end cores formed integrally. The external module group includes a base core, a riser top cover core, two side cores, and a gate core formed integrally.

9. The manufacturing method according to claim 8, characterized in that, The specific predetermined order in S2 is: First, place the crankshaft core on the base core so that the bottom surface of the crankshaft core is connected to the upper end face of the base core. Then, place the two end cores at the front and rear ends of the crankshaft core respectively, place the water jacket core on the upper side of the crankshaft core, place the two side cores on the left and right sides of the crankshaft core respectively, wrap the intermediate core inside, place the riser top cover core above the side cores, and place the gate core on one side of the side core on the base core.

10. The manufacturing method according to claim 8, characterized in that, The core modules are spliced through a mortise and tenon structure.

Images