Design method of feeding head structure

Abstract

The invention belongs to the field of aluminum magnesium alloy pouring systems, and relates to a design method of a feeding head structure. Calculating the modulus Mj of the position, needing feeding, of the casting according to computer numerical simulation or a formula method, selecting the modulus Mm = (1.1-1.2) Mj (cm) of the root position of the riser in order to ensure that the modulus of the riser part is larger than the modulus of the position, needing feeding, of the casting, and calculating the diameter phi d (mm) of the root of the riser according to the modulus Mm = (1.1-1.2) Mj (cm); and the diameter phi D (mm) and the height H (mm) of the final solidification part of the riser are calculated according to a special riser design formula disclosed by the invention, so that the riser structure disclosed by the invention can be efficiently designed. The modulus of the final solidification part of the riser is increased through the spherical part, the height of the riser is reduced, and the effects of reducing the amount of molten metal and prolonging the solidification time of the riser are achieved, so that the casting quality is improved, and the casting production qualification rate is increased.

Description

Technical Field

[0001] The invention belongs to the field of aluminum-magnesium alloy pouring systems and relates to a design method of a feeding riser structure. Background Art

[0002] Currently, the main risers used for aluminum-magnesium alloys include top risers, side risers, exposed risers, and concealed risers. The main risers used for aluminum-magnesium alloys include conformal risers, cylindrical risers, waist-round risers, hemispherical risers, and insulation risers. Insulation risers require specialized insulation materials, which are relatively expensive. Other risers have low shrinkage compensation efficiency, waste molten metal, and can easily cause overheating of the casting. Calculation methods for risers are primarily based on empirical calculations or rough calculations using the proportional method. This requires the designer to have extensive practical production experience and to continuously adjust the pouring plan based on actual production conditions, making it difficult to effectively promote. This significantly reduces the first-time success rate of castings, reduces the yield rate of castings, and affects the quality of castings. Summary of the Invention

[0003] Purpose of the Invention

[0004] The purpose of the present invention is to provide a high-efficiency feeding riser structure for the pouring system design process, which reduces the amount of molten metal used while improving the feeding capacity of the riser, and provides a riser size design method for the structure, making the riser design universal and efficient.

[0005] Technical Solution

[0006] To improve riser feeding efficiency and reduce molten metal usage, a method for designing a feeding riser structure is disclosed. The method first calculates the modulus Mj of the casting's feeding location based on computer numerical simulation or a formula method. To ensure that the riser modulus is greater than the casting's feeding location, the riser root modulus Mm is selected as (1.1-1.2)Mj (cm). Based on this, the riser root diameter φd (mm) is calculated. The riser's final solidification location diameter φD (mm) and height H (mm) are then calculated based on the dedicated riser design formula of the present invention. This allows for the efficient design of the riser structure shown in the present invention.

[0007] The specific steps include:

[0008] Step 1:

[0009] Calculate the modulus Mj (cm) of the location where the casting needs to be fed based on computer numerical simulation or formula method. Step 2:

[0010] The modulus Mm corresponding to the riser root φd position is set to Mm = (1.1-1.2)Mj (cm), and the riser root diameter is calculated based on this. Subsequent calculations need to be converted into mm units.

[0011] Step 3:

[0012] in accordance with Calculate the diameter φD (mm) of the spherical portion of the riser. Here, n is the ratio of the total volume of the riser to the volume of the cylindrical insulation riser, h (mm) is the distance from the bottom of the riser to the spherical root shown in the figure, and d (mm) is the diameter of the riser root.

[0013] Step 4:

[0014] in accordance with Calculate the height H of the center of the ball. The meanings of D, h, and d are as shown in step 3. Preferably, step 5 is also included:

[0015] In order to improve the shrinkage compensation capacity, R (30-40) mm transition is adopted between Φd and φD.

[0016] Preferably, the method further includes step six:

[0017] In order to facilitate demoulding, the sphere at position φD can be changed to a cylinder, and the cylinder is tangent to the upper hemisphere of the φD sphere, see Figure 2 .

[0018] Preferably, the method further comprises step seven:

[0019] In order to improve the shrinkage feeding capacity of the riser, insulation felt is attached to the cylindrical part of the riser, and the thickness of the insulation felt near the upper end of the riser is greater than that of the insulation felt at the lower end of the riser, which prolongs the solidification time of the riser. Figure 2 .

[0020] Preferably, in step 3, the value of n is 1.3-1.7. The value is determined based on the following: in order to improve the feeding effect and minimize the amount of molten metal, the total volume of the riser is compared with that of a cylindrical insulating riser with the same diameter Φd (the ratio of height to diameter is 3), and the ratio is set to 1.3-1.7. When the part to be fed is relatively thick, the value is closer to the upper limit, otherwise the value is closer to the lower limit.

[0021] Preferably, in step 4, h is specifically the distance from the bottom of the riser to the spherical root as shown in the accompanying drawings. Based on actual experience in feeder shrinkage, the value range is (30-40) mm. When the part to be fed is relatively thick, the value is closer to the lower limit, otherwise the value is closer to the upper limit.

[0022] Preferably, in step 2, the origin of d is:

[0023] The riser is a cylindrical insulation riser, and the ratio of the cylinder height to the diameter is 3. That is, when the riser diameter is d, the riser height is 3d, then:

[0024] Modulus

[0025] Simplify to get Preferably, in step 3, the D is derived from: if the total volume of the riser is n times the total volume of the cylindrical insulation riser, then the total volume of the riser is:

[0026] V ball + V cylinder = nV cylinder insulation

[0027] Right now

[0028] Simplified, we can get

[0029] Preferably, in step 4, the origin of H is: in this riser, according to the Pythagorean theorem:

[0030] (Hh) 2 +(d / 2) 2 =(D / 2) 2

[0031] Simplified, we can get The beneficial effects of this application are:

[0032] In order to improve the shrinkage feeding capacity of the riser, reduce the amount of molten metal and alleviate the tendency of castings to overheat, the present invention is improved on the basis of cylindrical insulation risers and conventional risers with draft angles. The modulus of the last solidification part of the riser is increased by the spherical part, and the height of the riser is reduced, so as to achieve the effect of reducing the amount of molten metal and extending the solidification time of the riser, thereby improving the quality of the castings and increasing the qualified rate of casting production.

[0033] Compared to cylindrical insulated risers, this riser boasts a volume 1.3-1.7 times that of a cylindrical insulated riser, but it offers a longer solidification time in the final solidification zone, resulting in better insulation. This also eliminates the need for specialized insulated riser materials, significantly saving costs. Compared to conventional risers with draft angles, this riser boasts a volume of only 68-88% of that of conventional risers, saving 12-32% of molten metal and providing improved shrinkage-feeding performance.

[0034] The technology of this invention can enhance the shrinkage-feeding effect of the riser and significantly reduce the weight of the molten metal within the riser, without the use of specialized insulating riser materials. This reduces the heating effect of the molten metal on the casting as it flows through the mold, effectively reducing overheating defects, thereby improving the quality of the casting and reducing waste losses. This method is simple to calculate and easy to promote. Currently, it has not only been successfully tested in the production of complex aviation aluminum-magnesium alloy castings, but also has expanded applications in aircraft cylinder blocks, cylinder head castings, and motor product castings. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a feeding riser structure of the present invention;

[0036] Figure 2It is a derivative structure of the feeding riser structure of the present invention;

[0037] Figure 3 It is a schematic diagram of the process of the present invention. DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solutions and advantages of the implementation of the present invention clearer, the technical solutions in the embodiments of the present invention will be described in more detail below in conjunction with the embodiments of the present invention. In the examples, the same or similar reference numerals throughout represent the same or similar originals or elements with the same or similar functions. The described embodiments are part of the embodiments of the present invention, not all of the embodiments. The embodiments described below by reference are illustrative and intended to be used to explain the present invention, and should not be understood as limiting the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. The following is a detailed description in conjunction with the embodiments of the present invention.

[0039] Example 1

[0040] The accessory casing of a helicopter is made of ZL114A alloy with a pouring weight of 200kg. A porosity defect often occurs at a cone position of the casting. To overcome this defect, a riser with this structure is used and the calculation steps are as follows: 1)

[0042] The modulus Mj=0.84 cm of the position where the casting needs to be fed is calculated based on computer numerical simulation or formula method. 2)

[0044] If the modulus Mm corresponding to the position φd at the root of the riser is set to Mm=1.15Mj=0.97cm, then:

[0045] 3)

[0047] in accordance with Calculate the diameter φD of the spherical part. Since Mj = 0.84 cm, which is not very thick, n is selected close to the lower limit, such as 1.4, and h can be selected close to the upper limit, such as h = 38 mm. Then, we have:

[0048] 4)

[0050] in accordance with Calculate the height H of the center of the sphere, then:

[0051] 5)

[0053] In order to improve the shrinkage compensation capacity, R35 transition is used at the Φ45 and φ77 positions. 6)

[0055] To facilitate demoulding, the upper end of the φ77 sphere is changed to a cylindrical shape, and the cylinder is tangent to the upper hemisphere of the φ77 sphere. 7)

[0057] In order to improve the shrinkage compensation capacity of the riser, insulation felt is attached to the cylindrical part of the upper end of the riser, and the thickness of the insulation felt close to the upper end of the riser is greater than that of the insulation felt at the lower end of the riser, thereby extending the solidification time of the riser.

[0058] Example 2

[0059] The mainframe casting of an aircraft is made of ZL105A alloy with a pouring weight of 400kg. One of the mounting edges of the casting often has a loose defect. To overcome this defect, a riser with this structure is used and the calculation steps are as follows: 1)

[0061] The module Mj=1cm of the position where the casting needs to be fed is calculated based on computer numerical simulation or formula method. 2)

[0063] If the modulus Mm corresponding to the position φd at the root of the riser is set to Mm=1.15Mj=1.15cm, then:

[0064] 3)

[0066] in accordance with Calculate the diameter φD of the spherical part. Since Mj = 1 cm, which is relatively thick, n is selected close to the upper limit, 1.6, and h is selected close to the lower limit, h = 32 mm, then:

[0067] 4)

[0069] in accordance with Calculate the height H of the center of the sphere, then:

[0070] 5)

[0072] In order to improve the shrinkage compensation capacity, R40 transition is used at the Φ53 and φ100 positions. 6)

[0074] To facilitate demoulding, the sphere at the φ100 position is changed to a cylinder, and the cylinder is tangent to the upper hemisphere of the φ100 ball. 7)

[0076] In order to improve the shrinkage compensation capacity of the riser, insulation felt is attached to the cylindrical part of the riser, and the thickness of the insulation felt near the upper end of the riser is greater than that of the insulation felt at the lower end of the riser, thereby extending the solidification time of the riser.

[0077] By following these steps, key parameters such as φd, φD, and H can be quickly calculated for this riser structure, allowing for rapid fabrication. Calculations show that the total weight of the molten metal within this structure is 68-88% of the total weight of the molten metal within a conventional cylindrical riser (non-insulated riser), and the solidification time of the molten metal within the riser is also longer than that within a cylindrical riser. This improves the feed capacity of the riser while saving 12-32% of the molten metal and reducing the heating effect of the molten metal on the mold.

[0078] In addition, unless otherwise defined, the technical or scientific terms used in the description of this application should have the ordinary meanings understood by those of ordinary skill in the art to which this application belongs. The words "upper," "lower," "left," "right," "center," "vertical," "horizontal," "inner," and "outer" used in the description of this application are only used to indicate relative directions or positional relationships, and do not imply that the device or component must have a specific orientation, be constructed, or operate in a specific orientation. When the absolute position of the described object changes, its relative positional relationship may also change accordingly. Therefore, they should not be understood as limitations on this application. The words "first," "second," "third," and similar terms used in the description of this application are used only for descriptive purposes to distinguish different components and should not be understood to indicate or imply relative importance. The words "one," "an," or "the" used in the description of this application should not be understood as absolute limitations on quantity, but should be understood as meaning the presence of at least one. The words "include" or "comprises" used in the description of this application mean that the element or object listed before the word includes the elements or objects listed after the word and their equivalents, but does not exclude other elements or objects.

[0079] In addition, it should be noted that, unless otherwise clearly stipulated and limited, the words "install", "connect", "connect" and similar terms used in the description of this application should be understood in a broad sense. For example, the connection can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, an indirect connection through an intermediate medium, or a connection between two components. Technical personnel in the field can understand their specific meanings in this application according to the specific circumstances.

[0080] The above description is only a specific embodiment of the present invention and is not intended to limit the present invention. Within the spirit and principles of the present invention, any technician familiar with the profession may use the technical content disclosed above to change or modify it into an equivalent embodiment with equivalent changes and apply it to other fields. However, any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the present invention without departing from the content of the technical solution of the present invention, any modification, equivalent replacement, improvement, etc. made should be included in the scope of protection of the present invention.

Claims

1. A design method for a feeding riser structure, characterized in that: First, the modulus Mj of the position where the casting needs to be fed is calculated based on computer numerical simulation or formula method. In order to ensure that the modulus of the riser part is greater than the modulus of the position where the casting needs to be fed, the modulus Mm of the root position of the riser is selected as 1.1-1.2Mj, and the root diameter φd of the riser is calculated based on this; then, the diameter φD and height H of the final solidification part of the riser are calculated according to the riser design formula, thereby obtaining the riser structure.

2. The method according to claim 1, wherein The specific steps include: Step 1: Calculate the modulus Mj of the position where the casting needs to be fed based on computer numerical simulation or formula method; Step 2: The modulus Mm corresponding to the riser root φd position is set to Mm=1.1-1.2Mj, and the riser root diameter is calculated based on this The unit must be converted into mm for subsequent calculations; Step 3: in accordance with Calculate the diameter of the spherical part of the riser φD; n is the ratio of the total volume of the riser to the volume of the cylindrical insulation riser, h is the distance from the bottom of the riser to the spherical root, and d is the diameter of the riser root; Step 4: in accordance with Calculate the height H of the center of the sphere.

3. The method according to claim 2, wherein Also includes step five: In order to improve the shrinkage compensation capability, an R transition is used between Φd and φD; R is specifically 30-40mm.

4. The method according to claim 3, wherein Also includes step six: In order to facilitate demoulding, the sphere at the φD position is changed to a cylinder, and the cylinder is tangent to the upper hemisphere of the φD sphere.

5. The method according to claim 4, wherein Also includes step seven: In order to improve the shrinkage compensation capacity of the riser, insulation felt is attached to the cylindrical part of the riser, and the thickness of the insulation felt near the upper end of the riser is greater than that of the insulation felt at the lower end of the riser, thereby extending the solidification time of the riser.

6. The method according to claim 5, wherein In step 3, n is set to 1.3-1.

7. The value is selected based on the following: to improve the feeding effect and minimize the amount of molten metal, the total volume of the riser is compared with that of a cylindrical insulation riser of the same diameter Φd, and the ratio is set to 1.3-1.

7. When the part to be fed is thicker, the value is set to the upper limit, otherwise the value is set to the lower limit. In step 4, h is specifically the distance from the bottom of the riser to the root of the ball. Based on actual experience in feeder shrinkage, the value range is 30-40 mm. When the part to be fed is thicker, the value is closer to the lower limit, otherwise the value is closer to the upper limit.

7. The method according to claim 6, wherein In step 2, the origin of d is: The riser is a cylindrical insulation riser, and the ratio of the cylinder height to the diameter is 3. That is, when the riser diameter is d, the riser height is 3d, then: Modulus Simplify to get 8. The method according to claim 7, wherein In step 3, D is derived from: if the total volume of the riser is n times the total volume of the cylindrical insulation riser, then the total volume of the riser is: V ball + V cylinder = nV cylinder insulation Right now Simplified, we can get .

9. The method according to claim 8, wherein In step 4, the origin of H is: In this riser, according to the Pythagorean theorem: (H-h) 2 +(d / 2) 2 =(D / 2) 2 Simplified, we can get .

Images