Method and device for removing high-pressure casting pouring system

Abstract

The invention discloses a method and a device for removing a high-pressure casting pouring system. The method comprises the following steps: generating a preset fracture guide structure on one side of a product body in a connecting area of the product body and a pouring system; the high-pressure casting with the structure is moved along a first axis of movement and is engaged with the moving gating system in a predetermined position by means of a separation tool. Through the synergistic effect of continuous movement of the workpiece and meshing hindering of the separation tool, a composite separation force composed of a shearing force and a bending / drawing force is generated at the preset fracture guiding structure, and therefore the pouring system is separated accurately in a low-damage mode along a preset path. According to the method, through a two-step method of'preset guiding and dynamic composite force separation ', rough impact fracture is converted into a controllable and low-stress crack propagation process, the problems that a product body is prone to being damaged, the fracture surface quality is poor and the percent of pass is low in a traditional process are fundamentally solved, and the automation level and precision of removal operation and the product quality are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of post-processing of metal formed parts, in particular to a high-pressure casting pouring system removal method and device. BACKGROUND

[0002] High-pressure casting (HPDC) is a widely used metal part forming process in modern industry, which is made by injecting molten metal into a mold cavity at high pressure and high speed. During the casting process, a pouring system (including a handle, a cross runner, an ingate, etc.) needs to be set up to guide the metal liquid to fill the cavity. After the casting is formed and demolded, this pouring system, as an excess part, must be removed from the casting body.

[0003] Currently, the common methods for removing the pouring system include:

[0004] 1. Manual knocking / hammering: workers use tools to manually knock off, which has high labor intensity, low efficiency, safety risks, and unstable removal quality, and is prone to damage the casting body or cause burr residue, and is not suitable for automated production.

[0005] 2. Mechanical punching: using a dedicated punching die and a press to punch off, which has high efficiency and is suitable for mass production. However, its main defects are: each casting needs to be matched with a dedicated die, resulting in high die cost, long changeover time, and poor flexibility; more importantly, the impact stress generated during the punching process may cause deformation, cracking or even internal micro-cracks in the casting (especially in thin-walled or complex structure areas), which seriously affects the final mechanical properties and reliability of the product.

[0006] 3. Sawing: using a band saw or a disc saw to cut, which has better universality, but lower efficiency, generates a large amount of metal chips and noise pollution, and has poor cut surface quality, often requiring secondary polishing treatment, and the saw blade wears out quickly, resulting in high operating costs.

[0007] In summary, the existing removal techniques for high-pressure casting pouring systems generally have one or more technical problems such as low efficiency, high cost, high quality risk, poor flexibility, low automation level, and poor working environment, and there is an urgent need for a new solution that is efficient, low-cost, high-quality, and easy to implement automation and flexible production. SUMMARY

[0008] The technical problem to be solved by the present application is to provide a high-pressure casting auxiliary forming part removal method and device to solve the problems of easy damage to the product body, low automation level, poor flexibility, etc. in the prior art, and to achieve precise, low-damage, and efficient automated removal of the auxiliary forming part.

[0009] To achieve the above object, in a first aspect, the application provides a method for removing an auxiliary forming part of a high-pressure casting, the high-pressure casting comprising a product body and an auxiliary forming part connected to the product body, characterized in that the method comprises the following steps:

[0010] a pre-treatment step of generating a preset fracture guide structure on the product body at a connecting area between the product body and the auxiliary forming part; and

[0011] a separation step of moving the high-pressure casting along a first movement axis and engaging a separation tool with the auxiliary forming part in movement to generate a composite separation force at the connecting area, so as to separate the auxiliary forming part from the product body along the preset fracture guide structure.

[0012] Thus, the product body damage problem caused by random fracture path and rough force in the conventional removal method is solved. Specifically, the uncontrollable fracture is converted into controllable engineering behavior by presetting the fracture path on the product body through the "pre-treatment step"; and the smooth and continuous composite force is used to replace the instantaneous and huge impact force in the conventional process through the dynamic coordination mode of workpiece movement and tool engagement in the "separation step". The combination of the two fundamentally realizes the accurate and low-damage separation of the gating system, ensures the structural integrity of the product body, and improves the quality of the separated section.

[0013] In some optional embodiments of the application, in the separation step, the separation tool applies a force component along a second movement axis to the gating system, the second movement axis intersecting the first movement axis. Thus, by defining two intersecting movement axes, an effective geometric model for generating a "shear + bending / tension" composite force is established. This composite force action mode can more efficiently initiate and expand cracks at the preset guide structure compared to a single-direction force, so as to complete the separation with smaller total energy and further reduce the damage risk to the product body.

[0014] Preferably, the composite separation force comprises a shear force component applied by the separation tool along the second movement axis, and a bending or tension force component generated due to the movement of the high-pressure casting along the first movement axis being hindered by the separation tool. Thus, the composite force is decomposed into a "shear force component" and a "bending or tension force component", so that the force loading mode is more clear and controllable. The combination of such forces, especially the introduction of the bending or tension component, utilizes the lever principle and can effectively amplify the separation action, so that the separation process is more efficient and energy-saving.

[0015] Preferably, the first movement axis is a vertical direction, and the second movement axis is a horizontal direction. In this way, the first movement axis in the "vertical direction" and the second movement axis in the "horizontal direction" conform to the direction of gravity and the habit of conventional mechanical design, so that the device structure design is simplified, easy to manufacture and maintain, and convenient to connect with the feeding and discharging process of the automatic production line, with high engineering practicability.

[0016] In some optional embodiments of the present application, the preset fracture guide structure is a groove extending along the connecting area.

[0017] Preferably, the groove is generated by mechanical extrusion, cutting or laser ablation.

[0018] The groove is a very effective and mature stress concentration structure, and its geometric shape (depth, angle) can be accurately controlled, so that the fracture threshold and the height of the residual surface after separation can be stably controlled, ensuring the stability of the process and the consistency of the product. At the same time, mechanical extrusion, cutting or laser ablation and other methods are provided, giving the present application greater flexibility. Users can choose the most suitable processing method according to the casting material, production rhythm and cost requirements, for example, laser ablation is non-contact and more friendly to thin-walled parts; mechanical extrusion is low in cost and suitable for mass production.

[0019] In some optional embodiments of the present application, before the preprocessing step, a positioning step is further included: determining the reference surface of the product body by a sensor to closed-loop control the generation position of the preset fracture guide structure. Through closed-loop control by a sensor, real-time calibration and accurate control of the generation position of the guide structure are realized. This greatly improves the robustness and precision of the process, ensuring the high consistency of the residual height of each product after separation, which is a key guarantee for high-quality automated production.

[0020] In a second aspect, the present application provides an auxiliary forming part removal device for high-pressure castings, characterized in that it comprises:

[0021] A preprocessing module configured to generate a preset fracture guide structure on the product body at the connecting area between the product body and the auxiliary forming part;

[0022] A workpiece conveying mechanism configured to drive the high-pressure casting to move along a first movement axis; and

[0023] A separation tool arranged on the movement path of the first movement axis and configured to engage with the auxiliary forming part when the high-pressure casting moves, so as to generate a composite separation force at the connecting area in cooperation with the movement of the workpiece conveying mechanism.

[0024] In some optional embodiments of the present application, the separating tool is further configured with a second driving mechanism for driving the separating tool to move along a second movement axis intersecting the first movement axis, so as to actively apply a force component to the gating system.

[0025] In some optional embodiments of the present application, the workpiece conveying mechanism comprises a positioning disc for carrying the high-pressure casting and a first driving mechanism for driving the positioning disc to move along the first movement axis.

[0026] In some optional embodiments of the present application, the first movement axis is vertical, and the second movement axis is horizontal; and the separating tool is a breaking tool head.

[0027] In some optional embodiments of the present application, the device further comprises a clamping module for positioning and fixing the high-pressure casting before the high-pressure casting moves.

[0028] In some optional embodiments of the present application, the pre-treatment module comprises a pre-treatment tool and a driving mechanism for driving the pre-treatment tool.

[0029] In some optional embodiments of the present application, the device further comprises a control system electrically connected with the pre-treatment module, the workpiece conveying mechanism and the separating tool, for cooperatively controlling actions of the pre-treatment module, the workpiece conveying mechanism and the separating tool.

[0030] Compared with the prior art, the present application has the following beneficial effects:

[0031] 1. Improved accuracy and quality of separation: Through the pre-treatment step, a fracture guide structure (such as a stress concentration groove) is generated on the product body in advance, which sets the starting position and expansion path of the fracture. This makes the subsequent fracture behavior change from a random event to a deterministic process along the preset trajectory, fundamentally avoiding damage to the product body, ensuring the flatness and position accuracy of the separated surface, and the residual height can be accurately controlled, reducing or eliminating the need for secondary processing.

[0032] 2. Reduced risk of damage to the product body: The separation step uses a composite separation force (such as the combination of shear force and tensile / bending force), which acts on the preset stress concentration point. Compared with a single large impact force, it can induce and expand the crack in a smaller total energy and more gentle manner, significantly reducing the impact stress on the entire casting, effectively preventing deformation, cracking or internal micro-cracks of the product body, and ensuring the mechanical properties and structural integrity of the product.

[0033] 3. Improved production efficiency and automation level: The method and apparatus of this invention decompose the complex removal process into standardized steps such as positioning, pretreatment, and separation, making it easy to achieve fully automated operation through program control. Its modular design concept, combined with adjustable positioning and execution mechanisms, gives it excellent flexibility, enabling it to quickly adapt to castings of different specifications. This solves the problems of long changeover time and high cost of traditional punching dies, and is an effective way to improve the overall efficiency of die casting production lines and achieve intelligent manufacturing. Attached Figure Description

[0034] To more clearly illustrate the technical solutions of the embodiments disclosed in this invention, the accompanying drawings of the embodiments will be briefly described below. These drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0035] Figure 1 This is a schematic diagram of the high-pressure casting and gating system of the present invention.

[0036] Figure 2 This is a schematic diagram of the overall structure of a device according to an embodiment of the present invention.

[0037] Figure 3 This is a partially enlarged schematic diagram of the preprocessing steps in an embodiment of the present invention.

[0038] Figure 4 These are comparison images of fracture morphology with and without stress grooves.

[0039] Figure 5 This is a block diagram of a control system according to an embodiment of the present invention.

[0040] Figure 6 This is a flowchart of a method according to an embodiment of the present invention. Detailed Implementation

[0041] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by way of listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0042] Example 1

[0043] like Figures 1 to 5 As shown in the figure. This embodiment provides a removal device for a high-pressure casting gating system. Figure 1 The workpiece to be processed is shown, consisting of product body 3 (i.e., high-pressure casting) and gating system, which are connected together. The goal of this device is to separate the gating system 8 from the product body without damage and efficiently.

[0044] The device mainly includes positioning tool, i.e. clamping module, slotting mechanism, i.e. pretreatment module 20, breaking mechanism, the core of which is separation tool 5, and workpiece conveying mechanism, and control system 40. The whole device is built on a frame welded by high-rigidity profile and aged to ensure the stability and long-term accuracy of the equipment during operation.

[0045] The positioning tool is the basis of the whole device, which is used for accurate positioning and stable clamping of the high-pressure casting with the gating system taken out from the die casting machine. In the embodiment, the positioning tool is customized according to the external contour and key positioning features of the product body 3, and the part in contact with the workpiece is preferably made of high-molecular wear-resistant material (such as MC nylon) to avoid scratching the surface of the casting. The positioning tool ensures that the casting does not have any macroscopic displacement or microscopic vibration during the subsequent slotting and separation process,

[0046] The slotting mechanism is used to generate a preset fracture guide structure on the product body 3. The mechanism mainly includes a first driving member 1 as a driving mechanism and a shear cutter head 2 as a pretreatment tool.

[0047] The first driving member 1 is preferably a rodless cylinder in the embodiment. The rodless cylinder has an external guide slider, which can provide high-rigidity linear motion. The two ends are configured with buffers, and the precision pressure reducing valve and bidirectional throttle valve are integrated in the air circuit, so that the control system 40 can accurately program control the motion speed, acceleration and final output force, instead of simple two-point reciprocation.

[0048] The shear cutter head 2 is installed on the slider of the rodless cylinder 1, and the cutting edge is designed as a specific V-shaped angle of 75° to obtain the best stress concentration effect. The cutter head material is PVD coated hard alloy to improve wear resistance and service life.

[0049] Work flow: After the device is started, the upper surface of the high-pressure casting product body 3 is first detected by the high-precision displacement sensor (resolution ≤0.01 mm) or photoelectric sensor installed on the adjustable positioning support, and the coordinate information of this position is fed back to the control system 40 as the reference (Z=0). The control system 40 controls the rodless cylinder 1 to drive the shear cutter head 2 to accurately travel to the target position according to the reference signal and the preset process parameters. For example, Figure 3 and Figure 4As shown, the target position is 1 mm above the upper surface of the product body 3, where the precise extrusion is performed at the junction of the ingate and the body. The shear cutter head 2 extrudes a V-shaped stress groove with a depth of about 1.5 mm at this position. After the slotting action is completed, the control system 40 instructs the rodless cylinder 1 to maintain the extrusion for 3 seconds, which is a pressure stabilization phase, and the purpose is to allow the internal stress of the metal material to be fully released and stabilized, to ensure that the microstructure of the root of the V-shaped groove is uniform, and to avoid weakening the stress concentration effect due to elastic recovery. The role of this V-shaped stress groove is to macroscopically create a geometric discontinuity of the weak cross section, and microscopically induce stress concentration, so that this area becomes the weakest link of the entire connecting part, laying the foundation for subsequent low-energy and precise separation.

[0050] The breaking mechanism cooperates with the workpiece conveying mechanism to generate a composite separation force and induce fracture through a dynamic process. The combined mechanism utilizes a clever mechanical coupling design, mainly including a flow guide plate 4, a breaking cutter head 5 as a separation tool, and a top cylinder 6 and a positioning disc 7 as main driving components of the workpiece conveying mechanism.

[0051] After the slotting step is completed, the top cylinder 6 (as the first driving mechanism of the workpiece conveying mechanism) drives the positioning disc 7 to press down, and the positioning disc 7 in turn pushes the flow guide plate 4. The flow guide plate 4 stably supports the entire casting during the pressing process and conveys it along the first movement axis (vertically downward) to the breaking position. The downward speed of the workpiece conveying mechanism is precisely controlled by the control system 40, for example, set to 0.5 mm / s, to ensure smooth and impact-free process.

[0052] During this process, the breaking cutter head 5 cooperates with the workpiece carried by the flow guide plate 4. The breaking cutter head 5 is fixedly installed at a predetermined height, or is driven by a separate second driving mechanism (such as a cylinder or a servo slide) to extend to the working position along the second movement axis (horizontal direction).

[0053] When the pouring system reaches the height of the breaking cutter head 5 along with the downward movement of the workpiece, the cooperative separation process begins:

[0054] Force component one (lateral shear force): the blade of the breaking cutter head 5 engages with the side wall of the pouring system, exerting a horizontal shear force that prevents it from passing.

[0055] Force component two (longitudinal traction force / bending force): at the same time, the workpiece conveying mechanism continues to drive the entire casting to move downward at a constant power. This downward macroscopic movement trend, due to the obstruction by the breaking cutter head 5 at the pouring system, generates a strong longitudinal traction force or bending moment at the previously formed V-shaped stress groove, which attempts to "bend" or "break" the pouring system downward.

[0056] The forces in these two directions—lateral shear force and longitudinal traction force—create a tensile-shear composite stress field at the previously formed V-shaped stress groove. The direction of the maximum principal stress in this composite stress field is precisely guided to be approximately perpendicular to the preset fracture surface of the V-shaped stress groove, thereby concentrating the energy required for fracture at this weak point. The fracture process is no longer the violent impact of traditional punching, but a controlled crack initiation and stable propagation process along a preset path, ultimately achieving precise separation of the gating system from the product body 3, with a smooth fracture surface and consistent residual height.

[0057] In this embodiment, the control system 40 uses a programmable logic controller (PLC) as its core and can also be configured with a touchscreen HMI. It receives signals from various sensors (such as high-precision displacement sensors, photoelectric sensors, and cylinder magnetic switches) and precisely controls the sequence of actions, movement speed, output force, and delay time of the actuators, including the rodless cylinder 1 and the top cylinder 6, according to a preset process formula. For example, the control system ensures that the positioning accuracy of the shearing head 2 reaches the 0.1mm level, accurately executes the 3-second pressure stabilization time after grooving, and strictly controls the 0.5mm / s moving speed of the workpiece conveying mechanism during the breaking process to achieve flexible fracture. All process parameters can be set, stored, and recalled on the HMI, facilitating production management and quality traceability.

[0058] Furthermore, this device can be designed with flexibility and modularity to adapt to the needs of multi-variety, small-batch production.

[0059] Flexibility: The position sensor is installed using an adjustable positioning mechanism. When replacing castings of different heights or shapes, maintenance personnel do not need complex mechanical modifications. They only need to call up the new program on the HMI and simply adjust the physical detection reference surface of the sensor to quickly complete the changeover and debugging.

[0060] Modular design: Components that directly contact the casting or are strongly related to the model, such as positioning fixtures, guide plates 4, shearing heads 2, and breaking heads 5, all use standardized interfaces for installation. When a completely new product needs to be produced, only these new modular components need to be designed and manufactured, and they can be quickly replaced, greatly shortening the cycle and cost of introducing new products.

[0061] Example 2

[0062] This embodiment details the specific process of implementing the gating system removal method using the above-described device. The following will combine... Figure 6 The method flowchart is explained in detail.

[0063] Step S101: Positioning Step

[0064] S101.1, loading and clamping: a high-pressure casting with a complete gating system is placed on the positioning fixture of the removal device by a mechanical arm or manually. The positioning pins and clamps on the positioning fixture automatically clamp and fix the casting.

[0065] S101.2, reference surface scanning positioning: the control system 40 is started, and the high-precision displacement sensor scans the upper surface of the casting body to determine an accurate Z-axis direction reference zero point.

[0066] Step S102: slotting step

[0067] S102.1, accurate extrusion of V-shaped slot: the control system 40 instructs the slotting mechanism to work, and drives the shear cutter head 2 to accurately extrude a V-shaped stress slot with a depth of 1.5 mm and located 1 mm away from the body 1 at the root of the ingate.

[0068] S102.2, pressure stabilization: the shear cutter head 2 maintains the extrusion state for 3 seconds to stabilize the material deformation and prepare for the controlled fracture in the next step.

[0069] S102.3, slotting mechanism reset: after the pressure stabilization is completed, the shear cutter head 2 is automatically reset.

[0070] Step S103: breaking step

[0071] S103.1, workpiece conveying to breaking station: the top pneumatic cylinder 6 is started to drive the positioning disc 7 and the flow guide plate 4 to stably convey the casting to the breaking station.

[0072] S103.2, engagement of separation tool: when the gating system reaches the predetermined height, the breaking cutter head 5 extends and engages with the gating system.

[0073] S103.3, composite force induced fracture: the workpiece continues to move downward, and its movement cooperates with the resistance of the breaking cutter head to generate a composite force at the V-shaped stress slot, inducing the crack to expand along the preset path, and finally achieving separation.

[0074] Step S104: separation and offline

[0075] S104.1, automatic collection of waste: the separated gating system slides off the flow guide plate 4 and enters the waste frame below.

[0076] S104.2, finished product offline: the clean casting body continues to be taken away by the conveying mechanism and enters the next process.

[0077] As Figure 4 shown, the effect of the present application is remarkable. Figure 4(A) shows the random, rough and body damage fracture caused by traditional punching process, metallographic test shows that there are dense micro-cracks (15-20 / mm2) in the damage area, which leads to a product rejection rate of up to 24%. And Figure 4 (B) shows the fracture morphology after using the method of the present application, the fracture surface is smooth, most importantly, the casting body is completely free of structural damage, and the final residual height is stably controlled within the range of 0.2±0.05mm, the product pass rate is improved to more than 99.6%, greatly improving the product quality and reliability.

[0078] Those skilled in the art can easily understand that the above is only a preferred embodiment of the present application, and is not intended to limit the present application, and any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present application are included in the protection scope of the present application.

Claims

1. A method of removing a gating system of a high pressure casting, the high pressure casting including a product body and a gating system connected to the product body, characterized by, The method comprises the following steps: a preprocessing step of forming a preset fracture guide structure on the product body at a connecting area between the product body and the gating system; and a separation step of moving the high-pressure casting along a first movement axis and engaging a separation tool with the moving gating system to generate a combined separation force at the connecting area, so as to separate the gating system from the product body along the preset fracture guide structure.

2. The method of claim 1, wherein, In the separation step, the separation tool applies a force component to the gating system along a second movement axis intersecting the first movement axis, and the combined separation force includes a shearing force component constituted by the force component, and a bending or tensile force component generated due to the movement of the high-pressure casting along the first movement axis being hindered by the separation tool.

3. The method of claim 2, wherein, The first movement axis is a vertical direction, and the second movement axis is a horizontal direction.

4. The method of claim 1, wherein, The preset fracture guide structure is a groove extending along the connecting area.

5. The method of claim 1, wherein, Before the preprocessing step, the method further comprises: a positioning step of determining a reference surface of the product body by a sensor to close-loop control the generated position of the preset fracture guide structure.

6. A gating system removal device for high pressure castings for carrying out the method according to any one of claims 1 to 5, characterized in that The method comprises: a preprocessing module configured to form a preset fracture guide structure on the product body at a connecting area between the product body and the gating system; a workpiece conveying mechanism configured to drive the high-pressure casting to move along a first movement axis; and a separation tool arranged on a movement path of the first movement axis and configured to engage with the gating system when the high-pressure casting moves, so as to generate a combined separation force at the connecting area in cooperation with the movement of the workpiece conveying mechanism. The preprocessing module comprises a preprocessing tool for forming a groove.

7. The apparatus of claim 6, wherein, The separation tool is configured to apply a force component to the gating system along a second movement axis intersecting the first movement axis, so as to generate a shearing force component; and the workpiece conveying mechanism is configured to continue driving the high-pressure casting to move while the separation tool applies the force component, so as to generate a bending or tensile force component.

8. The apparatus of claim 6, wherein, The workpiece conveying mechanism comprises a positioning disc for carrying the high-pressure casting and a first driving mechanism for driving the positioning disc to move in a vertical direction; and the separation tool is a breaking tool head configured to apply a force in a horizontal direction.

9. The apparatus of claim 8, wherein, The method further comprises a control system electrically connected with the preprocessing module and the workpiece conveying mechanism, and the control system comprises a position sensor for determining a reference surface of the product body to close-loop control the generated position of the preset fracture guide structure.

10. The apparatus of claim 8, wherein, ​

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