Casting device and casting method

Abstract

The multi-station continuous charging device comprises a vibration platform and a base plate installed on the vibration platform, a double-temperature-zone heating jacket is arranged on the base plate, a first containing space with the top open is formed in the double-temperature-zone heating jacket, a mold with the top open is arranged in the first containing space, and a second containing space with the top open is arranged in the second containing space. A sealing cover is arranged at the top end of the double-temperature-zone heating jacket; a support is further arranged on the base plate, and a lower pressing plate used for pressing the sealing cover tightly is arranged on the support. And a negative pressure suction pipe is arranged on the sealing cover in a penetrating manner. According to the device, melting, mixing and solidification can be achieved, the integration level is high, the stability is high, the overall reliability under the vibration condition is ensured, the problems that traditional equipment is dispersed and poor in synergism are solved, vibration parameters are precisely regulated and controlled in a staged mode, the melting and mixing time is greatly shortened, and the production efficiency is improved; particle precipitation is avoided, effective nucleation of a melt is promoted, and the defects of shrinkage cavities, coarse grains and the like are reduced.

Description

Technical Field

[0001] This invention belongs to the technical field of melting and casting process equipment, specifically relating to a melting and casting device and a melting and casting method. Background Technology

[0002] As a core technology in the field of materials processing, melting and casting is widely used in key industries such as aerospace and automobile manufacturing, and its molding quality directly determines product performance. However, traditional melting and casting processes have long faced dual bottlenecks in efficiency and quality: in the material heating stage, the melting and mixing process relying on natural heat conduction is inefficient, has a long production cycle, and is prone to component segregation due to uneven mixing; in the solidification stage, defects such as shrinkage cavities, shrinkage porosity, and coarse grains often occur, which seriously affect the mechanical properties and reliability of the material.

[0003] Vibration can enhance flow field disturbance and heat exchange, accelerating the melting rate of materials. It also optimizes solidification structure by promoting nucleation and refining grains. However, existing vibration-assisted equipment is mostly a single-function module with low integration with the melting and casting equipment. The precision of vibration parameter adjustment is insufficient, making it difficult to achieve coordinated control of the process. More importantly, traditional melting and casting processes lack comprehensive online monitoring methods. Key parameters such as temperature and acceleration during the melting and mixing stage, and stress and strain during the solidification stage, cannot be collected in real time. This results in poor matching between process parameters and molding quality, leading to significant fluctuations in product yield, which urgently needs improvement. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a melting and casting apparatus and a melting and casting method to solve the technical problems of low melting and solidification efficiency and poor quality in existing melting and casting processes.

[0005] The present invention is implemented using the following technical solution: A multi-station continuous charging device for casting explosives includes a vibrating platform and a chassis mounted on the vibrating platform. A dual-temperature zone heating jacket is provided on the chassis. A first accommodating space with an open top is provided inside the dual-temperature zone heating jacket. A mold with an open top is provided inside the first accommodating space. A sealing cover is provided at the top of the dual-temperature zone heating jacket. The chassis is also equipped with a bracket, and the bracket is equipped with a pressure plate for pressing the sealing cover; A negative pressure suction tube is installed on the sealing cap.

[0006] The present invention also has the following technical features: Specifically, the dual-temperature zone heating jacket includes a jacket housing disposed on the chassis, a second accommodating space disposed within the jacket housing, a lower jacket disposed within the second accommodating space, and an upper jacket disposed above the lower jacket; a first flow cavity disposed within the upper jacket, the first flow cavity being connected to an upper temperature zone inlet and an upper temperature zone outlet respectively disposed on the outer wall of the upper jacket; a second flow cavity disposed within the lower jacket, the second flow cavity being connected to a lower temperature zone inlet and a lower temperature zone outlet respectively disposed on the outer wall of the lower jacket.

[0007] Furthermore, the support includes two uprights and a crossbeam fixedly connected to the two uprights.

[0008] Furthermore, a sensor mounting base capable of vertical movement is provided on the crossbeam. The bottom end of the sensor mounting base is connected to the lower pressure plate. A fiber optic grating sensor is installed inside the sensor mounting base, and the fiber optic grating sensor is inserted into the mold through a through hole opened on the sealing cover.

[0009] Furthermore, an acceleration sensor is also installed on the sealing cover.

[0010] Furthermore, the lower pressure plate includes a connecting ring, and multiple pressing portions are evenly spaced on the outer circumferential surface of the connecting ring.

[0011] Furthermore, the sensor mounting base is inserted into the connecting ring, and a limit ring is provided at the bottom of the sensor mounting base.

[0012] The upper jacket is provided with a first flow cavity, and the lower jacket is provided with... This invention also protects a casting method, which is implemented by the casting apparatus described above, and includes the following steps: Step 1: Material loading Open the sealing cover and place the mold filled with material into the dual-temperature zone heating jacket to complete the installation of the device; Step 2: Material melting The heating temperature of the upper and lower jackets is set to 80~98℃. After setting the material melting parameters, the melting and mixing device is started. The material melting parameters include the acceleration of the vibration platform being 5~15g and the melting time being 5~10min. Step 3: Material mixing When the temperature values ​​collected at the upper, middle and lower test points are equal, it is determined that the material has melted completely. Adjust the position of the sensor mounting base so that the upper test point of the fiber optic grating sensor is 2-3 mm above the liquid interface. Adjust the acceleration of the vibration platform to 30-60 g and the mixing time to 2-5 min. Step 4: Material solidification Turn on the vacuum pump to reduce the pressure inside the mold to below 50 kPa, reduce the vibration acceleration to 5~15g, set the upper jacket temperature to 70~80℃ and the lower jacket temperature to 40~55℃, until the temperature at the upper test point is lower than the melting point of the material. Adjust the temperature of both the upper and lower jackets to 30~40℃, and set the acceleration to 0~5g. Continue melting and casting until the temperatures at the upper, middle, and lower test points all reach the set temperature of the jackets.

[0013] Preferably, in step 1, the filling height of the material is not less than 2 / 3 of the mold height.

[0014] Compared with the prior art, the beneficial effects of the present invention are: (1) The device of the present invention can realize melting, mixing and solidification, with high integration and strong stability, ensuring overall reliability under vibration conditions, and solving the problems of dispersion and poor coordination of traditional equipment.

[0015] (2) The method of the present invention significantly shortens the melting time and improves production efficiency by controlling the processing in stages; the parameter setting in the solidification stage avoids particle precipitation and promotes effective nucleation of the melt, reducing defects such as shrinkage cavities and coarse grains; the subsequent stress release stage further reduces internal stress and improves the mechanical properties of the product.

[0016] (3) The method of the present invention realizes dynamic matching between process parameters and molding quality, provides comprehensive data support for process optimization, and improves the stability of product qualification rate.

[0017] Other advantages of the present invention will be described in detail in the specific embodiments. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the device of the present invention; Figure 2 This is a cross-sectional view of the device of the present invention; Figure 3 This is a partial structural schematic diagram of the present invention.

[0019] Explanation of the labels in the diagram: 1-Vibration platform, 2-Chassis, 3-Dual-temperature zone heating jacket, 4-Mold, 5-Sealing cover, 6-Bracket, 7-Lower pressure plate, 8-Negative pressure suction pipe, 9-Sensor mounting base, 10-Fiber optic grating sensor, 11-Acceleration sensor, 12-Limiting ring; 301-Jacket housing, 302-Lower jacket, 303-Upper jacket; 601-Column, 602-Beam; 701-Connecting ring, 702-Crimping part; 3021-Lower temperature zone inlet, 3022-Lower temperature zone outlet; 3031-Upper temperature zone inlet, 3032-Upper temperature zone outlet. Detailed Implementation

[0020] The following provides specific embodiments of the present invention. It should be noted that, in the description of the present invention, unless otherwise explicitly specified and limited, terms such as "set" and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection, etc. Those skilled in the art can understand the specific meaning of the above terms in this technical solution according to the specific circumstances.

[0021] In this invention, unless otherwise stated, directional terms such as "upper," "lower," "bottom," and "top" are generally defined based on the drawing surface of the corresponding figure, "inner" and "outer" are defined based on the outline of the corresponding figure, and "front" and "rear" are defined based on the direction of gas flow.

[0022] This invention is not limited to the following specific embodiments. The various specific technical features described in the following specific embodiments can be combined in any suitable manner without contradiction, as long as they do not violate the spirit of this invention, and should also be regarded as the content disclosed by this invention.

[0023] Example 1 Following the above technical solutions, such as Figures 1 to 3 As shown, this embodiment discloses a casting apparatus, including a vibration platform 1 and a chassis 2 mounted on the vibration platform 1. A dual-temperature zone heating jacket 3 is provided on the chassis 2. The dual-temperature zone heating jacket 3 has a first accommodating space with an open top. A mold 4 with an open top is provided in the first accommodating space. A sealing cover 5 is provided at the top of the dual-temperature zone heating jacket 3. A bracket 6 is also provided on the chassis 2. A lower pressure plate 7 for pressing the sealing cover 5 is provided on the bracket 6. A negative pressure suction pipe 8 is passed through the sealing cover 5 and is connected to a vacuum pump.

[0024] The vibration platform 1 provides controllable mechanical vibration, which improves the density and internal quality of the casting. The dual-temperature heating jacket 3 can be sealed to the sealing cover 5 to provide an independent and precise temperature control environment for the mold 4, thereby achieving uniform or gradient heating / cooling of the material inside the mold 4 through heat conduction. The vacuum pump is used to extract the air and any volatile gases that may be generated in the mold cavity through the negative pressure suction pipe, creating a vacuum or low-pressure environment in the closed space.

[0025] As a preferred embodiment, the dual-temperature zone heating jacket 3 includes a jacket housing 301 disposed on the chassis 2, a second accommodating space disposed within the jacket housing 301, a lower jacket 302 disposed within the second accommodating space, and an upper jacket 303 disposed above the lower jacket 302; a first flow cavity disposed within the upper jacket 303, the first flow cavity being connected to an upper temperature zone inlet 3031 and an upper temperature zone outlet 3032 respectively disposed on the outer wall of the upper jacket 303; a second flow cavity disposed within the lower jacket 302, the second flow cavity being connected to a lower temperature zone inlet 3021 and a lower temperature zone outlet 3022 respectively disposed on the outer wall of the lower jacket 302.

[0026] The lower jacket 302 and the upper jacket 303 are used to control the temperature of the lower and upper heating zones of the mold, respectively. By introducing media of different temperatures into the lower jacket 302 and the upper jacket 303, a precise and controllable temperature gradient can be formed along the axis of the mold 4. This is crucial for achieving directional solidification or zone melting and can effectively reduce casting defects.

[0027] As a preferred embodiment, the support 6 includes two columns 601 and a crossbeam 602 fixedly connected to the two columns 601.

[0028] As a preferred embodiment, a sensor mounting base 9 capable of vertical movement is provided on the crossbeam 602. The bottom end of the sensor mounting base 9 is connected to the lower pressure plate 7. A fiber optic grating sensor 10 is installed inside the sensor mounting base 9. The fiber optic grating sensor 10 is inserted into the mold 4 through a through hole opened on the sealing cover 5. The fiber optic grating sensor 10 inserted into the mold 4 has upper test points, middle test points and lower test points arranged at equal intervals from top to bottom.

[0029] The sensor mounting base 9 is used to position and fix the fiber Bragg grating sensor. Its mobility allows the insertion depth of the fiber Bragg grating sensor 10 to be adjusted according to different mold and process requirements. The upper test point, middle test point and lower test point can measure the material temperature at different height positions inside the mold 4 in real time, in situ and synchronously.

[0030] As a preferred embodiment, an acceleration sensor 11 is also installed on the sealing cover 5.

[0031] As a preferred embodiment, the lower pressure plate 7 includes a connecting ring 701, and a plurality of pressing portions 702 are equally spaced on the outer peripheral surface of the connecting ring 701.

[0032] As a preferred embodiment, the sensor mounting base 9 is inserted into the connecting ring 701, and a limit ring 12 is provided at the bottom of the sensor mounting base 9.

[0033] During installation, the device of this invention is as follows: The chassis 2 is fixed onto the vibration platform 1; then the assembled dual-temperature zone heating jacket 3 is installed on the chassis 2; the mold 4 is placed inside the dual-temperature zone heating jacket 3; the column 601 is fixed onto the chassis 2, and the crossbeam 602 is installed. Then, the sealing cover 5 is placed at the top of the dual-temperature zone heating jacket 3; the connection between the external dual-temperature mold temperature controller and the dual-temperature zone heating jacket 3 is completed; one end of the negative pressure suction pipe 8 is connected to the sealing cover 5, and the other end is connected to the vacuum pump; the fiber optic grating sensor 10 is passed through the sensor mounting base 9, and the height of the sensor mounting base 9 on the crossbeam 602 is adjusted to a suitable position; the detection end of the fiber optic grating sensor 10 is inserted into the mold 4; the lower pressure plate 7 is connected to the bottom end of the sensor mounting base 9, and the sealing cover 5 is pressed tightly.

[0034] Example 2 This embodiment discloses a melting and casting method for melting, mixing, and solidifying a mixture of paraffin wax with a melting point of 78°C and sodium sulfate with an average particle size of 200 μm in the melting and casting apparatus provided in Example 1, including the following steps: Step 1: Material loading Open the sealing cover and place the mold filled with material into the dual-temperature zone heating jacket to complete the installation of the device; Step 2: Material melting The heating temperature of both the upper and lower jackets is set to 90℃, the acceleration of the vibration platform is 10g, and the melting time is 8min. The melting and mixing device is started. Under vibration conditions, the flow field and heat exchange can be accelerated, and the material melting can be accelerated.

[0035] Step 3: Material mixing When the temperature values ​​collected at the upper, middle, and lower test points are equal, it is determined that the material has melted completely. The position of the sensor mounting base 9 is adjusted so that the upper test point of the fiber optic grating sensor 10 is 2 mm above the liquid phase interface (to monitor the gas phase ambient temperature). The acceleration of the vibration platform 1 is adjusted to 45g, and the mixing time is 3 minutes. This vibration condition can promote the rapid and thorough mixing of different phases in the mold 4. Specifically, the vibration of the vibration platform 1 causes micro-movements in the mold 4 and the material, which breaks the thermal boundary layer of the material, allowing heat to be transferred to the interior of the material more quickly and evenly, thereby "accelerating the melting of the material".

[0036] Step 4: Material solidification Turn on the vacuum pump and keep the pressure inside the mold below 50 kPa. Reduce the vibration acceleration to 8g (this vibration can refine the grains and promote the rise of bubbles without causing excessive disturbance to the solidifying interface). Set the temperature of the upper heating zone of the heating jacket to 72℃ and the temperature of the lower heating zone to 45℃. The temperature of the upper test point is lower than the melting point of the material. The purpose of this setting is to form a temperature gradient from top to bottom, guiding the solidification interface to advance sequentially from bottom to top, which is beneficial for feeding and reducing shrinkage cavities. Adjust the temperature of both the upper and lower heating zones to 35℃ and set the acceleration to 5g. This acceleration and temperature setting allows the internal stress to be released after solidification, reducing the deformation and cracking tendency of the casting. Continue until the temperature of all test points inside the material is 35℃, then end the casting process.

[0037] Preferably, in step 1, the material filling height is not less than 2 / 3 of the mold height to ensure that there is sufficient material in the mold 4 so that a sufficiently deep molten pool can be formed after the material melts, which is beneficial for subsequent mixing and solidification control.

[0038] In this embodiment, vibration is no longer a simple auxiliary means, but a control variable that runs through the entire process of melting, mixing and solidification. Furthermore, during the solidification stage, directional solidification is achieved through independent temperature control of the upper and lower temperature zones, effectively controlling the solidification structure and defects. The method of this invention is particularly suitable for fields with extremely high requirements for uniformity, internal quality and stress level.

[0039] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0040] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

[0041] It should be noted that all components involved in this embodiment, unless otherwise specified, are components that can be obtained by purchase in the prior art.

Claims

1. A casting apparatus, comprising a vibrating platform (1) and a chassis (2) mounted on the vibrating platform (1), characterized in that, The chassis (2) is provided with a dual-temperature zone heating jacket (3). The dual-temperature zone heating jacket (3) is provided with a first accommodating space with an open top. The first accommodating space is provided with a mold (4) with an open top. The top of the dual-temperature zone heating jacket (3) is provided with a sealing cap (5). The chassis (2) is also provided with a bracket (6), and the bracket (6) is provided with a lower pressure plate (7) for pressing the sealing cover (5). The sealing cover (5) is provided with a negative pressure suction pipe (8), which is connected to a vacuum pump.

2. The casting apparatus as described in claim 1, characterized in that, The dual-temperature zone heating jacket (3) includes a jacket housing (301) disposed on the chassis (2), a second accommodating space is provided in the jacket housing (301), a lower jacket (302) is disposed in the second accommodating space, and an upper jacket (303) is disposed above the lower jacket (302); a first flow cavity is provided in the upper jacket (303), which is connected to the upper temperature zone inlet (3031) and the upper temperature zone outlet (3032) respectively opened on the outer wall of the upper jacket (303); a second flow cavity is provided in the lower jacket (302), which is connected to the lower temperature zone inlet (3021) and the lower temperature zone outlet (3022) respectively opened on the outer wall of the lower jacket (302).

3. The casting apparatus as described in claim 1, characterized in that, The support (6) includes two columns (601) and a crossbeam (602) fixedly connected to the two columns (601).

4. The casting apparatus as described in claim 3, characterized in that, A sensor mounting base (9) capable of vertical movement is provided on the crossbeam (602). The bottom end of the sensor mounting base (9) is connected to the lower pressure plate (7). A fiber optic grating sensor (10) is provided inside the sensor mounting base (9). The fiber optic grating sensor (10) is inserted into the mold (4) through a through hole opened on the sealing cover (5). The fiber optic grating sensor (10) inserted into the mold (4) has upper test points, middle test points and lower test points arranged at equal intervals from top to bottom.

5. The casting apparatus as described in claim 1, characterized in that, An acceleration sensor (11) is also installed on the sealing cover (5).

6. The casting apparatus as described in claim 1, characterized in that, The lower pressure plate (7) includes a connecting ring (701), and a plurality of pressing parts (702) are provided at equal intervals on the outer circumferential surface of the connecting ring (701).

7. The casting apparatus as described in claim 4, characterized in that, The sensor mounting base (9) is inserted into the connecting ring (701), and a limit ring (12) is provided at the bottom of the sensor mounting base (9).

8. A casting method, characterized in that, The method is implemented using the casting apparatus according to any one of claims 1 to 7, and includes the following steps: Step 1: Material loading Open the sealing cover (5), put the mold (4) filled with material into the dual-temperature zone heating jacket (3) to complete the installation of the device; Step 2: Material melting The heating temperature of the upper jacket (303) and the lower jacket (302) is set to 80~98℃. After setting the material melting parameters, the melting and mixing device is started. The material melting parameters include the acceleration of the vibration platform (1) being 5~15g and the melting time being 5~10min. Step 3: Material mixing When the temperature values ​​collected at the upper test point, middle test point and lower test point are equal, it is determined that the material has melted completely. Adjust the position of the sensor mounting base (9) so that the upper test point of the fiber optic grating sensor (10) is 2~3mm above the liquid interface. Adjust the acceleration of the vibration platform (1) to 30~60g and the mixing time to 2~5min. Step 4: Material solidification Turn on the vacuum pump to make the pressure inside the mold (4) lower than 50 kPa, reduce the vibration acceleration to 5~15 g, set the temperature of the upper jacket (303) to 70~80℃ and the temperature of the lower jacket (302) to 40~55℃, so that the temperature of the upper test point is lower than the melting point of the material. Adjust the temperature of both the upper jacket (303) and the lower jacket (302) to 30~40℃, set the acceleration to 0~5g, and stop the melting and casting process when the temperatures of the upper test point, middle test point and lower test point all reach the set temperature of the jacket.

9. The multi-station continuous charging method for cast explosives as described in claim 8, characterized in that, In step 1, the filling height of the material is not less than 2 / 3 of the height of the mold (4).

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