Casting mold and method for integrating different parts

Abstract

The invention discloses a casting mold and method for integrating different parts, the casting mold comprises a positive mold plate, a negative mold plate and a mold cavity system formed by the positive mold plate and the negative mold plate, the mold cavity system comprises a pouring system and a mold cavity which are connected with each other, and the mold cavity comprises at least one main part mold cavity and at least one auxiliary part mold cavity; the auxiliary part cavity is located in a free area, not occupied by the main part cavity, in the range of the mold cavity system. According to the scheme, an idle space in a traditional single part mold is ingeniously utilized for extra part production, maximization of the mold value is achieved, an existing casting production line does not need to be changed, synergistic production can be achieved only by replacing the mold, the cost is extremely low, the mold cost, the material cost and the time cost are remarkably reduced, economic benefits are huge, practicability is high, and popularization is easy. The popularization is easy.

Description

Technical Field

[0001] This invention belongs to the field of casting technology, specifically relating to a casting mold and method for integrating different parts. Background Technology

[0002] Currently, automotive parts such as engine mounts, transmission housings, and steering knuckles, along with precision components like compressor crankshafts, are all manufactured using separate casting molds. This approach has the following drawbacks: 1. High mold costs: Each part requires a separate casting mold, resulting in large mold investments; 2. Low production efficiency: a single casting mold can only produce one type of part at a time, resulting in low equipment utilization. 3. Waste of materials and space: The mold cavity of individual parts was not fully utilized, and the molten iron in the gating system was not maximized.

[0003] Therefore, there is a lack of a casting mold solution in the existing technology that can integrate different types and functions of parts into a single mold and form them in one go. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a casting mold and method that integrates different parts, which solves the problems of high mold cost, low production efficiency and waste of materials and space in the existing casting scheme, improves the space utilization rate in the mold, and enables the simultaneous production of two different parts through one mold, thereby improving efficiency and economic benefits.

[0005] According to the first aspect of the present invention, the present invention provides a casting mold integrating different parts, including a positive mold plate, a negative mold plate, and a mold cavity system formed by the positive mold plate and the negative mold plate. The mold cavity system includes a gating system and a cavity connected to each other. The cavity includes at least one main part cavity and at least one secondary part cavity. The secondary part cavity is located in a free area within the mold cavity system that is not occupied by the main part cavity.

[0006] In some embodiments, the gating system has a runner and a main riser; the location of the secondary cavity includes one or more combinations of the following: next to the runner, next to the main riser, and the runner itself.

[0007] In some implementations, the gating system is a single system to which all cavities are connected.

[0008] In some embodiments, the runner includes a runner and a sprue, with the sprue connected below the runner and all cavities located below the runner; the sprue cup is connected above the runner in the middle, and all runners and all cavities are symmetrical about the left and right relative to the sprue cup.

[0009] In some embodiments, the sprue is located on the side of the main component cavity and is connected to the main component cavity or the main component riser through the main component ingate. The lower part of the sprue forms a secondary component cavity, and the upper end of the secondary component cavity is connected to a secondary component riser, which is connected to the sprue.

[0010] In some embodiments, the volume occupied by the main part cavity is larger than the volume occupied by the secondary part cavity; the part corresponding to the secondary part cavity is a shaft part; and the length direction of at least a portion of the secondary part cavity is perpendicular to the plane where the runner is located.

[0011] In some embodiments, the main part cavity is located in the middle of the mold cavity system, and sprues are distributed on both sides of the main part cavity; at least a portion of the auxiliary part cavities are located next to the sprues on both sides of the main part cavity, and are located on the side of the sprues away from the main part cavity.

[0012] In some embodiments, the shape of the main part cavity corresponds to the automotive part to be formed, which is one of the following: engine bracket, gearbox housing, and steering knuckle; the shape of the auxiliary part cavity corresponds to the compressor crankshaft to be formed.

[0013] According to the second aspect of the technical solution of the present invention, the present invention provides a casting method for integrating different parts, which adopts the casting mold for integrating different parts described in the present invention; during casting, the composition of the molten iron used for casting is adjusted to simultaneously meet the material performance requirements of the parts corresponding to the main part cavity and the auxiliary part cavity.

[0014] In some embodiments, the shape of the main part cavity corresponds to the automotive part to be formed, which is one of the following: engine bracket, gearbox housing, or steering knuckle; the shape of the auxiliary part cavity corresponds to the compressor crankshaft to be formed; both the automotive part and the compressor crankshaft are made of ductile iron; the molten iron used for casting is prepared by reducing the content of C, Si, and Mn in the molten iron based on the original process material composition of the compressor crankshaft, so that the content of C, Si, and Mn in the molten iron is within the range of the content of C, Si, and Mn in the original process material composition of the automotive part, so that the produced automotive part and compressor crankshaft both meet the tensile strength requirements of the original process material.

[0015] Compared with the prior art, the beneficial technical effects of the present invention are as follows: The integrated casting mold and method for different parts of this invention, through structural innovation, cleverly utilizes the "idle" space in traditional single-part molds to produce additional parts, thereby improving space utilization and maximizing the value of the mold. It can produce two or more different parts simultaneously with one set of molds. For example, the mold cost of compressor crankshafts can be distributed to automotive main component molds, achieving "zero" additional cost for crankshaft production. There is no need to change the existing casting production line; simply replacing the mold can achieve increased production efficiency. The cost is extremely low, significantly reducing mold costs, material costs, and time costs, resulting in huge economic benefits. It is highly practical, easy to promote, and particularly suitable for small and medium-sized casting enterprises to upgrade their technology. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the positive template of a casting mold provided by the present invention.

[0017] Figure 2 Is with Figure 1 The diagram shows the structure of the reverse template that matches the positive template.

[0018] Figure 3 This is a schematic diagram of the positive template of another casting mold provided by the present invention.

[0019] Figure 4 Is with Figure 3 The diagram shows the structure of the reverse template that matches the positive template.

[0020] Explanation of reference numerals in the attached figures: 1. Positive mold plate; 2. Negative mold plate; 3. Main component cavity; 4. Secondary component cavity; 5. Main component riser; 6. Horizontal runner; 7. Direct runner; 8. Sprue cup; 9. Main component ingate; 10. Secondary component riser. Detailed Implementation

[0021] This invention provides a casting mold and method integrating different parts, solving the problems of high mold cost, low production efficiency, and material and space waste in existing casting solutions. It improves the space utilization rate within the mold, enabling the simultaneous production of two different parts using a single mold, thereby increasing efficiency and economic benefits. Specifically, this invention provides a novel and rationally laid-out integrated mold, typically an integrated mold for the efficient production of automotive parts; particularly, a mold capable of simultaneously casting automotive structural components (such as brackets, housings, and steering knuckles) and compressor crankshafts. This mold can simultaneously form automotive structural components and compressor crankshafts within a single mold body, significantly increasing the output per casting and reducing the mold cost and production cost per unit part. The key concept of this invention lies in adding a cavity for the secondary product (secondary part) to the mold structure of the main product (main part), forming a "symbiotic casting" scheme where the secondary product "parasitizes" the casting mold of the main product.

[0022] Please see Figure 1 , Figure 2 This invention discloses a casting mold integrating different parts. Similar to or similar to existing molds, it includes a positive mold plate 1, a negative mold plate 2, and a cavity system formed by the positive mold plate 1 and the negative mold plate 2. The cavity system includes a connected gating system and a mold cavity, which will not be elaborated further here. The "connection" relationship of the various parts in the cavity system described herein includes the meaning of "connected". The main innovation of this invention lies in that the mold cavity includes at least one main part cavity 3 and at least one secondary part cavity 4. The secondary part cavity 4 is located in the free area within the cavity system that is not occupied by the main part cavity 3, thereby significantly improving space utilization, eliminating the need for a separate mold for producing secondary parts, eliminating the need for raw materials in the gating system required for producing secondary parts separately, and eliminating the need for equipment and time required for casting secondary parts separately, thus achieving cost reduction and efficiency improvement.

[0023] More specifically, the gating system includes a sprue and a main component riser 5; the location of the secondary component cavity 4 includes one or more combinations of the following: next to the sprue (gating system parasitic scheme), next to the main component riser 5 (riser side parasitic scheme), and the sprue itself (gating system alternative parasitic scheme). It should be noted that the present invention is not limited to these three locations; other optional locations may exist depending on the specific circumstances. The above three locations are relatively typical and common solutions. In some embodiments, the present invention is based on the modification of an existing casting mold used for producing the main component. The modification method involves adding a secondary component cavity 4 in a selectable empty area, depending on the situation. The spatial layout of the secondary component cavity 4 is designed (based on the flow rate of the mold cavity system) so that it does not affect the filling of the main component cavity during the filling process, and it itself can obtain good molten iron feeding conditions.

[0024] In a preferred embodiment, the gating system is a single set, and all cavities are connected to the same set of gating systems; in other words, the main cavity 3 and the auxiliary cavity 4 share the same set of gating systems and are cast in one go.

[0025] More specifically, the gating system includes a horizontal sprue 6 and a vertical sprue 7. The horizontal sprue 6 is connected to the vertical sprue 7 below, and all cavities are located below the horizontal sprue 6. The sprue cup 8 is connected to the middle of the upper part of the horizontal sprue 6. All gating systems and cavities are symmetrical about the left and right relative to the sprue cup 8. In this design, a symmetrically arranged gating system with symmetrical branch paths forms a flow-dividing buffer structure, which helps to ensure that molten iron flows smoothly and synchronously into the main cavity 3 and the auxiliary cavity 4. As a supplementary explanation, generally, the main cavity 3 and the auxiliary cavity 4 are connected to the horizontal sprue 6 and / or the vertical sprue 7 respectively through their respective ingates.

[0026] like Figure 1 , Figure 2In the illustrated embodiment, the sprue 7 is located on the side of the main part cavity 3 and is connected to the main part cavity 3 or the main part riser 5 through the main part ingate 9. The lower part of the sprue 7 forms a secondary part cavity 4, which is a part of the sprue 7 (if necessary and space permits, it can also include a part extending below the original mold sprue, or a part extending below the required sprue length of the main part cavity 3). The upper end of the secondary part cavity 4 is connected to a secondary part riser 10, which is also connected to the sprue 7.

[0027] like Figure 1 , Figure 2 In the illustrated embodiment, the volume occupied by the main cavity 3 is larger than that occupied by the secondary cavity 4; the part corresponding to the secondary cavity 4 is a shaft-type part; at least a portion of the secondary cavities 4 have their length direction perpendicular to the plane where the runner is located. Shaft-type parts are in high demand and are easy to arrange spatially around a larger main product, thus the effect is better.

[0028] like Figure 1 , Figure 2 In the illustrated embodiment, the main cavity 3 is located in the middle of the mold cavity system, and sprues 7 are distributed on both sides of the main cavity 3. The sprues 7 are directly or indirectly (e.g., through risers) connected to the main cavity 3, which is beneficial for the filling of the main cavity 3 (especially larger and more complex-shaped main cavities 3). At least a portion of the auxiliary cavities 4 are located next to the sprues 7 on both sides of the main cavity 3, and are located on the side of the sprues 7 away from the main cavity 3. The auxiliary cavities 4 and the main cavity 3 are located on both sides of the sprues 7, which is beneficial for flow diversion and ensures the filling effect of the main and auxiliary cavities.

[0029] More specifically, in Figure 1 , Figure 2In the illustrated embodiment, there are three main component cavities 3, arranged side-by-side vertically below the middle of the horizontal runner 6. The main component cavities 3 are connected to the horizontal runner 6 and adjacent main component cavities 3 by vertical ingates. Each main component cavity 3 has a main component riser 5 on both its left and right sides. A vertical sprue 7 is provided on both the left and right sides of the main component cavity 3 and the main component riser 5. Each sprue 7 has a secondary component cavity 4 (hereinafter referred to as the first type of secondary component cavity for easy distinction) formed at its lower part. This first type of secondary component cavity corresponds to shaft-type parts, such as compressor crankshafts, and has similar dimensions to the runners. Since the upper part of the first type of sub-part cavity is the sprue 7 (the upper normal sprue), a large riser is not required. In the illustrated embodiment, the sub-part riser 10 is a relatively small spherical shape with a notch at the top. The sub-part riser 10 is a raised space structure added to the normal sprue above the first type of sub-part cavity to compensate for the shrinkage of the corresponding part of the first type of sub-part cavity. The riser neck of the sub-part riser 10 is relatively thin to facilitate the subsequent removal of the corresponding part from the casting. The first type of sub-part cavity does not need to be provided with an ingate to connect with the sprue 7 (the upper normal sprue). The main part ingate 9 is a thin sheet ingate to facilitate the subsequent removal of the corresponding part from the casting; the first type of sub-part cavity corresponds to the position of the lowest main part cavity 3 and is connected by a thin sheet main part ingate 9. On the side of the sprue 7 (the upper normal sprue) away from the main part cavity 3, three secondary part cavities 4 are also provided (hereinafter referred to as second-type secondary part cavities for easy distinction). These second-type secondary part cavities are connected to the sprue 7 (the upper normal sprue) through shorter ingates. These second-type secondary part cavities also correspond to shaft-type parts, and their length direction is perpendicular to the plane of the sprue.

[0030] exist Figure 3 , Figure 4 In the illustrated embodiment, only the second type of sub-part cavity is used, with the cavities of the shaft-like parts arranged on both sides. Furthermore, Figure 3 , Figure 4 In the embodiment shown, a secondary horizontal runner is provided below the horizontal runner 6 connected to the pouring cup 8. The sprue 7 is connected through this secondary horizontal runner. In this solution, the horizontal runner 6 forms an enlarged flow diversion and buffer structure similar to a buffer bag (in other embodiments, other methods can also be used to form an enlarged buffer bag) to ensure that the molten iron flows smoothly and synchronously into the main part cavity 3 and the auxiliary part cavity 4.

[0031] In summary, the typical design methods of the casting mold of the present invention include the following three types.

[0032] Method 1 (Parasitic Solution for Gating System): The original main product pattern (main part cavity) has filled the entire template, and the product size cannot add new cavities. By adding secondary part cavities next to the product's gating flow path (e.g., next to the runner), the number of finished products per type can be increased.

[0033] Method 2 (Riser Side Parasitic Solution): The original main product pattern (main part cavity) has filled the entire template, and the product size cannot add new cavities. There is no corresponding position next to the product gating system. The number of finished products per type can be increased by parasitizing at the riser (adding secondary part cavities).

[0034] Method 3 (Gating System Replacement Parasitic Solution): The original main product pattern (main part cavity) has filled the entire mold, and the product size cannot be increased by adding new mold cavities. By replacing the gating system (such as runners) with secondary products, the overall mold yield can be improved.

[0035] As a supplementary explanation, if parasitic by-products (sub-parts) are produced separately and molded separately, separate gating systems and risers are required to ensure the pouring and feeding of the product and prevent shrinkage cavities and porosity defects. With the parasitic and integrated production scheme, by-products can be fed using the gating system of the host product (main part) (without the need to set up additional risers for the sub-parts), which optimizes the casting process, reduces the overall volume and number of gating systems and risers, improves material utilization and production efficiency, and ensures the internal quality of the castings.

[0036] Preferably, the shape of the main cavity 3 corresponds to the automotive part to be formed, and the produced part is an automotive part, which is one of the following: engine mount, gearbox housing, or steering knuckle. The shape of the auxiliary cavity 4 corresponds to the compressor crankshaft to be formed, and the produced part is a compressor crankshaft. Automotive parts are relatively large, thus providing ample usable space; compressor crankshafts have relatively simple shapes, facilitating the arrangement of their cavities. Both types of parts are typical castings and are the main products of casting companies; integrating them into the same mold for production is particularly advantageous.

[0037] Based on the integrated casting mold of the present invention, the present invention also provides a casting method for integrating different parts. During casting, the composition of the molten iron used for casting is adjusted to simultaneously meet the material performance requirements of the parts corresponding to the main part cavity 3 and the auxiliary part cavity 4.

[0038] More specifically, for example, the shape of the main cavity 3 corresponds to the automotive part to be formed, which is one of the following: engine mount, gearbox housing, or steering knuckle; the shape of the auxiliary cavity 4 corresponds to the compressor crankshaft to be formed; both the automotive part and the compressor crankshaft are made of ductile iron. The molten iron used for casting is prepared by reducing the C, Si, and Mn content in the molten iron based on the original material composition of the compressor crankshaft, so that the C, Si, and Mn content in the molten iron is within the range of the C, Si, and Mn content in the original material composition of the automotive part, so that the produced automotive part and compressor crankshaft both meet the tensile strength requirements of the original material composition.

[0039] The following specific examples further illustrate this point.

[0040] The automotive parts are made of ductile iron. The by-products need to be of the same or similar material as the automotive parts. Therefore, composition adjustments are made to allow different materials of ductile iron to coexist. The automotive part is a certain model bracket, and its material (the material from the original process) is QT450. Its main components include C: 3.5-3.8%, Si: 2.5-2.8%, Mn: 0.2-0.3%, P: <0.05%, S: 0.012-0.02%, Sn: <0.015%, Cu: 0.2-0.3%. The actual test results for the material properties are: tensile strength 520MPa. The air compressor crankshaft is a certain model, and its material (the material of the original process) is QT500. Its main components include C: 3.85-3.95%, Si: 2.6-3.0%, Mn: 0.25-0.4%, P: <0.05%, S: 0.012-0.02%, Sn: 0.01-0.02%, Cu: 0.2-0.3%. The actual test result of the material properties is a tensile strength of 569 MPa. This solution adjusts the material composition of the air compressor crankshaft, changing the C content to 3.5-3.8%, the Si content to 2.5-2.8%, the Mn content to 0.25-0.3%, and the Sn content to <0.015%. Through testing, it has been verified that reducing the C, Si, and Mn alloy content in the molten iron can achieve the same tensile strength as the parasitic byproducts, ensuring that the mechanical properties of the parasitic byproducts are qualified. The actual test result of the adjusted material properties is a tensile strength of 577 MPa. It should be noted that this solution changes the product layout. Under the original process of producing a single product, there are many products to be arranged, the heat is concentrated, and the solidification speed is slow during production. After the product is parasitized in this solution, the solidification environment of the parasitized by-products is changed compared with the solidified product of the whole plate mold. Therefore, the strength of the product is improved after reducing the composition ratio on the basis of the original process.

[0041] In summary, the integrated casting mold and method for different parts of this invention, through structural innovation, cleverly utilizes the "idle" space in traditional single-part molds to produce additional parts, thereby improving space utilization and maximizing mold value. It can produce two or more different parts simultaneously with a single mold. For example, the mold cost of compressor crankshafts can be distributed to automotive main component molds, achieving "zero" additional cost for crankshaft production. There is no need to change the existing casting production line; simply replacing the mold can achieve increased production efficiency. The cost is extremely low, significantly reducing mold costs, material costs, and time costs, resulting in huge economic benefits. It is highly practical, easy to promote, and particularly suitable for small and medium-sized casting enterprises to upgrade their technology.

[0042] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; obviously, the described embodiments are some embodiments of the present invention, but not all embodiments; based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention; in the absence of conflict, the embodiments and features in the embodiments of the present invention can be combined with each other; modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions for some of the technical features, do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A casting mold integrating different parts, comprising a positive mold plate (1), a negative mold plate (2), and a mold cavity system formed by the positive mold plate (1) and the negative mold plate (2), the mold cavity system comprising a gating system and a cavity connected to each other, characterized in that, The cavity includes at least one main cavity (3) and at least one secondary cavity (4), the secondary cavity (4) being located in a free area within the cavity system that is not occupied by the main cavity (3).

2. The casting mold integrating different parts according to claim 1, characterized in that, The gating system has a gating system and a main riser (5); the location of the secondary cavity (4) includes one or more combinations of the following: next to the gating system, next to the main riser (5), and the gating system itself.

3. The casting mold integrating different parts according to claim 1, characterized in that, The gating system is a single system, and all cavities are connected to this single gating system.

4. The casting mold integrating different parts according to claim 3, characterized in that, The gating system includes a horizontal gating (6) and a vertical gating (7). The horizontal gating (6) is connected to the vertical gating (7) below. All cavities are located below the horizontal gating (6). The gating cup (8) is connected to the middle of the upper part of the horizontal gating (6). All gating systems and all cavities are symmetrical about the left and right sides of the gating cup (8).

5. The casting mold integrating different parts according to claim 4, characterized in that, The sprue (7) is located on the side of the main part cavity (3) and is connected to the main part cavity (3) or the main part riser (5) through the main part ingate (9). The lower part of the sprue (7) forms the sub-part cavity (4). The upper end of the sub-part cavity (4) is connected to the sub-part riser (10), and the sub-part riser (10) is connected to the sprue (7).

6. The casting mold integrating different parts according to claim 1, characterized in that, The main cavity (3) occupies a larger volume than the secondary cavity (4); the part corresponding to the secondary cavity (4) is a shaft part; at least a portion of the secondary cavities (4) have a length direction perpendicular to the plane where the gating is located.

7. The casting mold integrating different parts according to claim 1, characterized in that, The main cavity (3) is located in the middle of the mold cavity system, and sprues (7) are distributed on both sides of the main cavity (3); at least a portion of the auxiliary cavity (4) is located next to the sprues (7) on both sides of the main cavity (3), and is located on the side of the sprues (7) away from the main cavity (3).

8. The casting mold for integrating different parts according to any one of claims 1 to 7, characterized in that, The shape of the main part cavity (3) corresponds to the automotive part to be formed, which is one of the engine bracket, gearbox housing, and steering knuckle; the shape of the auxiliary part cavity (4) corresponds to the compressor crankshaft to be formed.

9. A casting method for integrating different parts, characterized in that, It adopts a casting mold that integrates different parts according to any one of claims 1 to 7; during casting, the composition of the molten iron used for casting is adjusted to simultaneously meet the material performance requirements of the parts corresponding to the main part cavity (3) and the auxiliary part cavity (4).

10. The casting method for integrating different parts according to claim 9, characterized in that, The shape of the main part cavity (3) corresponds to the automotive part to be formed, which is one of the engine bracket, gearbox housing, and steering knuckle; the shape of the auxiliary part cavity (4) corresponds to the compressor crankshaft to be formed; the automotive part and the compressor crankshaft are both made of ductile iron. The molten iron used for casting is made by reducing the content of C, Si, and Mn in the molten iron based on the original process material composition of the compressor crankshaft, so that the content of C, Si, and Mn in the molten iron is within the range of the C, Si, and Mn content in the original process material composition of the automotive parts, so that the produced automotive parts and compressor crankshafts can meet the tensile strength requirements of the original process materials.

Images