Casting integrated device

Abstract

The fusion casting integrated device comprises a double-temperature-zone heating jacket, a first containing space with the top open is formed in the double-temperature-zone heating jacket, a mold with the top open is vertically arranged in the first containing space, and a sealing cover is arranged at the top end of the double-temperature-zone heating jacket; a negative pressure suction pipe is arranged on the sealing cover in a penetrating mode and connected with a vacuum pump. The double-temperature-zone heating jacket comprises a jacket shell, a second accommodating space is arranged in the jacket shell, and a lower jacket and an upper jacket arranged above the lower jacket are arranged in the second accommodating space; a first overflowing cavity is formed in the upper jacket and is respectively communicated with an upper temperature area water inlet and an upper temperature area water outlet which are formed in the outer wall of the upper jacket; and a second overflowing cavity is formed in the lower jacket and is respectively communicated with a lower temperature area water inlet and a lower temperature area water outlet which are formed in the outer wall of the lower jacket.

Description

Technical Field

[0001] This invention belongs to the technical field of melting and casting process equipment, and specifically relates to an integrated melting and casting device. Background Technology

[0002] In the field of materials science and engineering, melting and casting is one of the core processes for preparing metals, polymers, and special composite materials. This process involves the melting, flow, solidification, and phase transformation of materials, and the precise control of process parameters directly determines the microstructure, mechanical properties, and reliability of the final product. With the increasing demands for material performance in high-end manufacturing, traditional melting and casting technology has gradually revealed many shortcomings in terms of temperature control accuracy, process monitoring, and process optimization, making it difficult to meet the production requirements of high precision and high stability. Specifically, these shortcomings include: First, in terms of temperature control in melting and casting equipment, traditional single-temperature zone heating jackets or segmented heating structures have significant limitations. Single-temperature zone jackets cannot meet the differentiated temperature requirements of different areas of the material, easily leading to uneven heating and causing component segregation or internal defects. Although some segmented heating devices attempt to achieve multi-temperature zone control, heat crosstalk easily occurs between temperature zones, making it difficult to meet the stringent requirements of high-end materials for temperature field uniformity. Simultaneously, the design of the thickness ratio between the water-passing area and the wall thickness of traditional jackets is unreasonable, easily leading to poor medium flow or localized overheating, further affecting the stability of temperature control. Secondly, traditional molds often employ a fixed structure with assembly gaps between the mold and the jacket, requiring shims or fillers to compensate. This results in discontinuous heat transfer paths and significant heat loss, reducing casting efficiency and potentially causing mold deformation or uneven material solidification due to localized temperature differences. Finally, traditional casting process monitoring methods struggle to achieve real-time, high-precision monitoring of multiple parameters, failing to reflect the overall temperature field distribution within the material. Stress and strain generated during melting and solidification often require offline testing of finished product performance to infer process rationality, leading to delays in process optimization. Furthermore, data acquisition and analysis are mostly offline, unable to provide real-time feedback to the casting control system, hindering dynamic adjustment of process parameters. This results in poor controllability of the casting process and significant fluctuations in product yield, necessitating urgent improvement. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides an integrated melting and casting device to solve the technical problems of low single-temperature zone control accuracy and incomplete process detection in existing melting and casting devices.

[0004] The present invention is implemented using the following technical solution: An integrated melting and casting device includes a dual-temperature zone heating jacket disposed on a vibration platform. The dual-temperature zone heating jacket has a first accommodating space with an open top. A mold with an open top is vertically disposed in the first accommodating space. A sealing cover is disposed at the top of the dual-temperature zone heating jacket. A negative pressure suction tube is inserted through the sealing cover, and the negative pressure suction tube is connected to a vacuum pump; The dual-temperature zone heating jacket includes a jacket shell, a second accommodating space within the jacket shell, a lower jacket within the second accommodating space, and an upper jacket positioned above the lower jacket. The upper jacket has a first flow cavity, which is connected to an upper temperature zone inlet and an upper temperature zone outlet located on the outer wall of the upper jacket. The lower jacket has a second flow cavity, which is connected to a lower temperature zone inlet and a lower temperature zone outlet located on the outer wall of the lower jacket.

[0005] The present invention also has the following technical features: Specifically, the ratio of the wall thickness of the mold to the wall thickness of the dual-temperature zone heating jacket is 1:2 to 2:3.

[0006] Furthermore, a first fiber Bragg grating sensor and a second fiber Bragg grating sensor are inserted into the mold. The first fiber Bragg grating sensor and the second fiber Bragg grating sensor are inserted into the mold through the first mounting hole and the second mounting hole opened on the sealing cover, respectively. The first fiber Bragg grating sensor and the second fiber Bragg grating sensor inserted into the mold are each provided with an upper test point, a middle test point and a lower test point at equal intervals from top to bottom.

[0007] Furthermore, an acceleration sensor is also installed on the sealing cover.

[0008] Furthermore, the sealing cover is provided with a first mounting hole, a second mounting hole, a third mounting hole and a fourth mounting hole. The negative pressure suction tube passes through the first mounting hole, the accelerometer passes through the second mounting hole, the first fiber optic grating sensor passes through the third mounting hole, and the second fiber optic grating sensor passes through the fourth mounting hole.

[0009] Furthermore, the space between the dual-temperature heating jacket and the mold is filled with vacuum grease.

[0010] Furthermore, the dual-temperature zone heating jacket is connected to a dual-temperature mold temperature controller.

[0011] Compared with the prior art, the beneficial effects of the present invention are: (1) The upper and lower jackets of the dual-temperature zone heating jacket of the present invention are designed with independent chambers, which can effectively avoid crosstalk between the upper and lower temperature zones, greatly improve the temperature control accuracy during the melting and casting process, meet the requirements of high-end materials for gradient cooling of the temperature field, and reduce defects such as internal cracks and shrinkage cavities in the melting and casting products.

[0012] (2) The device of the present invention has strong adaptability and balances efficiency and reliability: the convenient installation structure of the mold and the pressure cap reduces the difficulty of operation, avoids vacuum leakage, and improves the reliability of operation; the multi-point and multi-parameter monitoring (temperature field, stress and strain field) of the fiber optic grating sensor and the vibration monitoring of the acceleration sensor break the limitations of traditional single-point and offline detection, and obtain key data of the entire melting and casting process in real time, providing direct and comprehensive basis for process optimization and avoiding optimization lag; the vacuum grease between the dual-temperature heating jacket and the mold ensures the continuity of the heat transfer path and improves the heat exchange efficiency.

[0013] (3) The present invention integrates the casting device and the detection element to avoid the compatibility problem between independent systems, simplify the overall layout, reduce the space occupied by the equipment, and realize the linkage between detection data and casting control, improve process controllability, and help improve the stability of product qualification rate.

[0014] Other advantages of the present invention will be described in detail in the specific embodiments. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of the device of the present invention; Figure 2 It is a cross-sectional view of a temperature zone heating jacket fitted with a mold; Figure 3 This is a cross-sectional view of the device of the present invention; Explanation of the labels in the diagram: 1-Dual-temperature zone heating jacket; 2-Mold; 3-Sealing cover; 4-Negative pressure suction pipe; 5-First fiber optic grating sensor; 6-Acceleration sensor; 7-Second fiber optic grating sensor; 8-Upper test point; 9-Middle test point; 10-Lower test point; 101-Jacket housing; 102-Lower jacket; 103-Upper jacket; 1021-Lower temperature zone inlet; 1022-Lower temperature zone outlet; 1031-Upper temperature zone inlet; 1032-Upper temperature zone outlet. Detailed Implementation

[0016] 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.

[0017] 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.

[0018] 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.

[0019] Unless otherwise specified, the components (e.g., the first fiber Bragg grating sensor, the accelerometer, and the second fiber Bragg grating sensor) and raw materials (e.g., vacuum grease) in this invention are all commercially available.

[0020] Example 1 Following the above technical solutions, such as Figures 1 to 3 As shown, this embodiment discloses an integrated melting and casting device, including a dual-temperature zone heating jacket 1 set on a vibration platform. The dual-temperature zone heating jacket 1 has a first accommodating space with an open top. A mold 2 with an open top is vertically arranged in the first accommodating space. A sealing cover 3 is provided at the top of the dual-temperature zone heating jacket 1. The outer diameter of the mold 2 matches the inner diameter of the dual-temperature zone heating jacket 1. During installation, vacuum grease is applied to the outer wall of the mold 2, and then the mold 2 is pushed into the dual-temperature zone heating jacket 1 to ensure that the mold 2 and the dual-temperature zone heating jacket 1 fit tightly, reduce the heat transfer gap, and meet good heat transfer conditions.

[0021] A negative pressure suction pipe 4 is installed on the sealing cover 3. The negative pressure suction pipe 4 is connected to a vacuum pump. With the help of the vacuum pump and the negative pressure suction pipe, air and volatile gases in the cavity of the mold 2 can be extracted to establish a vacuum or low-pressure environment. The vacuum environment can prevent material oxidation, reduce porosity in castings, and work synergistically with the thermal field and vibration field to improve material quality.

[0022] The dual-temperature zone heating jacket 1 can be sealed to the sealing cover 3 to provide an independent and precise temperature control environment for the mold 2, thereby achieving uniform or gradient heating / cooling of the material inside the mold 2 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, and to establish a vacuum or low-pressure environment in the closed space. The dual-temperature zone heating jacket 1 is connected to an external dual-temperature mold temperature controller to form a complete temperature control loop. Specifically, the dual-temperature zone heating jacket 1 includes a jacket housing 101, a second accommodating space is provided inside the jacket housing 101, a lower jacket 102 is provided inside the second accommodating space, and an upper jacket 103 is provided above the lower jacket 102. The upper jacket 103 is provided with a first flow cavity, which is connected to the upper temperature zone inlet 1031 and the upper temperature zone outlet 1032 respectively opened on the outer wall of the upper jacket 103. The lower jacket 102 is provided with a second flow cavity, which is connected to the lower temperature zone inlet 1021 and the lower temperature zone outlet 1022 respectively opened on the outer wall of the lower jacket 102. The upper and lower parts of the mold 2 can be independently and precisely controlled by the independent upper jacket 103 and lower jacket 102. In particular, by introducing media of different temperatures into the upper jacket 103 and lower jacket 102, a controllable temperature gradient can be actively created in the axial direction of the mold 2.

[0023] Preferably, the vertical distance between the bottom plate of the upper sleeve 103 and the top plate of the lower sleeve 102 is 5~ The 15mm thickness effectively isolates the two temperature zones, preventing heat crosstalk, while also ensuring the structural strength of the jacket. The upper jacket 103 and lower jacket 102 both have a wall thickness of 3mm, and the mold 2 has a wall thickness of 2mm.

[0024] The lower jacket 102 and the upper jacket 103 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 102 and the upper jacket 103, a precise and controllable temperature gradient can be formed along the axis of the mold 2. This is crucial for achieving directional solidification or zone melting and can effectively reduce casting defects.

[0025] As a preferred embodiment, the ratio of the wall thickness of the mold 2 to the wall thickness of the dual-temperature zone heating jacket 1 is 1:2 to 2:3, which ensures smooth flow of the heating medium and improves heat exchange efficiency.

[0026] In a preferred embodiment, a first fiber Bragg grating sensor 5 and a second fiber Bragg grating sensor 7 are installed inside the mold 2. The first fiber Bragg grating sensor 5 and the second fiber Bragg grating sensor 7 are used for temperature and stress-strain measurement. The first fiber Bragg grating sensor 5 and the second fiber Bragg grating sensor 7 are inserted into the mold 2 through the first mounting hole and the second mounting hole opened on the sealing cover 3, respectively. The first fiber Bragg grating sensor 5 and the second fiber Bragg grating sensor 7 inserted into the mold 2 are each provided with an upper test point 8, a middle test point 9 and a lower test point 10 at equal intervals from top to bottom. Preferably, in this embodiment, the upper test point 8, the middle test point 9 and the lower test point 10 are respectively set at the highest point, the middle and the bottom of the material in the mold, so that the upper test point 8, the middle test point 9 and the lower test point 10 can acquire the temperature and stress-strain data of the material at different height positions in the mold 2 in real time, in situ and synchronously.

[0027] As a preferred embodiment, an acceleration sensor 6 is also installed on the sealing cover 3.

[0028] As a preferred embodiment, the sealing cover 3 is provided with a first mounting hole, a second mounting hole, a third mounting hole and a fourth mounting hole. The negative pressure suction tube 4 passes through the first mounting hole, the acceleration sensor 6 passes through the second mounting hole, the first fiber optic grating sensor 5 passes through the third mounting hole, and the second fiber optic grating sensor 7 passes through the fourth mounting hole.

[0029] As a preferred embodiment, vacuum grease is filled between the dual-temperature zone heating jacket 1 and the mold 2 to ensure that the mold and the jacket can fit together effectively, reduce the heat transfer gap, and meet good heat transfer conditions.

[0030] As a preferred embodiment, the dual-temperature heating jacket is connected to a dual-temperature mold temperature controller, which can deliver media of different temperatures to the lower jacket 102 and the upper jacket 103 respectively, so that the lower jacket 102 and the upper jacket 103 have different temperatures.

[0031] During installation, the device of this invention is as follows: the assembled dual-temperature zone heating jacket 3 is installed on the vibration platform; the mold 2 is placed inside the dual-temperature zone heating jacket 1; 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 4 is connected to the sealing cover 3, and the other end is connected to the vacuum pump; the detection ends of the first fiber optic grating sensor 5 and the second fiber optic grating sensor 7 are inserted into the mold 2; and the sealing cover 3 is pressed tightly.

[0032] When using this embodiment: Open the sealing cover 3 and place the mold 2 filled with material into the dual-temperature zone heating jacket 1 to complete the device installation. Start the vacuum pump and evacuate the device to the required vacuum level through the negative pressure suction pipe 4. Set the heating temperature and melting time of the upper jacket 103 and lower jacket 102, start the dual-temperature mold temperature controller to begin heating, and start the vibration platform to complete the material melting and casting operation. During the melting and casting process, the acceleration sensor 6, the first fiber optic grating sensor 5, and the second fiber optic grating sensor 7 collect and monitor data in real time. After reaching the set melting and casting time, cool the mold. After completion, turn off all equipment, break the vacuum, open the sealing cover, and remove the formed casting.

[0033] 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.

[0034] 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.

[0035] 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 fused integration device, comprising a double-temperature-zone heating jacket (1) arranged on a vibrating platform, a first accommodating space with an open top being arranged in the double-temperature-zone heating jacket (1), a mold (2) with an open top being arranged vertically in the first accommodating space, and a sealing cover (3) being arranged at the top end of the double-temperature-zone heating jacket (1); a negative pressure suction pipe (4) is arranged through the sealing cover (3), and the negative pressure suction pipe (4) is connected with a vacuum pump; the double-temperature-zone heating jacket (1) comprises a jacket shell (101), a second accommodating space is arranged in the jacket shell (101), a lower jacket (102) is arranged in the second accommodating space, and an upper jacket (103) is arranged above the lower jacket (102); a first flow cavity is arranged in the upper jacket (103), and the first flow cavity is in communication with an upper-temperature-zone water inlet (1031) and an upper-temperature-zone water outlet (1032) respectively arranged on the outer wall of the upper jacket (103); a second flow cavity is arranged in the lower jacket (102), and the second flow cavity is in communication with a lower-temperature-zone water inlet (1021) and a lower-temperature-zone water outlet (1022) respectively arranged on the outer wall of the lower jacket (102).

2. The cast-in unit of claim 1, wherein The ratio of the wall thickness of the mold (2) to the wall thickness of the double-temperature-zone heating jacket (1) is 1:2-2:

3.

3. The molded integrated device of claim 2, wherein, A first fiber grating sensor (5) and a second fiber grating sensor (7) are arranged through the mold (2), the first fiber grating sensor (5) and the second fiber grating sensor (7) pass into the mold (2) through a first mounting hole and a second mounting hole respectively arranged on the sealing cover (3), and the first fiber grating sensor (5) and the second fiber grating sensor (7) passing into the mold (2) are arranged with an upper test point (8), a middle test point (9) and a lower test point (10) at equal intervals from top to bottom.

4. The molded integrated device of claim 3, wherein, An acceleration sensor (6) is further arranged on the sealing cover (3).

5. The molded integral device of claim 4, wherein, The sealing cover (3) is provided with a first mounting hole, a second mounting hole, a third mounting hole and a fourth mounting hole, the negative pressure suction pipe (4) passes through the first mounting hole, the acceleration sensor (6) passes through the second mounting hole, the first fiber grating sensor (5) passes through the third mounting hole, and the second fiber grating sensor (7) passes through the fourth mounting hole.

6. The molded integral device of claim 1 wherein, Vacuum grease is filled between the double-temperature-zone heating jacket (1) and the mold (2).

7. The cast-in unit of claim 1, wherein The double-temperature-zone heating jacket (1) is connected with a double-temperature mold temperature machine.

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