Molding apparatus for castings

Abstract

The present application relates to a kind of casting forming device, comprising: mould board sand core, for connecting pouring system;First group of sand core, including at least two sand core one, sand core two and be arranged on mould board sand core, for forming the bottom flange of casting and part lower cylinder;Second group of sand core, including one or more sand core three, sand core four, sand core five, the bottom of second group of sand core is surrounded and is accommodated in area, first group of sand core is arranged in accommodating area, for forming another part lower cylinder of casting and thin-walled rib plate outer side edge profile and a part of inside profile;Third group of sand core, including multiple sand core six and is embedded in second group of sand core, for forming remaining part lower cylinder and remaining part inside profile of thin-walled rib plate;Double-layer cover core, it is arranged on third group of sand core, for forming the intermediate flange of casting, upper cylinder and top flange.The device realizes large mould split manufacturing, overall forming, solves the problem that casting mould making is difficult, maintenance cost is high.

Description

Technical Field

[0001] This invention relates to the field of casting technology, and in particular to a casting forming apparatus. Background Technology

[0002] In the production and manufacturing process of large gas turbine exhaust cylinder castings, due to their huge structural size, complex internal flow channel system and cavity, as well as the strict requirements for non-destructive testing of castings, the traditional casting method relying on wooden molds is difficult to meet the modern industrial demand for dimensional accuracy, production efficiency and quality reliability. Moreover, when traditional wooden molds are used to optimize the casting process to improve the quality of castings or to improve the structure and size of castings, even small process adjustments may lead to the modification or even scrapping and remaking of the entire set of molds, resulting in high iteration costs. Summary of the Invention

[0003] Therefore, it is necessary to provide a casting forming device that can overcome mold dependence and improve the accuracy of casting cavities to address the problem of high iteration costs for large cylinder castings.

[0004] This invention provides a casting forming apparatus, the casting forming apparatus comprising: The gating plate sand core is used to connect the casting system; The first set of sand cores, including at least two sand cores, sand core one and sand core two, are set on the jig sand cores to form the bottom flange and part of the lower cylinder body of the casting; The second set of sand cores includes one or more sand cores three, four, and five. The bottom of the second set of sand cores forms a receiving area. The first set of sand cores is placed in the receiving area. The second set of sand cores is used to form the outer edge profile and a portion of the inner profile of another part of the lower cylinder body and thin-walled stiffener of the casting. The third set of sand cores, including multiple sand cores, is embedded in the second set of sand cores and is used to form the remaining inner contour of the remaining lower cylinder block and thin-walled rib plate. A double-layer cap core, set on the third set of sand cores, is used to form the intermediate flange, upper cylinder body, and top flange of the casting.

[0005] In one embodiment, the first set of sand cores are each provided with through holes for placing insulating risers.

[0006] In one embodiment, the inner ring of the second set of sand cores has a plurality of grooves, the shape of which matches the shape of the sixth sand core, and the sixth sand core is disposed in the grooves.

[0007] In one embodiment, the groove is a groove with a trapezoidal or near-trapezoidal cross-section.

[0008] In one embodiment, the double-layer cover core includes a first layer cover core and a second layer cover core. The first layer cover core includes at least two sand cores seven and eight for forming the intermediate flange and upper cylinder of the casting. The second layer cover core includes at least two sand cores nine for forming the top flange of the casting.

[0009] In one embodiment, the outer contour dimensions of the sand core 7 and the sand core 8 are larger than those of the sand core 9, and both the sand core 7 and the sand core 8 are provided with through holes for placing insulation risers.

[0010] In one embodiment, the height of both the first and second sand cores is designed to extend to the upper edge of the insulation riser.

[0011] In one embodiment, the substrate sand core is provided with a plurality of sand holes and a plurality of gating ceramic tubes, the gating ceramic tubes being disposed in the sand holes.

[0012] The present invention also provides a forming method using the casting forming apparatus as described above, comprising the following steps: S1: Prepare the tire plate sand core, the first group of sand cores, the second group of sand cores, the third group of sand cores, and the double-layer cover core; S2: Lay the lower box casting system on the sand core of the tire plate; S3: The first set of sand cores is assembled and placed on the mold plate sand core to form the cavity of the bottom flange of the casting and part of the lower cylinder body, and the heat insulation riser is placed through the reserved through hole; S4: Cover the bottom receiving area of ​​the second set of sand cores onto the first set of sand cores accordingly; S5: The third set of sand cores is embedded into the second set of sand cores, and together with the second set of sand cores, they form the cavity of the remaining lower cylinder body and the complete thin-walled rib plate. S6: Assemble and place the lower cover core of the double-layer cover core to form the cavity of the casting intermediate flange and the upper cylinder body, and place the heat-insulating riser through its reserved through hole; S7: Place the upper cover core of the double-layer cover core to form the cavity of the top flange of the casting; S8: The mold is closed, and the exhaust cylinder casting is obtained by pouring through the inner sprue ceramic tube.

[0013] The aforementioned casting forming apparatus, on top of the base sand core, assembles and places a first set of sand cores, consisting of two sand cores (one and two sand cores), to form the bottom flange and the cavity of the lower cylinder body, approximately half its height. Then, a second set of sand cores, consisting of one or more sand cores (three, four, and five), is installed onto the first set of sand cores. The bottom of the second set of sand cores has a receiving area that precisely encloses the first set of sand cores below, achieving rapid and precise positioning and assembly. This second set of sand cores forms another portion of the lower cylinder body and the outer edge contour and part of the inner contour of the thin-walled rib plate. Next, a third set of sand cores, consisting of multiple sand cores (six), is embedded into the corresponding pre-set positions on the second set of sand cores. The sand cores (six) fill the middle part of the thin-walled rib plate cavity and, together with the second set of sand cores, form the complete cavity of the thin-walled rib plate. Finally, the double-layer core covers are sequentially installed. The lower core cover forms the cavity for the larger intermediate flange and upper cylinder block of the casting, while the upper core cover forms the top flange, thus completing the assembly of the entire casting cavity. This casting forming device enables the separate manufacturing and overall forming of large gas turbine cylinder block casting molds. Multiple sand core modules are manufactured independently and precisely using 3D printing, solving the problems of high difficulty in manufacturing, maintenance, and iteration costs of the overall mold. Furthermore, the modules, through their accommodating space and interlocking fit, make the actual core-setting operation simple, reliable, and highly operable, reducing reliance on worker experience, improving the alignment accuracy between the cavities of each component, and ensuring the dimensional accuracy and consistency of the final casting, especially complex thin-walled stiffening plate structures.

[0014] The above-described molding method uses the above-described casting molding apparatus and has the same beneficial effects as the above-described casting molding apparatus, which will not be elaborated here. Attached Figure Description

[0015] Figure 1 This is an overall structural diagram of the casting in one embodiment; Figure 2 This is a schematic diagram of the structure of the jig plate of the casting forming device in one embodiment; Figure 3 This is a schematic diagram showing the connection between the first set of sand cores and the jig in one embodiment of the casting forming device. Figure 4 This is a schematic diagram showing the connection of the second set of sand cores in a casting forming device according to one embodiment; Figure 5 This is a schematic diagram of the bottom view of the second set of sand cores in a casting forming apparatus according to one embodiment; Figure 6 This is a schematic diagram of the single structure of the second set of sand cores in one embodiment of the casting forming device; Figure 7 This is a schematic diagram of the third set of sand cores in a casting forming device according to one embodiment; Figure 8This is a schematic diagram showing the connection of the third set of sand cores in a casting forming device according to one embodiment; Figure 9 This is a schematic diagram showing the connection of the first cover core of the casting forming device in one embodiment; Figure 10 This is a schematic diagram of the overall structure of the casting forming device in one embodiment.

[0016] Label Explanation: 1. Bottom flange; 2. Lower cylinder block; 3. Intermediate flange; 4. Thin-walled stiffener; 5. Exhaust port; 6. Upper cylinder block; 7. Top flange; 8. Sand core of the mold plate; 9. Porcelain tube of the gating gate; 10. Sand hole; 11. Sand core one; 12. Sand core two; 13. Sand core three; 14. Sand core four; 15. Sand core five; 16. Receiving area; 17. Groove; 18. Sand core six; 19. Sand core seven; 20. Sand core eight; 21. Sand core nine. Detailed Implementation

[0017] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0018] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0019] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0020] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., 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 mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0021] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0022] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0023] See Figures 1 to 10 This invention addresses the high iteration cost of large cylinder block castings by providing a casting forming device that overcomes mold dependence and improves the accuracy of casting cavities, comprising: Sand core 8, used to connect the casting system; The first set of sand cores, including at least two sand cores 11 and 12, are set on the jig sand core 8 to form the bottom flange 1 and part of the lower cylinder body 2 of the casting; The second set of sand cores includes one or more sand cores 13, 14, and 15. The bottom of the second set of sand cores forms a receiving area 16. The first set of sand cores is placed in the receiving area 16. The second set of sand cores is used to form the outer edge contour and a part of the inner contour of another part of the lower cylinder body 2 and thin-walled stiffener 4 of the casting. The third set of sand cores includes multiple sand cores 18 and is embedded in the second set of sand cores to form the remaining inner contour of the remaining lower cylinder body 2 and thin-walled rib plate 4. A double-layer cap core is set on the third set of sand cores to form the intermediate flange 3, the upper cylinder body 6, and the top flange 7 of the casting.

[0024] The aforementioned casting forming apparatus, on the jig sand core 8, assembles and places a first set of sand cores, consisting of two sand cores 11 and two sand cores 12, to form the bottom flange 1 and the cavity of the lower cylinder body 2 at approximately half its height. Then, a second set of sand cores, consisting of one or more sand cores 13, 14, and 15, is installed onto the first set of sand cores. The bottom of the second set of sand cores has a receiving area 16 that precisely encloses the first set of sand cores below, achieving rapid and precise positioning and assembly. This second set of sand cores is used to form another portion of the lower cylinder body 2 and the outer edge contour and part of the inner contour of the thin-walled rib plate 4. Then, a third set of sand cores, consisting of multiple sand cores 18, is embedded into the corresponding positions preset on the second set of sand cores. The sand cores 18 fill the middle part of the cavity of the thin-walled rib plate 4, and together with the second set of sand cores, form the complete cavity of the thin-walled rib plate 4. Finally, the double-layer core covers are sequentially installed. The lower core cover forms the cavity for the larger intermediate flange 3 and the upper cylinder block 6, while the upper core cover forms the top flange 7, thus completing the assembly of the entire casting cavity. This casting forming device enables the separate manufacturing and overall forming of large gas turbine cylinder block casting molds. Multiple sand core modules are manufactured independently and precisely using 3D printing, solving the problems of high difficulty in manufacturing, maintenance, and iteration costs of the overall mold. Furthermore, the modules, through their accommodating space and interlocking fit, make the actual core-setting operation simple, reliable, and highly operable, reducing reliance on worker experience, improving the alignment accuracy between the cavities of each component, and ensuring the dimensional accuracy and consistency of the final casting, especially the complex thin-walled stiffener 4 structure.

[0025] In one embodiment, each of the first set of sand cores is provided with through holes for placing insulating risers. Optionally, according to the requirements of the bottom flange 1 of the casting, two through holes are provided on sand core 11 and three through holes are provided on sand core 12 to facilitate the placement of insulating risers into the reserved through holes during assembly.

[0026] Optionally, two sand cores 11 are arranged opposite each other, and two sand cores 22 are also arranged opposite each other. Sand cores 11 and 22 are evenly distributed in the inner ring of the jig sand core 8 to ensure uniform and good heat preservation effect and improve the quality of casting.

[0027] In one embodiment, the inner ring of the second set of sand cores has multiple grooves 17, the shape of which matches the shape of the sixth sand core 18, and the sixth sand core 18 is disposed within the grooves 17. It can be understood that the second set of sand cores is composed of multiple individual structures, namely, one third sand core 13, two or three fourth sand cores 14, and five sand cores 15, the specific number being determined according to the spatial distribution of the thin-walled reinforcing plates 4. Grooves 17 for placing the sixth sand core 18 are machined or directly printed on each third sand core 13, fourth sand core 14, and fifth sand core 15.

[0028] In one embodiment, the groove 17 is a groove with a trapezoidal or near-trapezoidal cross section, which facilitates the smooth insertion of the sand core 18 into the groove 17, while preventing the sand core from shifting or drifting, thus ensuring the accuracy of the cavity and the quality of the casting.

[0029] In one embodiment, the double-layer cover core includes a first layer cover core and a second layer cover core. The first layer cover core includes two or three sand cores 719 and 820, used to form the intermediate flange 3 and the upper cylinder body 6 of the casting. The second layer cover core includes two, three, or four sand cores 921, used to form the top flange 7 of the casting. The double-layer cover core design avoids the limitation of operating space caused by a locally large structure in the middle, and the layered design facilitates inspection and ensures the quality of the mold cavity.

[0030] In one embodiment, the outer contour dimensions of sand core 7 19 and sand core 8 20 are larger than those of sand core 9 21, and both sand core 7 19 and sand core 8 20 are provided with through holes for placing insulating risers. This bottom-large, top-small distribution achieves the desired casting cavity while not hindering the placement of risers on the lower sand cores 7 19 and sand core 8 20, thus improving operability.

[0031] In one embodiment, the height of both the first sand core 11 and the second sand core 12 is designed to extend to the upper edge of the insulation riser.

[0032] In one embodiment, the mold core 8 is provided with a plurality of sand holes 10 and a plurality of gating ceramic tubes 9, the gating ceramic tubes 9 being disposed in the sand holes 10. By pre-setting the gating ceramic tubes 9 on the mold core 8, it is beneficial to smoothly and evenly fill the cavity formed by the sand core assembly during casting.

[0033] The present invention also provides a forming method using the casting forming apparatus as described above, comprising the following steps: S1: Prepare the tire plate sand core 8, the first group of sand cores, the second group of sand cores, the third group of sand cores, and the double-layer cover core; S2: Lay the lower box casting system on the sand core 8 of the tire plate; S3: The first set of sand cores is assembled and placed on the jig sand core 8 to form the cavity of the bottom flange 1 and part of the lower cylinder 2 of the casting, and the heat insulation riser is placed through the reserved through hole. S4: Cover the bottom receiving area 16 of the second set of sand cores onto the first set of sand cores; S5: The third set of sand cores is embedded into the second set of sand cores, and together with the second set of sand cores, they form the cavity of the remaining lower cylinder body 2 and the complete thin-walled rib plate 4; S6: Assemble and place the lower cover core of the double-layer cover core to form the cavity of the casting intermediate flange 3 and the upper cylinder body 6, and place the heat-insulating riser through its reserved through hole; S7: Place the upper cover core of the double-layer cover core to form the cavity of the top flange 7 of the casting; S8: The mold is closed, and the casting is carried out through the inner sprue ceramic tube 9 to obtain the exhaust cylinder casting.

[0034] The aforementioned casting forming device, on the jig sand core 8, assembles and places a first set of sand cores, consisting of two sand cores 11 and two sand cores 12, to form the bottom flange 1 and the cavity of the lower cylinder body 2 at approximately half its height. Then, a second set of sand cores, consisting of two sand cores 13, 14, and 15, is installed on top of the first set. The bottom of the second set has a receiving area 16 that precisely encloses the first set of sand cores below, achieving rapid and precise positioning and assembly. This second set of sand cores forms another portion of the lower cylinder body 2 and the outer edge contour and part of the inner contour of the thin-walled rib plate 4. Then, a third set of sand cores, consisting of multiple sand cores 18, is embedded into the corresponding positions preset on the second set of sand cores. The sand cores 18 fill the middle part of the cavity of the thin-walled rib plate 4, and together with the second set of sand cores, form the complete cavity of the thin-walled rib plate 4. Finally, the double-layer core covers are sequentially installed. The lower core cover forms the cavity for the larger intermediate flange 3 and the upper cylinder block 6, while the upper core cover forms the top flange 7, thus completing the assembly of the entire casting cavity. This casting forming device enables the separate manufacturing and overall forming of large gas turbine cylinder block casting molds. Multiple sand core modules are manufactured independently and precisely using 3D printing, solving the problems of high difficulty in manufacturing, maintenance, and iteration costs of the overall mold. Furthermore, the modules, through their accommodating space and interlocking fit, make the actual core-setting operation simple, reliable, and highly operable, reducing reliance on worker experience, improving the alignment accuracy between the cavities of each component, and ensuring the dimensional accuracy and consistency of the final casting, especially the complex thin-walled stiffener 4 structure.

[0035] The above-described molding method uses the above-described casting molding apparatus and has the same beneficial effects as the above-described casting molding apparatus, which will not be elaborated here.

[0036] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0037] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A casting forming apparatus, characterized in that, The casting forming apparatus includes: The gating plate sand core is used to connect the casting system; The first set of sand cores, including at least two sand cores, sand core one and sand core two, are set on the jig sand cores to form the bottom flange and part of the lower cylinder body of the casting; The second set of sand cores includes one or more sand cores three, four, and five. The bottom of the second set of sand cores forms a receiving area. The first set of sand cores is placed in the receiving area. The second set of sand cores is used to form the outer edge profile and a portion of the inner profile of another part of the lower cylinder body and thin-walled stiffener of the casting. The third set of sand cores, including multiple sand cores, is embedded in the second set of sand cores and is used to form the remaining inner contour of the remaining lower cylinder block and thin-walled rib plate. A double-layer cap core, set on the third set of sand cores, is used to form the intermediate flange, upper cylinder body, and top flange of the casting.

2. The casting forming apparatus according to claim 1, characterized in that, The first set of sand cores are all provided with through holes for placing insulation risers.

3. The casting forming apparatus according to claim 1, characterized in that, The inner ring of the second set of sand cores has multiple grooves, the shape of which matches the shape of the sixth sand core, and the sixth sand core is disposed in the grooves.

4. The casting forming apparatus according to claim 3, characterized in that, The groove is a groove with a trapezoidal or nearly trapezoidal cross-section.

5. The casting forming apparatus according to claim 1, characterized in that, The double-layer cover core includes a first layer cover core and a second layer cover core. The first layer cover core includes at least two sand cores seven and eight, which are used to form the intermediate flange and upper cylinder of the casting. The second layer cover core includes at least two sand cores nine, which are used to form the top flange of the casting.

6. The casting forming apparatus according to claim 1, characterized in that, The outer contour dimensions of the sand core 7 and the sand core 8 are larger than those of the sand core 9, and both the sand core 7 and the sand core 8 are provided with through holes for placing the heat insulation riser.

7. The casting forming apparatus according to claim 1, characterized in that, The height of both the first and second sand cores is designed to extend to the upper edge of the insulation riser.

8. The casting forming apparatus according to claim 1, characterized in that, The substrate sand core is provided with multiple sand holes and multiple gating ceramic tubes, and the gating ceramic tubes are arranged in the sand holes.

9. A forming method using the casting forming apparatus as described in any one of claims 1-8, characterized in that, Includes the following steps: S1: Prepare the tire plate sand core, the first group of sand cores, the second group of sand cores, the third group of sand cores, and the double-layer cover core; S2: Lay the lower box casting system on the sand core of the tire plate; S3: The first set of sand cores is assembled and placed on the mold plate sand core to form the cavity of the bottom flange of the casting and part of the lower cylinder body, and the heat insulation riser is placed through the reserved through hole; S4: Cover the bottom receiving area of ​​the second set of sand cores onto the first set of sand cores accordingly; S5: The third set of sand cores is embedded into the second set of sand cores, and together with the second set of sand cores, they form the cavity of the remaining lower cylinder body and the complete thin-walled rib plate. S6: Assemble and place the lower cover core of the double-layer cover core to form the cavity of the casting intermediate flange and the upper cylinder body, and place the heat-insulating riser through its reserved through hole; S7: Place the upper cover core of the double-layer cover core to form the cavity of the top flange of the casting; S8: The mold is closed, and the exhaust cylinder casting is obtained by pouring through the inner sprue ceramic tube.

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