A multi-element combined casting machine for super large castings

Abstract

The present application relates to metal casting equipment technical field, disclose a kind of super large casting with multiple element co-casting machine, wherein co-casting machine includes base frame, smelting tilting unit and modular co-casting mold unit, smelting tilting unit and modular co-casting mold unit are installed in base frame, smelting tilting unit is communicated with modular co-casting mold unit by pouring runner, multiple mold modules are spliced along co-mould guide rail to form super large mold cavity, and the adjacent mold modules are matched by positioning pin sleeve and sealed by sealing element.The present application solves the technical problems of the size limitation of traditional integral mold and the orderly pouring of multiple metal materials in the same mold cavity.

Description

Technical Field

[0001] This invention relates to the field of metal casting equipment technology, and more specifically, to a multi-element casting machine for ultra-large casting. Background Technology

[0002] In the production of ultra-large metal castings, traditional casting molds are usually integral structures. The size of their mold cavities is limited by the manufacturing capacity and transportation conditions of individual molds, making it difficult to meet the requirements of integral molding of ultra-large castings. When the size of the casting exceeds the limit of the individual mold, it is often necessary to cast in sections and then weld them together, resulting in a decrease in the overall performance of the casting and weak areas at the joints.

[0003] In terms of casting methods, traditional casting equipment typically uses a crane to transport ladles between the melting device and the mold for casting. During the transfer of molten metal, the temperature loss is significant, and the flow rate is difficult to control stably. In the filling process of ultra-large mold cavities, casting defects such as cold shuts and incomplete pouring are prone to occur.

[0004] Furthermore, when different metal materials need to be poured into different areas of the same mold cavity to achieve composite casting, traditional equipment lacks a structural solution that combines the melting device with the mold, making it impossible to achieve orderly partitioned filling of multiple metal materials in the same mold cavity, thus failing to meet the production needs of composite casting. Summary of the Invention

[0005] This invention provides a multi-element casting machine for ultra-large casting, which solves the technical problems in related technologies such as the limited size of traditional casting mold cavities, the need for segmented casting and welding of ultra-large castings, the large temperature loss of molten metal during the melting device and mold pouring process, and the inability to achieve orderly filling of multiple metal materials in the same mold cavity.

[0006] This invention discloses a multi-element casting machine for ultra-large casting, comprising a base frame, a melting tilting unit, and a modular casting mold unit. The base frame is a horizontally arranged rigid frame structure; the melting tilting unit is installed on the base frame and includes a furnace support frame, a furnace body, a tilting hydraulic cylinder, and a pouring channel. The furnace body is rotatably mounted on a pivot seat at the top of the furnace support frame via a pivot. The tilting hydraulic cylinder drives the furnace body to tilt around the pivot. The pouring channel is fixedly connected to the base frame, with its inlet end located below the pouring path of the furnace body opening; the modular casting mold unit is installed on the base frame and includes a pair of mold closing guide rails, multiple mold modules, a fixed end plate, a mold closing hydraulic cylinder, and a mold closing pressure plate. After the multiple mold modules are sequentially assembled along the assembly direction, the mold cavities of each unit are interconnected to form a complete mold cavity. The mold closing hydraulic cylinder drives the mold closing pressure plate to clamp all mold modules between the mold closing pressure plate and the fixed end plate; wherein, the outlet end of the pouring channel is connected to the mold cavity.

[0007] Furthermore, each mold module has a module positioning pin fixed on one end face along the assembly direction and a module positioning sleeve fixed on the other end face. When two adjacent mold modules are assembled, the module positioning pin of one mold module is inserted into the module positioning sleeve of the other mold module to form an insertion fit, thereby realizing the alignment between adjacent mold modules.

[0008] Furthermore, an inter-module seal is embedded between the mating surfaces of each pair of adjacent mold modules, and the inter-module seal is embedded in the sealing groove opened on the mating surface of the mold modules.

[0009] Furthermore, there are multiple melting tilting units, each equipped with an independent furnace body and casting channel. The outlet end of each casting channel is connected to different areas of the mold cavity. Different melting tilting units can accommodate different types of metal materials, realizing the partitioned casting of multiple metal materials in the same mold cavity.

[0010] Furthermore, the base frame has multiple sets of bolt mounting holes along the assembly direction. The fixed end plate is fixed by bolts at different positions of the bolt mounting holes to accommodate changes in the total length after assembling different numbers of mold modules.

[0011] Furthermore, it also includes an auxiliary clamping mechanism, which includes a clamping beam and a locking screw. The clamping beam spans the top of the mold module, and one end of the locking screw passes through the clamping beam and is threaded to the base frame. When the locking screw is tightened, the clamping beam presses the mold module onto the mold closing guide rail in the vertical direction.

[0012] Furthermore, the gating runner adopts a bottom-injection structure, with the outlet end of the gating runner connected to the bottom area of ​​the mold cavity.

[0013] Furthermore, the tail end of the tilting hydraulic cylinder body is hinged to the furnace support frame via a hinge pin, and the head end of the tilting hydraulic cylinder piston rod is hinged to the lug provided on the outer wall of the furnace body via a hinge pin. The axis of the tilting hydraulic cylinder body is located in the vertical plane of the pivot.

[0014] Furthermore, the surface of the mold clamping plate is parallel to the end face of the outermost mold module. The transmission path of the mold clamping locking force is as follows: the piston rod of the mold clamping hydraulic cylinder, the mold clamping plate, the outermost mold module, transmitted sequentially through the splicing surfaces of each adjacent mold module, the last mold module, the fixed end plate, and the base frame. Beneficial effects

[0015] This invention solves the technical problem of limited cavity size in traditional integral molds, which are difficult to adapt to the forming needs of ultra-large castings, by arranging multiple standardized mold modules sequentially along a mold closing guide and locking them together with a mold closing hydraulic cylinder. This achieves the technical effect that the cavity size can be expanded as needed and the mold modules can be repeatedly combined and used. Furthermore, by setting an insertion and mating structure of positioning pins and positioning sleeves on the joint surfaces of adjacent mold modules and embedding sealing elements in the sealing grooves, this invention solves the technical problems of insufficient alignment accuracy and sealing performance of modular assembly molds, achieving precise alignment of adjacent mold modules and preventing molten metal leakage from the joint surfaces. Technical effects: By combining and connecting the melting tilting unit and the modular casting mold unit to the same base frame and directly connecting them with the pouring channel, the technical problems of large temperature loss and difficult flow control of molten metal caused by the overhead crane ladle transportation method are solved. The technical effects of shortening the molten metal transfer path and reducing the risk of cold shuts and incomplete pouring defects are achieved. By setting up multiple independent melting tilting units and configuring their own pouring channels, the technical problem of traditional equipment being unable to pour different metal materials into different areas in the same mold cavity is solved. The technical effect of being able to achieve zoned pouring of multiple metal materials in the same mold cavity and meet the production needs of composite casting is achieved. Attached Figure Description

[0016] Figure 1 This is a front view of an ultra-large casting mold that combines the smelting equipment and the casting mold of the present invention. Figure 2 This is a longitudinal sectional view of the modular composite casting mold unit of the present invention; Figure 3 This is a cross-sectional view of the mold module of the present invention; Figure 4 This is a cross-sectional view of the melting tilting unit of the present invention; Figure 5 This is a cross-sectional view of the interface between adjacent mold modules of the present invention; Figure 6 This is a top view of the ultra-large casting mold of the present invention.

[0017] In the diagram: Base frame-1, Furnace support frame-2, Furnace body-3, Tilting hydraulic cylinder body-4, Tilting hydraulic cylinder piston rod-5, Sprue runner-6, Mold closing guide rail-7, Mold module-8, Module slider-9, Module positioning pin-10, Module positioning sleeve-11, Fixed end plate-12, Mold closing hydraulic cylinder body-13, Mold closing hydraulic cylinder piston rod-14, Mold closing pressure plate-15, Inter-module seal-16, Pressing crossbeam-17, Locking screw-18. Detailed Implementation

[0018] Reference Figure 1-6This embodiment provides a multi-element casting machine for ultra-large casting, which includes at least a base frame 1, a melting tilting unit and a modular casting mold unit. The melting tilting unit and the modular casting mold unit are both installed on the base frame 1. The melting tilting unit is connected to the modular casting mold unit through the pouring channel 6. The molten metal flows into the ultra-large mold cavity formed by the assembly of multiple mold modules 8 through the pouring channel 6.

[0019] The base frame 1 is a horizontally arranged rigid frame structure used to bear the clamping force and the weight of the equipment, and to serve as the installation reference for each unit.

[0020] The smelting tilting unit includes a furnace support frame 2, a furnace body 3, a tilting hydraulic cylinder, and a pouring channel 6. The furnace support frame 2 is fixedly connected to the base frame 1, and a pivot seat is provided on the top of the furnace support frame 2. The furnace body 3 is rotatably mounted on the pivot seat via a pivot, allowing the furnace body 3 to swing around the pivot. The furnace opening of the furnace body 3 faces the pouring channel 6. When the furnace body 3 tilts around the pivot, the molten metal inside the furnace body 3 pours out from the furnace opening and flows into the pouring channel 6. The tail end of the tilting hydraulic cylinder is hinged to the furnace support frame 2 via a hinge pin, and the head end of the tilting hydraulic cylinder piston rod is hinged to an ear seat provided on the outer wall of the furnace body 3 via a hinge pin. The axis of the tilting hydraulic cylinder body 4 is located in the vertical plane of the pivot. When the piston rod 5 of the tilting hydraulic cylinder extends, it pushes the furnace body 3 to tilt around the pivot axis to one side of the pouring channel 6, and the molten metal flows out from the furnace opening under the action of gravity; when the piston rod 5 of the tilting hydraulic cylinder retracts, the furnace body 3 returns to the upright position. The pouring channel 6 is fixedly connected to the base frame 1. The inlet end of the pouring channel 6 is located directly below the tilting path of the furnace opening of the furnace body 3, and the outlet end of the pouring channel 6 is connected to the mold cavity formed by the modular casting mold unit. The pouring channel 6 guides the molten metal downward into the mold cavity in the vertical direction.

[0021] The modular casting mold unit includes a pair of mold closing guide rails 7, multiple mold modules 8, a fixed end plate 12, a mold closing hydraulic cylinder, and a mold closing pressure plate 15. The pair of mold closing guide rails 7 are fixedly connected to the base frame 1 parallel to the assembly direction of the mold modules 8, forming an installation space for the mold modules 8 between the two guide rails 7. Each mold module 8 is a standardized mold cavity unit. After multiple mold modules 8 are arranged and assembled sequentially along the assembly direction, the unit mold cavities within each mold module 8 are interconnected, collectively forming a large, complete mold cavity. A module slider 9 is fixedly connected to the bottom of each mold module 8. The module slider 9 and the mold closing guide rails 7 form a sliding pair, allowing each mold module 8 to slide along the assembly direction on the mold closing guide rails 7 to adjust the position and number of mold modules 8.

[0022] Each mold module 8 has a module positioning pin 10 fixedly installed on one end face along the assembly direction, with the module positioning pin 10 protruding from the end face along the assembly direction; each mold module 8 has a module positioning sleeve 11 fixedly installed on the other end face along the assembly direction, with the module positioning sleeve 11 recessed into the end face along the assembly direction. When two adjacent mold modules 8 are assembled, the module positioning pin 10 of one mold module 8 is inserted into the module positioning sleeve 11 of the other mold module 8, and the module positioning pin 10 and the module positioning sleeve 11 form an insertion fit to achieve precise alignment between adjacent mold modules 8. A module seal 16 is embedded between the mating surfaces of each pair of adjacent mold modules 8, and the module seal 16 is embedded in the sealing groove opened on the mating surface of the mold modules 8 to prevent molten metal from leaking from the module joint.

[0023] The fixed end plate 12 is bolted to one end of the base frame 1 along the assembly direction to bear the reaction force from one side of the mold module 8 during mold closing. The cylinder body of the mold closing hydraulic cylinder is fixedly connected to the other end of the base frame 1 along the assembly direction, and the piston rod of the mold closing hydraulic cylinder moves linearly reciprocating along the assembly direction. The mold closing pressure plate 15 is fixedly connected to the end of the piston rod 14 of the mold closing hydraulic cylinder, and the plate surface of the mold closing pressure plate 15 is parallel to the end face of the outermost mold module 8. When the piston rod 14 of the mold closing hydraulic cylinder extends along the assembly direction, the mold closing pressure plate 15 pushes all the mold modules 8 to slide along the mold closing guide rail 7 towards the fixed end plate 12 until the last mold module 8 abuts against the fixed end plate 12. At this time, all the mold modules 8 are clamped and locked between the mold closing pressure plate 15 and the fixed end plate 12, and the module positioning pins 10 of each adjacent mold module 8 are fully inserted into the corresponding module positioning sleeves 11. The inter-module seals 16 are pressurized to seal each mating surface. The transmission path of the mold clamping force is as follows: mold clamping hydraulic cylinder piston rod 14, mold clamping pressure plate 15, outermost mold module 8, transmitted sequentially through the splicing surfaces of each adjacent mold module 8, the last mold module 8, fixed end plate 12, and base frame 1.

[0024] In some embodiments, multiple melting tilting units are installed on the base frame 1. Each melting tilting unit is equipped with an independent furnace body 3 and a pouring channel 6. The outlet end of each pouring channel 6 is connected to a different area of ​​the mold cavity. With this arrangement, different melting tilting units can respectively accommodate and melt different types of metal materials. Each molten metal flows into a designated area of ​​the mold cavity through its corresponding pouring channel 6, thereby achieving the partitioned pouring of multiple metal materials within the same mold cavity to form a composite casting.

[0025] In some embodiments, the base frame 1 has multiple sets of bolt mounting holes along the assembly direction, and the fixed end plate 12 can be fixed by selecting bolt mounting holes at different positions, thereby adapting to the changes in the total length after assembling different numbers of mold modules 8.

[0026] Furthermore, in order to prevent the impact force of the molten metal during the pouring process from causing the mold module 8 to shift vertically, the base frame 1 is also provided with an auxiliary clamping mechanism in the vertical direction. The auxiliary clamping mechanism includes a clamping beam 17 and a locking screw 18. The clamping beam 17 spans the top of the mold module 8, and one end of the locking screw 18 passes through the clamping beam 17 and is threaded to the base frame 1. When the locking screw 18 is tightened, the clamping beam 17 presses the mold module 8 vertically onto the mold closing guide rail 7, thus limiting the displacement of the mold module 8 in the vertical direction.

[0027] Furthermore, in order to reduce the turbulence of the molten metal during the pouring process and improve the quality of the casting, the pouring channel 6 adopts a bottom pouring structure. The outlet end of the pouring channel 6 is connected from the bottom area of ​​the mold cavity. The molten metal gradually fills the mold cavity from the bottom upwards, so that the molten metal surface rises steadily and reduces molten metal splashing and gas entrapment.

[0028] Working principle: In use, first determine the required number of mold modules 8 according to the size of the target casting, and place the corresponding number of mold modules 8 sequentially on the mold closing guide rail 7. Each mold module 8 is arranged along the assembly direction by the module slider 9 at the bottom. Adjust the installation position of the fixed end plate 12 on the base frame 1 so that the distance between the fixed end plate 12 and the mold closing pressure plate 15 is adapted to the total length of all mold modules 8 after assembly.

[0029] When the mold closing hydraulic cylinder is activated, the piston rod 14 of the mold closing hydraulic cylinder extends along the assembly direction. The mold closing pressure plate 15 pushes all the mold modules 8 to slide along the mold closing guide rail 7 towards the fixed end plate 12. The module positioning pins 10 of adjacent mold modules 8 are inserted into the corresponding module positioning sleeves 11 one by one to achieve alignment. The inter-module seals 16 are pressed to seal the joints of each splicing surface. All the mold modules 8 are locked between the mold closing pressure plate 15 and the fixed end plate 12 to form a complete ultra-large mold cavity.

[0030] In some embodiments, after the mold is closed and locked, an auxiliary pressing step is performed: the pressing beam 17 is placed across the top of the mold module 8, the locking screw 18 is tightened, and the mold module 8 is pressed onto the mold closing guide rail 7 in the vertical direction.

[0031] Metal material is added to the furnace body 3 and melted. After the metal material has melted, the tilting hydraulic cylinder is activated. The piston rod 5 of the tilting hydraulic cylinder extends and pushes the furnace body 3 to tilt around the pivot axis to one side of the pouring channel 6. The molten metal flows out from the furnace opening and into the mold cavity through the pouring channel 6. The extension amount of the piston rod 5 of the tilting hydraulic cylinder is controlled according to the filling condition of the mold cavity, and the tilting angle of the furnace body 3 is adjusted, thereby controlling the outflow speed and flow rate of the molten metal.

[0032] In some embodiments, when multiple metal materials need to be cast to form a composite casting, multiple melting tilting units are loaded with different types of metal materials and melted separately. The tilting hydraulic cylinders are activated sequentially or simultaneously according to a predetermined casting sequence, so that different molten metals flow into the corresponding areas of the mold cavity through their respective casting channels 6.

[0033] After the molten metal is filled, the piston rod 5 of the tilting hydraulic cylinder is retracted, the furnace body 3 returns to an upright position, and the pouring stops. After the molten metal in the mold cavity cools and solidifies, the mold closing hydraulic cylinder is activated to retract the piston rod 14 of the mold closing hydraulic cylinder, the mold closing plate 15 disengages from the mold module 8, and each mold module 8 separates from the mold along the mold closing guide rail 7, and the casting is removed.

[0034] This embodiment arranges multiple standardized mold modules 8 sequentially along the mold closing guide rail 7 and locks them together with a mold closing hydraulic cylinder. The unit mold cavities of each mold module 8 are interconnected to form an ultra-large complete mold cavity. Therefore, the mold cavity size is no longer limited by the manufacturing limit of a single mold. The size of the mold cavity can be adjusted by flexibly increasing or decreasing the number of mold modules 8 according to the size of the casting. This solves the problem that traditional integral molds are difficult to adapt to the forming requirements of ultra-large castings.

[0035] By setting the module positioning pin 10 and module positioning sleeve 11 insertion and mating structure on the splicing surface of adjacent mold modules 8, and embedding the inter-module sealing element 16 in the sealing groove, the mold modules 8 can be accurately aligned to ensure the continuity of the mold cavity shape, and the molten metal can be effectively prevented from leaking from the splicing surface joint. Therefore, the shortcomings of modular assembly mold in terms of alignment accuracy and sealing performance are overcome.

[0036] By combining the smelting tilting unit and the modular casting mold unit on the same base frame 1, and directly connecting the furnace opening of the furnace body 3 and the mold cavity with the pouring channel 6, the molten metal is poured directly from the furnace body 3 into the mold cavity through the pouring channel 6, which shortens the transfer path of the molten metal. Therefore, it reduces the temperature loss during the pouring process and lowers the risk of cold shut and incomplete pouring defects.

[0037] By setting up multiple independent melting tilting units and configuring their own pouring channels 6, different types of metal materials can be melted separately and flow into different areas of the mold cavity through their respective pouring channels 6. Therefore, it is possible to achieve zoned pouring of multiple metal materials in the same mold cavity, which meets the production needs of composite casting.

[0038] The embodiments of the present invention have been described above. However, the embodiments are not limited to the specific implementation methods described above. The specific implementation methods described above are merely illustrative and not restrictive. Those skilled in the art can make more equivalent embodiments under the guidance of the present embodiments, and all of them are within the protection scope of the present embodiments.

Claims

1. A multi-element composite casting machine for ultra-large casting, characterized in that, include: The base frame (1) is a horizontally arranged rigid frame structure; The smelting tilting unit is installed on the base frame (1) and includes a furnace support frame (2), a furnace body (3), a tilting hydraulic cylinder and a pouring channel (6). The furnace support frame (2) is fixedly connected to the base frame (1). The furnace body (3) is rotatably mounted on the pivot seat at the top of the furnace support frame (2) via a pivot. The cylinder body (4) of the tilting hydraulic cylinder is hinged to the furnace support frame (2). The piston rod (5) of the tilting hydraulic cylinder is hinged to the furnace body (3) to drive the furnace body (3) to tilt around the pivot. The pouring channel (6) is fixedly connected to the base frame (1), and its inlet end is located below the tilting path of the furnace mouth of the furnace body (3). A modular casting mold unit is installed on the base frame (1) and includes a pair of mold closing guide rails (7), multiple mold modules (8), a fixed end plate (12), a mold closing hydraulic cylinder and a mold closing pressure plate (15). The mold closing guide rails (7) are fixed parallel to the base frame (1) along the assembly direction. Each mold module (8) has a module slider (9) at the bottom, which forms a sliding pair with the mold closing guide rails (7). After multiple mold modules (8) are assembled in sequence along the assembly direction, the mold cavities of each unit are interconnected to form a complete mold cavity. The fixed end plate (12) is fixed to one end of the base frame (1) along the assembly direction. The cylinder body (13) of the mold closing hydraulic cylinder is fixed to the other end of the base frame (1) along the assembly direction. The mold closing pressure plate (15) is fixed to the end of the piston rod (14) of the mold closing hydraulic cylinder. The mold closing hydraulic cylinder drives the mold closing pressure plate (15) to clamp all the mold modules (8) between the mold closing pressure plate (15) and the fixed end plate (12). The outlet end of the casting channel (6) is connected to the mold cavity.

2. The ultra-large casting mold according to claim 1, characterized in that, Each mold module (8) has a module positioning pin (10) fixed on one end face along the assembly direction and a module positioning sleeve (11) fixed on the other end face. When two adjacent mold modules (8) are assembled, the module positioning pin (10) of one mold module (8) is inserted into the module positioning sleeve (11) of the other mold module (8) to form an insertion fit, thereby realizing the alignment between adjacent mold modules (8).

3. The ultra-large casting mold according to claim 2, characterized in that, Each pair of adjacent mold modules (8) is fitted with an inter-module seal (16) between their mating surfaces. The inter-module seal (16) is embedded in the sealing groove opened on the mating surface of the mold module (8).

4. The ultra-large casting mold according to claim 1, characterized in that, The number of melting tilting units is multiple. Each melting tilting unit is equipped with an independent furnace body (3) and a pouring channel (6). The outlet end of each pouring channel (6) is connected to different areas of the mold cavity. Different melting tilting units can accommodate different types of metal materials, so as to realize the partitioned pouring of multiple metal materials in the same mold cavity.

5. The ultra-large casting mold according to claim 1, characterized in that, The base frame (1) has multiple sets of bolt mounting holes along the assembly direction. The fixed end plate (12) is fixed by bolts at different positions of the bolt mounting holes to adapt to the changes in the total length after the assembly of different numbers of mold modules (8).

6. The ultra-large casting mold according to claim 1, characterized in that, It also includes an auxiliary clamping mechanism, which includes a clamping beam (17) and a locking screw (18). The clamping beam (17) spans the top of the mold module (8). One end of the locking screw (18) passes through the clamping beam (17) and is threaded to the base frame (1). When the locking screw (18) is tightened, the clamping beam (17) presses the mold module (8) onto the mold closing guide rail (7) in the vertical direction.

7. The ultra-large casting mold according to claim 1, characterized in that, The gating channel (6) adopts a bottom-injection structure, and the outlet end of the gating channel (6) is connected from the bottom area of ​​the mold cavity.

8. The ultra-large casting mold according to claim 1, characterized in that, The tail end of the tilting hydraulic cylinder is hinged to the furnace support frame (2) by a hinge pin, and the head end of the tilting hydraulic cylinder piston rod (5) is hinged to the ear seat provided on the outer wall of the furnace body (3) by a hinge pin. The axis of the tilting hydraulic cylinder body (4) is located in the vertical plane of the pivot.

9. The ultra-large casting mold according to claim 1, characterized in that, The surface of the mold plate (15) is parallel to the end face of the outermost mold module (8).

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