Uniform water inlet bottom pouring device and casting method for thick-wall base casting

Abstract

The present application relates to the technical field of thick-walled base casting, and particularly relates to a uniform water inlet bottom pouring device and a casting method for thick-walled base casting, which comprises a base, a mold is arranged on the top of the base, a bottom pouring port is arranged on the top of the mold, a first ceramic pipe is arranged in the mold, an installation block is fixedly connected to the outside of the first ceramic pipe, and a second ceramic pipe is fixedly connected to the top of the first ceramic pipe. The second sliding rod, the first sliding rod, the linkage rotating shaft and the rotating disc are rotated, the storage and extension of the stop block are accurately controlled, the ceramic pouring pipeline can be stably opened and closed, the molten material can be uniformly and stably filled in the mold in cooperation with the bottom pouring feeding structure, the problems such as vortex, splashing and uneven filling in the traditional pouring mode are avoided, the forming requirement of the thick-walled base casting is effectively adapted, the overall structure of the casting is compact and the wall thickness is uniform, and the casting defect rate is greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of casting technology for thick-walled base castings, specifically to a uniform water-injection bottom-pouring device and casting method for thick-walled base castings. Background Technology

[0002] Thick-walled base castings are core basic components in the fields of machinery, heavy industry, and equipment bases. They have large overall wall thickness and high requirements for structural density. The uniformity, purity, and appearance integrity of the casting directly determine the operational stability and service life of the entire machine or equipment.

[0003] Currently, the industry mostly uses bottom-pouring casting process for thick-walled base castings. Compared with top-pouring and side-pouring processes, bottom-pouring can effectively reduce the impact of molten iron and reduce air entrapment, making it the preferred process for forming thick-walled castings.

[0004] Existing pouring pipelines are mostly fixed pipe structures, lacking a controllable opening and closing sealing and material-blocking structure. During pouring intervals, equipment idle periods, and demolding waiting periods, external dust, casting slag, and other impurities can easily enter the pouring pipeline and mold cavity, mixing into the molten iron. This leads to quality defects such as slag inclusions and local porosity in the formed castings, significantly reducing the finished product qualification rate of thick-walled base castings.

[0005] Therefore, a uniform water-inlet bottom-pouring casting device and casting method for thick-walled base castings are proposed to solve the problems mentioned above. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a uniform bottom-pouring casting device and casting method for thick-walled base castings. This method solves the problem that existing casting pipelines are mostly fixed pipe structures, lacking a controllable opening and closing sealing and material-blocking structure. During casting intervals, equipment idle periods, and demolding waiting stages, external dust, casting slag, and other impurities can easily enter the casting pipeline and mold cavity, mixing into the molten iron and causing quality defects such as slag inclusions and local porosity in the formed castings, significantly reducing the yield of finished thick-walled base castings.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a uniform water inlet bottom pouring device and casting method for thick-walled base castings, comprising a base, a mold provided on the top of the base, a bottom pouring port provided on the top of the mold, a first ceramic tube provided inside the mold, an installation block fixedly connected to the outside of the first ceramic tube, and a second ceramic tube fixedly connected to the top of the first ceramic tube. The second ceramic tube is fixed to the outside of a fixing block, the inside of which is provided with a storage groove, the bottom of which is provided with a through groove, and a stop block is slidably connected inside the storage groove. The bottom of the stop block is provided with a driving mechanism, which includes a fixed rod, a rotating shaft, a turntable and a guide groove. The fixed rod is fixedly connected to the bottom of the stop block, the rotating shaft is rotatably connected to the inside of the base, the turntable is fixedly connected to the outside of the rotating shaft, and the guide groove is opened on the top of the turntable.

[0008] Preferably, the fixing rod is slidably connected through the through groove and through the guide groove, and the outer wall of the fixing rod is in contact with the inner wall of the through groove and the guide groove.

[0009] Preferably, the outer wall of the stop block is in contact with the inner wall of the storage groove, and the outer wall of the stop block is in contact with the inner wall of the second ceramic tube.

[0010] Preferably, the guide groove is inclined and is equidistantly distributed on the outside of the turntable, and a damping structure is provided at the connection between the rotating shaft and the base.

[0011] Preferably, the base is internally provided with a transmission mechanism, which includes a protrusion, a guide rail, a first slide rod, a protrusion, a sliding sleeve, a second slide rod, a cover plate, a limiting block, and a bolt. The protrusion is fixedly connected to one end of the rotating shaft, the guide rail is fixedly connected to the bottom of the inner cavity of the base, the first slide rod is slidably connected through the outside of the guide rail, the protrusion is fixedly connected to the top of the first slide rod, the sliding sleeve is slidably connected to the outside of the first slide rod, the second slide rod is fixedly connected to the outside of the sliding sleeve, the cover plate is fixedly connected to the top of the second slide rod, the limiting block is fixedly connected to the top of the base, and the bolt is threadedly connected to the top of the limiting block.

[0012] Preferably, there are two protrusions, and the sliding sleeve is disposed between the two protrusions.

[0013] Preferably, one end of the first slide rod is fixed with a connecting rod, which is slidably connected inside the protrusion.

[0014] Preferably, the bottom of the cover plate fits into the port of the bottom injection port, and the bolt is slidably connected through the top of the second slide rod.

[0015] Preferably, the second slide bar is slidably connected to the outside of the base.

[0016] Preferably, the bottom-pouring casting method includes the following steps: Step 1: Fix the mold in place, then slide the second slide bar, and then inject the material into the bottom injection port so that the material fills the first ceramic tube and the second ceramic tube. Step 2: Slide the second slide rod again, causing the first slide rod to slide along with it. While the first slide rod is sliding, the rotating shaft is driven to rotate through the setting of the protrusion. The guide groove of the turntable guides and drives the fixed rod to slide. The stop block is put into the receiving groove. Then, the injection material is continuously injected to carry out the bottom injection pouring operation. Step 3: After the bottom injection is completed, the second slide bar is reset in two stages, causing the rotating shaft to reverse and drive the stop block to reset, thus blocking the second ceramic tube and preventing foreign objects from entering the second ceramic tube. The product is then cooled and demolded.

[0017] Compared with the prior art, the present invention provides a uniform water-injection bottom-pouring casting device and casting method for thick-walled base castings, which has the following beneficial effects: 1. By linking the second slide rod and the first slide rod with the rotating shaft and turntable, the retraction and extension of the stop block can be precisely controlled, allowing for the smooth opening and closing of the ceramic pouring pipeline. Combined with the bottom-pouring feeding structure, the molten material can fill the mold interior evenly and smoothly, avoiding problems such as eddies, splashing, and uneven filling that occur in traditional pouring methods. This effectively adapts to the molding requirements of thick-walled base castings, ensuring a dense overall structure and uniform wall thickness, and significantly reducing the casting defect rate.

[0018] 2. Through the sealable second ceramic tube structure, the baffle can be quickly reset and block the pipeline after the casting is completed. During the idle period and the intermittent period of casting, it can effectively prevent external dust, waste residue and other foreign objects from entering the casting pipeline and the mold, avoid foreign objects from mixing into the molten material, avoid the casting from the source to avoid quality problems such as slag inclusion and impurities, and significantly improve the finished product quality and reliability of thick-walled base castings.

[0019] 3. Multiple stops can be opened and closed synchronously by sliding a single set of slide bars. The operation is simple and the action linkage is precise. No complicated electrical control equipment is required, making it suitable for industrial continuous casting operations. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the base structure of the present invention; Figure 3 This is a schematic diagram of the stop block structure of the present invention; Figure 4 This is a schematic diagram of the bottom injection port structure of the present invention; Figure 5 This is a schematic diagram of the turntable structure of the present invention; Figure 6 This is a schematic diagram of the protrusion structure of the present invention; Figure 7 For the present invention Figure 3 Enlarged structural diagram at point A in the middle.

[0021] In the diagram: 1. Base; 2. Mold; 3. Bottom injection port; 4. First ceramic tube; 5. Mounting block; 6. Second ceramic tube; 7. Fixing block; 8. Storage groove; 10. Through groove; 11. Stop block; 12. Fixing rod; 13. Rotating shaft; 14. Turntable; 15. Guide groove; 16. Plug; 17. Guide rail; 18. First slide rod; 19. Protrusion; 20. Sliding sleeve; 21. Second slide rod; 22. Cover plate; 23. Limiting block; 24. Bolt. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and 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.

[0023] Example: Please see Figures 1-7 The uniform water inlet bottom pouring device and casting method for thick-walled base casting in this embodiment includes a base 1, a mold 2 is provided on the top of the base 1, a bottom pouring port 3 is provided on the top of the mold 2, a first ceramic tube 4 is provided inside the mold 2, an installation block 5 is fixedly connected to the outside of the first ceramic tube 4, and a second ceramic tube 6 is fixedly connected to the top of the first ceramic tube 4. The second ceramic tube 6 is fixed to the outside of a fixing block 7. The inside of the fixing block 7 is provided with a storage groove 8. The bottom of the inner cavity of the storage groove 8 is provided with a through groove 10. A stop block 11 is slidably connected inside the storage groove 8. The bottom of the stop block 11 is provided with a drive mechanism, which includes a fixed rod 12, a rotating shaft 13, a turntable 14 and a guide groove 15. The fixed rod 12 is fixedly connected to the bottom of the stop block 11, the rotating shaft 13 is rotatably connected to the inside of the base 1, the turntable 14 is fixedly connected to the outside of the rotating shaft 13, and the guide groove 15 is opened on the top of the turntable 14.

[0024] The base 1 has a transmission mechanism inside, which includes a protrusion 16, a guide rail 17, a first slide rod 18, a protrusion 19, a sliding sleeve 20, a second slide rod 21, a cover plate 22, a limiting block 23, and a bolt 24. The protrusion 16 is fixedly connected to one end of the rotating shaft 13. The guide rail 17 is fixedly connected to the bottom of the inner cavity of the base 1. The first slide rod 18 is slidably connected through the outside of the guide rail 17. The protrusion 19 is fixedly connected to the top of the first slide rod 18. The sliding sleeve 20 is slidably connected to the outside of the first slide rod 18. The second slide rod 21 is fixedly connected to the outside of the sliding sleeve 20. The cover plate 22 is fixedly connected to the top of the second slide rod 21. The limiting block 23 is fixedly connected to the top of the base 1. The bolt 24 is threadedly connected to the top of the limiting block 23.

[0025] Before use, clean the surface of the base 1 to remove dust and slag, and remove the dust from the top of the stop block 11. Then, install and fix the mold 2. When using the equipment, remove the bolt 24, and then slide the second slide rod 21 so that the sliding sleeve 20 disengages from one protrusion 19 and fits with the other protrusion 19. At this time, the cover plate 22 does not coincide with the bottom inlet 3. Then pour the material into the bottom inlet 3 so that the material fills the first ceramic tube 4 and the second ceramic tube 6. Then slide the second slide rod 21 in two stages, and pull the first slide rod through the second slide rod 21. 18 Sliding: While the first slide rod 18 slides, the internal sliding groove of the protrusion 16 guides the rotating shaft 13 to rotate, and the turntable 14 rotates accordingly. At this time, the guide groove 15 pulls the fixed rod 12 to slide. At this time, the stop block is stored in the storage groove 8, and then the material is continuously injected, thereby realizing the bottom pouring operation of water entering multiple channels evenly. The setting to prevent foreign objects from entering can avoid the blockage of a single channel, which would prevent the even water entry and cause product defects or unqualified products. In the initial state, a protrusion 19 is in contact with and fits against one side of the guide rail 17; When the pouring is completed, the first slide bar 18 and the second slide bar 21 slide back to their original positions, and a protrusion 19 is in contact with the guide rail 17 again. At this time, the turntable 14 reverses and resets, and the stop block 11 covers the second ceramic tube 6 again, cutting off the injection material. This can facilitate demolding and prevent foreign objects from entering the second ceramic tube 6. By using or closing the second ceramic tube 6 midway, it is possible to prevent foreign objects from entering and causing impurities inside the product during bottom pouring, which would affect product quality. Furthermore, by pulling the second slide bar 21, multiple stops 11 can be quickly opened and closed, improving the ease of use of the equipment. Moreover, the first ceramic tube 4, the second ceramic tube 6, and the stops 11 are all made of ceramic, which can prevent the product from being difficult to demold. In addition, graphite seals are provided at all joints that require sealing, especially at the connection between the outer surface of the stops 11 and the receiving groove 8. Graphite seals: Molten iron wets the surface of high-purity graphite, which is a completely non-wetting system. The molten iron will not spread or penetrate the pores of the graphite surface. The interface adhesion is extremely low. After cooling, the cast iron shrinks, and gaps naturally appear at the interface. They can be separated by tapping, without the need for additional release agent.

[0026] The base 1 adopts an integral cast steel base structure, which is rigid and has minimal deformation under stress. It can be adapted to long-term casting operations of heavy and thick-walled castings, reducing the problems of casting misalignment and forming deviation caused by the shaking and displacement of traditional split bases, and providing a stable working foundation for the overall casting operation. Bottom inlet 3 adopts a flared structure design, which ensures smooth material flow and effectively avoids splashing and overflow when molten iron is fed. At the same time, it makes it easy for workers to observe the internal material filling status, is suitable for manual uniform feeding operations, and ensures feeding stability. The dual-section coaxial ceramic tube flow guiding structure has a smooth and flat inner wall with extremely low roughness, resulting in low flow resistance and uniform flow rate of molten material. It can achieve stable bottom-up filling of thick-walled castings, effectively solving defects such as air entrapment, slag inclusion, and uneven wall thickness caused by excessively fast filling and turbulent flow in thick-walled castings, and significantly improving the uniformity of casting.

[0027] When the equipment is not in use, the second slide bar 21 is reset and then fixed with bolts 24.

[0028] Furthermore, the fixing rod 12 is slidably connected through the inside of the through groove 10 and the inside of the guide groove 15. The outer wall of the fixing rod 12 is in contact with the inner wall of the through groove 10 and the guide groove 15. The outer wall of the stop block 11 is in contact with the inner wall of the storage groove 8 and the outer wall of the stop block 11 is in contact with the inner wall of the second ceramic tube 6. The guide groove 15 is inclined and is equidistantly distributed outside the turntable 14. A damping structure is provided at the connection between the rotating shaft 13 and the base 1.

[0029] Furthermore, there are two protrusions 19, and a sliding sleeve 20 is disposed between the two protrusions 19. One end of the first sliding rod 18 is fixed with a connecting rod, which is slidably connected inside the protrusion 16. The bottom of the cover plate 22 is fitted with the port of the bottom injection port 3. The bolt 24 is slidably connected through to the top of the second sliding rod 21, and the second sliding rod 21 is slidably connected through to the outside of the base 1.

[0030] Furthermore, the bottom-pouring casting method includes the following steps: Step 1: Fix the mold 2 in place, then slide the second slide bar 21, and then inject the material into the bottom injection port 3 so that the material fills the first ceramic tube 4 and the second ceramic tube 6. Step 2: Slide the second slide bar 21 again, causing the first slide bar 18 to slide along with it. While the first slide bar 18 is sliding, the rotating shaft 13 is rotated by the setting of the protrusion 16. The guide groove 15 of the turntable 14 guides and drives the fixed rod 12 to slide. The stop block 11 is put into the storage groove 8. Then, the injection material is continuously injected to carry out the bottom injection pouring operation. Step 3: After the bottom injection is completed, the second slide bar 21 is reset in two stages, causing the rotating shaft 13 to reverse and drive the stop block 11 to reset, thus blocking the second ceramic tube 6 and preventing foreign objects from entering the second ceramic tube 6. The product is then cooled and demolded.

[0031] The actual mold is inspected according to the drawings and mold process, and any inaccurate parts of the mold are repaired to ensure that the trial-produced mold is qualified.

[0032] Technical briefings were conducted with on-site workers in accordance with process documents and work instructions to ensure that production was carried out according to the process.

[0033] Preparation of production materials before production, such as sand boxes, resin, chills, risers, etc.

[0034] Production process: According to the production plan, the entire production process is tracked and recorded to ensure that the whole process is carried out in accordance with the process. At the same time, when analyzing problems that arise after the castings are produced, there are corresponding clues and evidence.

[0035] The entire production process is as follows: molding and core making - painting - core placement - box assembly - casting - post-treatment. Problems encountered and their solutions are recorded during the process, and key points of the process are also recorded.

[0036] For core making, chills, risers, etc. are placed according to process requirements. A three-box molding process is adopted, with positioning pins placed between each box for positioning. After the resin sand is placed, the resin and curing agent are allowed to react. After about 2-3 hours, the mold is removed. The surface of the sand mold and core is inspected, burrs are polished, and damaged parts are repaired.

[0037] After inspecting the sand mold surface and blowing away loose sand with an air gun, apply the refractory coating, recording relevant data such as the number of coats. Once the coating is complete, lightly sand the surface to remove brush marks and improve the surface quality of the casting.

[0038] After core placement and mold assembly, place the sand core into the corresponding position in the sand mold according to the work instructions. Use tools such as an air gun to remove loose sand from the entire cavity, then close the mold. Before closing the mold, inspect the casting to check if the wall thickness and other specifications meet the drawing requirements.

[0039] For casting, the material of this product is QT600-3. After the chemical composition is measured and found to be qualified during melting, it is poured from the furnace at a temperature of 1370-1360℃, using in-flow inoculation, and a slow-fast-slow pouring method. After pouring, it is kept in place for 48 hours before being unpacked and the sand removed.

[0040] The installation, connection, or setting methods disclosed in this embodiment are all common mechanical connection methods. As long as they can achieve their beneficial effects, they can be implemented. Therefore, this embodiment will not elaborate on their specific structural composition and working principle.

[0041] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A uniform water-injection bottom-pouring casting device for thick-walled base castings, characterized in that: Includes a base (1), a mold (2) is provided on the top of the base (1), a bottom injection port (3) is provided on the top of the mold (2), a first ceramic tube (4) is provided inside the mold (2), an installation block (5) is fixedly connected to the outside of the first ceramic tube (4), and a second ceramic tube (6) is fixedly connected to the top of the first ceramic tube (4). The second ceramic tube (6) is fixed with a fixing block (7) on the outside. The fixing block (7) has a storage groove (8) inside. The bottom of the inner cavity of the storage groove (8) has a through groove (10). The storage groove (8) is slidably connected with a stop block (11). The bottom of the stop (11) is provided with a driving mechanism, which includes a fixed rod (12), a rotating shaft (13), a turntable (14) and a guide groove (15). The fixed rod (12) is fixedly connected to the bottom of the stop (11), the rotating shaft (13) is rotatably connected to the inside of the base (1), the turntable (14) is fixedly connected to the outside of the rotating shaft (13), and the guide groove (15) is opened on the top of the turntable (14).

2. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 1, characterized in that: The fixing rod (12) is slidably connected inside the through groove (10) and the fixing rod (12) is slidably connected inside the guide groove (15). The outer wall of the fixing rod (12) is in contact with the inner wall of the through groove (10) and the guide groove (15).

3. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 2, characterized in that: The outer wall of the block (11) is in contact with the inner wall of the storage groove (8), and the outer wall of the block (11) is in contact with the inner wall of the second ceramic tube (6).

4. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 3, characterized in that: The guide groove (15) is inclined and is equidistantly distributed outside the turntable (14). A damping structure is provided at the connection between the rotating shaft (13) and the base (1).

5. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 1, characterized in that: The base (1) is equipped with a transmission mechanism, which includes a protrusion (16), a guide rail (17), a first slide rod (18), a protrusion (19), a sliding sleeve (20), a second slide rod (21), a cover plate (22), a limiting block (23), and a bolt (24). The protrusion (16) is fixedly connected to one end of the rotating shaft (13). The guide rail (17) is fixedly connected to the bottom of the inner cavity of the base (1). The first slide rod (18) is slidably connected to the outside of the guide rail (17). The protrusion (19) is fixedly connected to the top of the first slide rod (18). The sliding sleeve (20) is slidably connected to the outside of the first slide rod (18). The second slide rod (21) is fixedly connected to the outside of the sliding sleeve (20). The cover plate (22) is fixedly connected to the top of the second slide rod (21). The limiting block (23) is fixedly connected to the top of the base (1). The bolt (24) is threadedly connected to the top of the limiting block (23).

6. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 5, characterized in that: Two protrusions (19) are provided, and the sliding sleeve (20) is provided between the two protrusions (19).

7. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 6, characterized in that: One end of the first slide bar (18) is fixed with a connecting rod, which is slidably connected inside the protrusion (16).

8. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 6, characterized in that: The bottom of the cover plate (22) fits into the port of the bottom injection port (3), and the bolt (24) slides through and connects to the top of the second slide rod (21).

9. The uniform water-inlet bottom-pouring casting device for thick-walled base castings according to claim 6, characterized in that: The second slide bar (21) slides through the outside of the base (1).

10. A uniform water-injection bottom-pouring casting method for thick-walled base castings, characterized in that: The uniform water-inlet bottom-pouring casting device for thick-walled base castings as described in any one of claims 1-9, the bottom-pouring casting method includes the following steps: Step 1: Fix the mold (2) in place, then slide the second slide bar (21), and then inject the material into the bottom injection port (3) so that the material fills the first ceramic tube (4) and the second ceramic tube (6). Step 2: Slide the second slide bar (21) again to drive the first slide bar (18) to slide. While the first slide bar (18) is sliding, the rotating shaft (13) is driven to rotate through the setting of the bracket (16). The guide groove (15) of the turntable (14) guides and drives the fixed rod (12) to slide. The stop block (11) is put into the storage groove (8). Then, the injection material is continuously injected to carry out the bottom injection pouring operation. Step 3: After the bottom injection is completed, the second slide bar (21) is reset in two stages, so that the rotating shaft (13) is reversed, which drives the stop block (11) to reset and block the second ceramic tube (6) to prevent foreign objects from entering the second ceramic tube (6). The product is cooled and then demolded.

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