Anti-deformation method for integrated cast axle housing production and special mold and cast axle housing
Patent Information
- Application Number
- CN202611136038.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-29
- Publication Date
- 2026-10-30
AI Technical Summary
本申请可有效解决一体化桥壳的易变形难题，使一体化铸造桥壳的关键部位壁厚合格，提高桥壳产品的质量，保证桥壳产品的使用寿命
[0005]根据本申请上述实施例的一体化铸造桥壳生产的防变形方法，依据一体化铸造桥壳量产铸件的实测变形数据，在铸造模具对应下推支架的成型区域，预留反向增厚加工余量，抵消下推支架的冷却收缩向内偏移量；同时，在铸造模具对应主减加强圈的成型区域，增设均匀补正余量，补偿主减加强圈的冷却塌陷变形量。经模具优化后浇注成型的桥壳毛坯，其变形量可精准控制在加工公差范围内，机加工后可完全消除黑皮缺陷，保证主减加强圈壁厚均匀达标，有效提升铸件结构稳定性与使用寿命，工艺适配性强、可批量量产。由此，本申请可有效解决一体化桥壳的易变形难题，使一体化铸造桥壳的关键部位壁厚合格，提高桥壳产品的质量，保证桥壳产品的使用寿命。
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Abstract
Description
Technical Field
[0001] This application relates to the field of integrated cast bridge housing technology. Specifically, this application relates to a method for preventing deformation in the production of integrated cast bridge housing, as well as a special mold and cast bridge housing. Background Technology
[0002] The integrated cast axle housing is integrally cast from ductile iron, representing an upgraded version of the traditional stamped and welded axle housing. Early commercial vehicles primarily used stamped and welded steel plates for axle housings; while the process was mature, the welds were prone to fatigue cracking, the multiple welding processes lengthened production cycles, and the resulting welding deformation and subsequent correction costs were high. With the growing demand for lightweight and high reliability, integrated cast axle housings are gradually replacing traditional products in large quantities. Their seamless structure significantly improves fatigue strength and reduces leakage and fracture failures. The integrated molding simplifies processing, reduces stamping and welding tooling investment, and wall thickness optimization achieves weight reduction. Furthermore, it facilitates integrated installation, resulting in lower overall manufacturing costs. It is now widely used in heavy and light trucks, becoming the mainstream axle technology. However, the integrated cast axle housing is relatively large, posing a challenge of deformation during production. This invention proposes a method to prevent deformation during the production of integrated cast axle housings, which solves this problem. Summary of the Invention
[0003] This application aims to at least partially solve one of the technical problems in the related art. Therefore, the purpose of this application is to propose a method for preventing deformation in the production of integrated cast bridge housings, as well as a dedicated mold and casting bridge housing. This application can effectively solve the problem of easy deformation in integrated bridge housings, ensure the wall thickness of key parts of the integrated cast bridge housing is qualified, improve the quality of the bridge housing product, and guarantee the service life of the bridge housing product.
[0004] In a first aspect of this application, a method for preventing deformation during the production of an integrally cast bridge housing is proposed. According to an embodiment of this application, the method includes: (1) Collect measured deformation data of mass-produced integrated cast bridge shells, and respectively count the inward offset of cooling shrinkage of the push-down bracket and the cooling collapse deformation of the main reducing reinforcement ring. (2) Based on the deformation data obtained in step (1), reverse allowance compensation design is made for the corresponding forming area of the casting mold. For the forming area of the push support, a reverse thickening machining allowance is reserved to match the cooling shrinkage inward offset of the push support. For the forming area of the main reducing and reinforcing ring, a compensation allowance is added to match the cooling collapse deformation of the main reducing and reinforcing ring. (3) Using a casting mold optimized with allowance compensation, ductile iron is integrally cast to obtain an integrated cast bridge shell blank; (4) The integral cast bridge shell blank is cut and processed to remove the black skin of the blank on the assembly surface, and an integral cast bridge shell is obtained.
[0005] According to the anti-deformation method for integrated cast bridge housing production according to the above embodiments of this application, based on the measured deformation data of mass-produced integrated cast bridge housing castings, a reverse thickening machining allowance is reserved in the forming area of the lower support corresponding to the casting mold to offset the inward offset of the lower support due to cooling shrinkage; at the same time, a uniform compensation allowance is added in the forming area of the main reducing reinforcement ring corresponding to the casting mold to compensate for the cooling collapse deformation of the main reducing reinforcement ring. After mold optimization, the deformation of the cast bridge housing blank can be precisely controlled within the machining tolerance range. After machining, the black skin defect can be completely eliminated, ensuring that the wall thickness of the main reducing reinforcement ring is uniform and meets the standard, effectively improving the structural stability and service life of the casting, with strong process adaptability and mass production capability. Therefore, this application can effectively solve the problem of easy deformation of integrated bridge housings, ensure that the wall thickness of key parts of the integrated cast bridge housing is qualified, improve the quality of bridge housing products, and guarantee the service life of bridge housing products.
[0006] In addition, the anti-deformation method for producing integrated cast bridge housings according to the above embodiments of this application may also have the following additional technical features: In some embodiments of this application, the inward offset of the cooling contraction of the push-down bracket is x, and the reverse thickening machining allowance reserved in the forming area of the push-down bracket is x~(x+0.5mm); and / or, the cooling collapse deformation of the main reducing and reinforcing ring is y, and the compensation allowance added to the forming area of the main reducing and reinforcing ring is y~(y+1mm).
[0007] In some embodiments of this application, the forming area of the push-down bracket has a reserved reverse thickening machining allowance of 1mm to 5mm; and / or, the forming area of the main reducing reinforcement ring has an additional compensation allowance of 1mm to 7mm.
[0008] In some embodiments of this application, in step (2), the method of reserving a reverse thickening machining allowance for matching the cooling shrinkage inward offset of the push-down bracket is: offsetting the forming contour of the push-down bracket to the outside of the bridge housing, and the offset size matching the cooling shrinkage inward offset of the push-down bracket.
[0009] In some embodiments of this application, in step (2), the method of adding a compensation allowance to match the cooling collapse deformation of the main reducing and reinforcing ring is: raising the forming reference surface of the main reducing and reinforcing ring, and the raising value is matched with the cooling collapse deformation of the main reducing and reinforcing ring.
[0010] In a second aspect of this application, a casting mold for an integrated cast bridge housing is proposed. According to an embodiment of this application, the casting mold for the integrated cast bridge housing is used to implement the anti-deformation method for producing the integrated cast bridge housing according to the first aspect; the casting mold includes a first forming cavity corresponding to the lower support and a second forming cavity corresponding to the main reducing and reinforcing ring; the first forming cavity is provided with a reverse thickening compensation structure, and the second forming cavity is provided with a collapse compensation structure. The reverse thickening compensation structure is used to counteract the inward contraction and offset of the lower support during casting cooling, and the collapse compensation structure is used to compensate for the collapse deformation of the main reducing and reinforcing ring during casting cooling.
[0011] According to the casting mold of the integrated cast bridge housing according to the above embodiments of this application, a reverse thickening compensation structure is set in the first forming cavity of the casting mold corresponding to the push-down bracket to offset the inward offset of the push-down bracket due to cooling contraction; at the same time, a collapse compensation structure is set in the second forming cavity of the casting mold corresponding to the main reducing and reinforcing ring to compensate for the cooling collapse deformation of the main reducing and reinforcing ring. After the mold is optimized, the deformation of the cast bridge housing blank can be precisely controlled within the machining tolerance range. After machining, the black skin defect can be completely eliminated, ensuring that the wall thickness of the main reducing and reinforcing ring is uniform and meets the standard, effectively improving the structural stability and service life of the casting. It has strong process adaptability and can be mass-produced. Therefore, the casting mold of this application can effectively solve the problem of easy deformation of integrated bridge housings, ensure that the wall thickness of key parts of the integrated cast bridge housing is qualified, improve the quality of bridge housing products, and guarantee the service life of bridge housing products.
[0012] In addition, the casting mold for the integrated cast bridge housing according to the above embodiments of this application may also have the following additional technical features: In some embodiments of this application, the compensation thickness of the reverse thickening compensation structure is x ~ (x + 0.5 mm), where x is the inward offset of the cooling shrinkage of the push-down bracket in mass-produced castings; and / or, the compensation height of the collapse compensation structure is y ~ (y + 1 mm), where y is the cooling collapse deformation of the main reducing reinforcing ring in mass-produced castings.
[0013] In some embodiments of this application, the thickness of the reverse thickening compensation structure is 1mm to 5mm; and / or, the compensation height of the collapse compensation structure is 1mm to 7mm.
[0014] In some embodiments of this application, the reverse thickening compensation structure is a thickened cavity wall formed by the overall outward expansion of the first molding cavity contour toward the outside of the bridge shell; and / or, the collapse compensation structure is a compensation platform formed by the overall upward raising of the reference surface of the second molding cavity.
[0015] In a third aspect of this application, an integrated cast bridge housing is proposed. According to embodiments of this application, the aforementioned integrated cast bridge housing is prepared using the anti-deformation method of the first aspect or using the casting mold of the second aspect. Therefore, the integrated cast bridge housing of this application can completely eliminate black skin defects, ensure qualified wall thickness in key parts of the integrated cast bridge housing, improve the quality of the bridge housing product, and guarantee the service life of the bridge housing product.
[0016] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description
[0017] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic diagram of a method for preventing deformation in the production of an integrated cast bridge housing according to some embodiments of this application; Figure 2 This is a schematic diagram of the structure of a casting mold for an integrated cast bridge housing according to some embodiments of this application. Detailed Implementation
[0018] The embodiments of this application are described in detail below. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.
[0019] In the first aspect of this application, a method for preventing deformation during the production of an integrally cast bridge housing is proposed. According to an embodiment of this application, refer to the appendix... Figure 1 The above method includes: S100: collecting measured deformation data of mass-produced integrated cast bridge housings, and respectively calculating the inward offset of cooling shrinkage of the push-down bracket and the cooling collapse deformation of the main reducing reinforcement ring; S200: performing reverse allowance compensation design on the corresponding forming area of the casting mold based on the deformation data obtained in step S100, wherein, for the forming area of the push-down bracket, a reverse thickening machining allowance is reserved to match the inward offset of cooling shrinkage of the push-down bracket, and for the forming area of the main reducing reinforcement ring, a compensation allowance is added to match the cooling collapse deformation of the main reducing reinforcement ring; S300: using the casting mold optimized by allowance compensation, integral casting of ductile iron is performed to obtain an integrated cast bridge housing blank; S400: machining the integrated cast bridge housing blank to remove the black skin of the assembly surface blank to obtain an integrated cast bridge housing.
[0020] The following is a detailed explanation of the beneficial effects achievable by the anti-deformation method for the integrated cast bridge shell production proposed in this application: This application optimizes the forming deformation defects of the bridge housing push-down support and main damping reinforcement ring during mass production. In actual casting production, during the cooling process of the integrated bridge housing casting, the push-down support is prone to inward displacement and deformation due to uneven wall thickness and differences in solidification shrinkage. Subsequent machining cannot completely remove the black skin of the blank, resulting in poor fit of the assembly surface and excessive assembly accuracy. The main damping reinforcement ring is prone to collapse and deformation, resulting in local wall thinning after machining, which significantly reduces the structural strength and fatigue resistance, and shortens the service life of the casting.
[0021] To address this challenge, this application employs a method of increasing machining allowances at corresponding locations in the mold to ensure casting quality. Specifically, based on deformation data from multiple batches of mass production, this application reserves a reverse thickening machining allowance in the forming area of the lower support corresponding to the casting mold to offset the inward offset caused by cooling contraction of the lower support. Simultaneously, a uniform compensation allowance is added in the forming area of the main reducing reinforcement ring corresponding to the casting mold to compensate for the cooling collapse deformation of the main reducing reinforcement ring. After mold optimization, the deformation of the cast bridge housing blank can be precisely controlled within the machining tolerance range. After machining, black skin defects can be completely eliminated, ensuring uniform and compliant wall thickness of the main reducing reinforcement ring, effectively improving the structural stability and service life of the casting. This method exhibits strong process adaptability and is suitable for mass production. Therefore, this application effectively solves the problem of easy deformation in integrated bridge housings, ensuring the wall thickness of key components in integrated cast bridge housings meets standards, improving the quality of bridge housing products, and guaranteeing their service life.
[0022] Specifically, see the attached document. Figure 1 The above methods include: S100: Collect measured deformation data of mass-produced integrated cast bridge housings, and separately calculate the inward offset of the cooling shrinkage of the push-down bracket and the cooling collapse deformation of the main reducing reinforcement ring. In this step, measured deformation data of multiple batches of integrated cast bridge housings were collected, and the inward offset of the cooling shrinkage of the push-down bracket and the cooling collapse deformation of the main reducing reinforcement ring were statistically analyzed.
[0023] S200: Based on the deformation data obtained in step S100, perform reverse allowance compensation design on the corresponding forming area of the casting mold; In this step, a reverse allowance compensation design is performed on the corresponding forming area of the casting mold based on the deformation data obtained in step S100. Specifically, for the forming area of the push-down bracket, a reverse thickening machining allowance is reserved to match the inward offset of the cooling shrinkage of the push-down bracket, thereby offsetting the inward offset of the cooling shrinkage of the push-down bracket. For the forming area of the main reducing and reinforcing ring, a compensation allowance is added to match the cooling collapse deformation of the main reducing and reinforcing ring, thereby compensating for the cooling collapse deformation of the main reducing and reinforcing ring.
[0024] According to some specific embodiments of this application, if the inward offset of the cooling contraction of the push-down bracket is x, then the reverse thickening machining allowance reserved in the forming area of the push-down bracket is x~(x+0.5mm). For example, the reverse thickening machining allowance reserved in the forming area of the push-down bracket can be x, x+0.1mm, x+0.2mm, x+0.3mm, x+0.4mm, x+0.5mm, or any range between the two. By limiting the reverse thickening machining allowance reserved in the forming area of the push-down bracket to the above range, it can be further ensured that the inward offset of the cooling contraction of the push-down bracket is offset.
[0025] According to some specific embodiments of this application, the cooling collapse deformation of the main reducing and reinforcing ring is y, and the compensation allowance added to the forming area of the main reducing and reinforcing ring is y~(y+1mm). For example, the compensation allowance added to the forming area of the main reducing and reinforcing ring can be y, y+0.1mm, y+0.3mm, y+0.5mm, y+0.8mm, y+1mm, or any range between the two. By limiting the compensation allowance added to the forming area of the main reducing and reinforcing ring to the above range, the cooling collapse deformation of the main reducing and reinforcing ring can be further compensated.
[0026] As some specific embodiments, the reverse thickening machining allowance reserved in the forming area of the push-down bracket is 1mm to 5mm, for example, it can be 1mm, 2mm, 3mm, 4mm, 5mm or any range between the two. By limiting the reverse thickening machining allowance reserved in the forming area of the push-down bracket to the above range, it can be further ensured that the inward offset of the cooling shrinkage of the push-down bracket is offset.
[0027] As in some specific embodiments, the forming area of the main reducing and reinforcing ring is provided with a compensation allowance of 1mm to 7mm, for example, it can be 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm or any range between the two. By limiting the compensation allowance of the forming area of the main reducing and reinforcing ring to the above range, the amount of cooling collapse deformation of the main reducing and reinforcing ring can be further ensured.
[0028] According to some specific embodiments of this application, in step S200, the method of reserving the reverse thickening machining allowance for the inward offset of the cooling shrinkage of the push-down bracket is as follows: the forming contour of the push-down bracket is offset to the outside of the bridge housing, and the offset size is matched with the inward offset of the cooling shrinkage of the push-down bracket.
[0029] According to some specific embodiments of this application, in step S200, the method of adding compensation allowance to match the cooling collapse deformation of the main reducing reinforcement ring is: raising the forming reference surface of the main reducing reinforcement ring, and the raising value is matched with the cooling collapse deformation of the main reducing reinforcement ring.
[0030] S300: Using a casting mold optimized with allowance compensation, ductile iron is integrally cast to obtain an integrated cast bridge shell blank. In this step, the deformation of the bridge shell blank, which is cast after mold optimization, can be precisely controlled within the machining tolerance range. After subsequent S400 machining, the black skin defect can be completely eliminated, ensuring that the wall thickness of the main reducing and reinforcing ring is uniform and meets the standard, effectively improving the structural stability and service life of the casting. It has strong process adaptability and can be mass-produced.
[0031] S400: The integral cast bridge housing blank is machined to remove the black skin on the assembly surface of the blank, thus obtaining the integral cast bridge housing.
[0032] In this step, the bridge housing blank is machined to completely remove the black skin from the assembly surface, ensuring the fitting accuracy of the lower support assembly surface, and at the same time ensuring that the wall thickness of the main reducing and reinforcing ring is uniform and meets the design standard.
[0033] In a second aspect of this application, a casting mold for an integrally cast bridge housing is provided. According to an embodiment of this application, refer to the attached... Figure 2 The aforementioned casting mold is used to implement the anti-deformation method for the integrated casting bridge housing production of the first aspect; the casting mold includes a first forming cavity corresponding to the lower push bracket 2 and a second forming cavity corresponding to the main reducing reinforcing ring 1; the first forming cavity is provided with a reverse thickening compensation structure, and the second forming cavity is provided with a collapse compensation structure. The reverse thickening compensation structure is used to offset the inward shrinkage and offset of the lower push bracket when the casting is cooled, and the collapse compensation structure is used to compensate for the collapse deformation of the main reducing reinforcing ring when the casting is cooled.
[0034] As some specific embodiments of this application, see the appendix. Figure 2 The aforementioned push-down bracket 2 is located on the outermost side of the casting mold, and the aforementioned main reducing reinforcing ring 1 is located in the middle section of the casting mold.
[0035] This application incorporates a reverse thickening compensation structure in the first forming cavity of the casting mold corresponding to the lower support, to counteract the inward offset of the lower support due to cooling contraction. Simultaneously, a collapse compensation structure is incorporated in the second forming cavity of the casting mold corresponding to the main reducing and reinforcing ring, to compensate for the cooling collapse deformation of the main reducing and reinforcing ring. The deformation of the bridge housing blank, after mold optimization, can be precisely controlled within the machining tolerance range. Machining completely eliminates black skin defects, ensuring uniform and compliant wall thickness of the main reducing and reinforcing ring, effectively improving the structural stability and service life of the casting. It also exhibits strong process adaptability and is suitable for mass production. Therefore, the casting mold of this application effectively solves the problem of easy deformation in integrated bridge housings, ensuring qualified wall thickness in key parts of the integrated cast bridge housing, improving the quality of the bridge housing product, and guaranteeing its service life.
[0036] According to some specific embodiments of this application, the compensation thickness of the above-mentioned reverse thickening compensation structure is x~(x+0.5mm), where x is the inward offset of the cooling shrinkage of the push-down bracket in mass-produced castings. By limiting the compensation thickness of the reverse thickening compensation structure within the above range, it can be further ensured that the inward offset of the cooling shrinkage of the push-down bracket is offset.
[0037] According to some specific embodiments of this application, the compensation height of the above-mentioned collapse compensation structure is y~(y+1mm), where y is the amount of cooling collapse deformation of the main reducing reinforcement ring in the mass-produced casting. By limiting the compensation height of the collapse compensation structure within the above range, the amount of cooling collapse deformation of the main reducing reinforcement ring can be further ensured.
[0038] As some specific embodiments, the thickness of the above-mentioned reverse thickening compensation structure is 1mm to 5mm, for example, it can be 1mm, 2mm, 3mm, 4mm, 5mm or any range between the two. By limiting the thickness of the reverse thickening compensation structure to the above range, it can be further ensured that the inward offset of the cooling contraction of the push-down bracket is offset.
[0039] As some specific embodiments, the compensation height of the above-mentioned collapse compensation structure is 1mm to 7mm, for example, it can be 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm or any range between the two. By limiting the compensation height of the collapse compensation structure to the above range, the amount of cooling collapse deformation of the main reducing and reinforcing ring can be further ensured.
[0040] According to some specific embodiments of this application, the above-mentioned reverse thickening compensation structure is a thickened cavity wall formed by the overall outward expansion of the first molding cavity contour toward the outside of the bridge housing.
[0041] According to some specific embodiments of this application, the above-mentioned collapse compensation structure is a compensation platform formed by raising the reference surface of the second molding cavity upward as a whole.
[0042] In a third aspect of this application, an integrated cast bridge housing is proposed. According to embodiments of this application, the aforementioned integrated cast bridge housing is prepared using the anti-deformation method of the first aspect or using the casting mold of the second aspect. Therefore, the integrated cast bridge housing of this application can completely eliminate black skin defects, ensure qualified wall thickness in key parts of the integrated cast bridge housing, improve the quality of the bridge housing product, and guarantee the service life of the bridge housing product.
[0043] The embodiments of this application are described in detail below. It should be noted that the embodiments described below are exemplary and are only used to explain this application, and should not be construed as limiting this application. In addition, unless otherwise specified, all reagents used in the following embodiments are commercially available or can be synthesized according to the methods described herein or known methods. For reaction conditions not listed, they are also readily available to those skilled in the art.
[0044] Example 1 This embodiment provides a method for preventing deformation in the production of integrated cast bridge housings, including: Step S1: Collect deformation data: Collect measured deformation data of multiple batches of integrated cast bridge shell mass production castings, and separately count the inward offset of the cooling shrinkage of the push-down bracket and the cooling collapse deformation of the main reducing reinforcement ring, as shown in Table 1.
[0045] Table 1
[0046] Step S2, Mold Pre-compensation Optimization: Based on the deformation data obtained in Step S1, reverse allowance compensation design is performed on the corresponding forming area of the casting mold; specifically, for the forming area of the mold's push-down bracket, a reverse thickening machining allowance is reserved to match the inward offset deformation of the bracket, used to offset the inward shrinkage and offset of the bracket during casting cooling; for the forming area of the mold's main reducing reinforcing ring, a uniform correction allowance is added to match the collapse deformation, compensating for the collapse defects generated during the cooling process. As shown in Table 2.
[0047] Table 2
[0048] Step S3, Casting and Molding: Using a casting mold optimized with allowance compensation, ductile iron is integrally cast to obtain an integrated cast bridge shell blank. The deformation at key positions of the blank is controlled within the machining tolerance range, as shown in Table 3.
[0049] Table 3
[0050] Step S4, Blank Machining: The bridge housing blank is machined to completely remove the black skin from the assembly surface, ensuring the fitting accuracy of the lower support assembly surface, and at the same time ensuring that the wall thickness of the main reducing and reinforcing ring is uniform and meets the design standard.
[0051] By comparing Tables 1 and 3, it can be seen that the deformation of the bridge shell blank after mold optimization can be precisely controlled within the processing tolerance range. After machining, the black skin defect can be completely eliminated, ensuring that the wall thickness of the main reducing and reinforcing ring is uniform and meets the standard.
[0052] Example 2 This embodiment provides a casting mold for an integrated cast bridge housing, used to implement the anti-deformation method for the integrated cast bridge housing production of Embodiment 1. The casting mold includes a first forming cavity corresponding to the lower support and a second forming cavity corresponding to the main reducing and reinforcing ring. The first forming cavity is provided with a reverse thickening compensation structure (the reverse thickening compensation structure is a thickened cavity wall formed by the overall outward expansion of the contour of the first forming cavity towards the outside of the bridge housing), and the second forming cavity is provided with a collapse compensation structure (the collapse compensation structure is a compensation platform formed by the overall upward raising of the reference surface of the second forming cavity). The reverse thickening compensation structure is used to offset the inward contraction and offset of the lower support during casting cooling, and the collapse compensation structure is used to compensate for the collapse deformation of the main reducing and reinforcing ring during casting cooling. The compensation thickness of the above-mentioned reverse thickening compensation structure and the compensation height of the collapse compensation structure are shown in Table 4.
[0053] Table 4
[0054] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.
[0055] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.
Claims
1. A method for preventing deformation in the production of an integrated cast bridge shell, characterized in that, include: (1) Collect measured deformation data of mass-produced integrated cast bridge shells, and respectively count the inward offset of cooling shrinkage of the push-down bracket and the cooling collapse deformation of the main reducing reinforcement ring. (2) Based on the deformation data obtained in step (1), reverse allowance compensation design is made for the corresponding forming area of the casting mold. For the forming area of the push support, a reverse thickening machining allowance is reserved to match the cooling shrinkage inward offset of the push support. For the forming area of the main reducing and reinforcing ring, a compensation allowance is added to match the cooling collapse deformation of the main reducing and reinforcing ring. (3) Using a casting mold optimized with allowance compensation, ductile iron is integrally cast to obtain an integrated cast bridge shell blank; (4) The integral cast bridge shell blank is cut and processed to remove the black skin of the blank on the assembly surface, and an integral cast bridge shell is obtained.
2. The anti-deformation method according to claim 1, characterized in that, The cooling shrinkage of the push-down bracket is offset inward by x, and the forming area of the push-down bracket has a reserved reverse thickening machining allowance of x~(x+0.5mm). And / or, the cooling collapse deformation of the main reducing and reinforcing ring is y, and the forming area of the main reducing and reinforcing ring is provided with a compensation allowance of y~(y+1mm).
3. The anti-deformation method according to claim 2, characterized in that, The forming area of the push-down bracket has a reverse thickening machining allowance of 1mm to 5mm; And / or, the forming area of the main reducing and reinforcing ring is provided with a compensation allowance of 1mm~7mm.
4. The anti-deformation method according to any one of claims 1 to 3, characterized in that, In step (2), the method of reserving the reverse thickening machining allowance for matching the cooling shrinkage inward offset of the push bracket is: offset the forming contour of the push bracket to the outside of the bridge shell, and the offset size matches the cooling shrinkage inward offset of the push bracket.
5. The anti-deformation method according to any one of claims 1 to 3, characterized in that, In step (2), the method of adding compensation allowance to match the cooling collapse deformation of the main reducing and reinforcing ring is to raise the forming reference surface of the main reducing and reinforcing ring, and the raising value matches the cooling collapse deformation of the main reducing and reinforcing ring.
6. A casting mold for an integrated cast bridge shell, characterized in that, A method for preventing deformation in the production of an integrated cast bridge housing as described in any one of claims 1 to 5; The casting mold includes a first forming cavity corresponding to the lower push bracket and a second forming cavity corresponding to the main reducing and reinforcing ring; the first forming cavity is provided with a reverse thickening compensation structure, and the second forming cavity is provided with a collapse compensation structure. The reverse thickening compensation structure is used to offset the inward shrinkage and offset of the lower push bracket when the casting is cooled, and the collapse compensation structure is used to compensate for the collapse deformation of the main reducing and reinforcing ring when the casting is cooled.
7. The casting mold according to claim 6, characterized in that, The compensation thickness of the reverse thickening compensation structure is x~(x+0.5mm), where x is the inward offset of the cooling shrinkage of the mass-produced casting's push-down bracket. And / or, the compensation height of the collapse compensation structure is y~(y+1mm), where y is the amount of cooling collapse deformation of the main reducing reinforcing ring of the mass-produced casting.
8. The casting mold according to claim 7, characterized in that, The thickness of the reverse thickening compensation structure is 1mm to 5mm. And / or, the compensation height of the collapse compensation structure is 1mm to 7mm.
9. The casting mold according to any one of claims 6 to 8, characterized in that, The reverse thickening compensation structure is a thickened cavity wall formed by the overall outward expansion of the first molding cavity contour toward the outside of the bridge shell; And / or, the collapse compensation structure is a compensation platform formed by raising the reference surface of the second molding cavity upward as a whole.
10. An integrated cast bridge shell, characterized in that, It is prepared by the anti-deformation method according to any one of claims 1 to 5 or by the casting mold according to any one of claims 6 to 9.