Improved structure of machine body casting gating system

Abstract

The utility model discloses an improved structure of an engine body casting pouring system, and belongs to the technical field of automobile engine body casting. The structure comprises a machine body casting, a plurality of chilling blocks are arranged on the two sides of the top of the machine body casting, a main sand core and a long sand core are arranged in the machine body casting, the main sand core comprises a first sand core, a second sand core and a third sand core which are integrally formed, and a cross gate is arranged at the bottom of the machine body casting; and a plurality of bottom sprues and a plurality of bottom middle sprues are arranged at the top of the cross gate. By arranging the bottom pouring gate, the bottom middle pouring gate and the side pouring gates, molten metal can enter the multiple inner pouring gates when a casting is poured, thin-wall parts of a water channel and an air channel can be rapidly filled with the molten metal after mold filling, the thin-wall parts can be rapidly filled, and therefore the technical reasons such as cold shut caused by insufficient molten metal pouring of the thin-wall parts are avoided; the arrangement of the middle gate at the bottom solves the problem that molten metal cannot be filled in time due to the flow and distance of the side gate.

Description

Technical Field

[0001] The utility model belongs to the technical field of casting of automobile engine blocks. Specifically, it relates to a structure for improving the gating system of block casting. Background Art

[0002] The casting process of automobile engine blocks is a very important link in the field of automobile production, and it plays a crucial role in the performance and quality of automobile engines. For a 10-cylinder heavy-duty block, the material of the body is ZL114A, and the weight of the body is as high as 170 KG. It has a complex shape and structure, with many internal cooling channels and air ducts. During the casting process, the design of the gating process is very important. Often, when parameters such as material, pouring temperature, and pouring speed remain unchanged, changes in the gating system, risers, chillers, and vent holes in the gating process directly affect the quality and yield of the castings. Currently, the qualified rate of such parts is only 50%. The casting of such aluminum castings is very difficult, and there are many defects in the castings.

[0003] In the existing gating process, due to the unreasonable settings of the gating, chillers, risers, and vent holes in the gating system, such as too small or too small in diameter of the bottom gate, and a small number of side gates, many defects are generated in such castings, such as shrinkage porosity, trapped air, unstable metal liquid level during filling, and metal liquid backflow. Shrinkage porosity mainly concentrates at several places where the wall thickness difference between adjacent cylinders is large, and it is extremely easy to have trapped air at the air duct of the block, resulting in air holes on the product; during the entire casting process of the block, due to the unreasonable design of the gating process, the survival rate is low and there are many internal defects in the castings; the number and position of the bottom gates are incorrect, resulting in an unstable metal liquid level during filling. The bottom middle gate is set too small and incorrect, resulting in metal liquid backflow and air entrainment during filling. When making traditional sand cores, as many splits as possible should be made to facilitate coating brushing, but the more splits are made, the worse the dimensional accuracy. For such a large and complex block, the dimensional error has a very large impact on the thin-walled parts, resulting in uneven wall thickness at the thin-walled parts, and it is easy to leak oil and water when the parts are used. Summary of the Utility Model

[0004] In view of the deficiencies of the prior art, the purpose of the present utility model is to provide a structure for improving the gating system of block casting to solve the technical problems raised in the background art section.

[0005] To achieve the above object, the present utility model provides the following technical solutions: An improved structure of a body casting gating system, including a body casting, on both sides of the top of the body casting, a number of chill blocks are provided, inside the body casting, a main core and a long core are provided, the main core includes a core one, a core two and a core three integrally formed, at the bottom of the body casting, a cross-riser is provided, on the top of the cross-riser, a number of bottom gates and a number of bottom intermediate gates are provided, both the bottom gates and the bottom intermediate gates are communicated with the inside of the body casting, the long core penetrates through the body casting and both ends of the long core respectively extend to both sides of the body casting, inside the long core, a core frame is provided, and a number of vent holes are provided on the core frame.

[0006] As a preferred technical solution of the present utility model, on both sides of the top of the body casting, five cylinder holes are provided, the number of chill blocks is twelve and every six are in a group, and each group of chill blocks corresponds to five cylinder holes.

[0007] As a preferred technical solution, between adjacent two chill blocks, there is no contact and an arc opening avoiding the cylinder hole is provided between adjacent two chill blocks, and the thickness of the chill block is 20 mm.

[0008] As a preferred technical solution of the present utility model, the cross-riser is in a grid shape, a number of the bottom intermediate gates are arranged in a row at the middle position on the top of the cross-riser, and the height of the bottom intermediate gate is greater than the height of the bottom gate.

[0009] As a preferred technical solution of the present utility model, it further includes side gates, the number of side gates is eleven, among which five side gates are provided on one side of the body casting, and the other six side gates are provided on the other side of the body casting.

[0010] As a preferred technical solution of the present utility model, both sides of the cross-riser protrude to both sides of the body casting and two vertical risers are provided at the top of both sides of the cross-riser, one end of the side gate far from the body casting is connected to one side of the vertical riser, and a liquid inlet is provided at the middle position of the bottom of the cross-riser.

[0011] As a preferred technical solution of the present utility model, the diameter of the bottom intermediate gate is greater than 90 mm.

[0012] As a preferred technical solution of the present utility model, the long core is formed by 3D printing, the inner hole diameter of the long core is 21 mm, the diameter of the long core is 38 mm, the length of the long core is greater than the length of the body casting, and the core frame is a hollow tube.

[0013] As a preferred technical solution of the present utility model, a plurality of risers are provided at the top of the body casting, and at least one vent hole is provided at the top of the vertical sprue and the body casting.

[0014] Compared with the prior art, the improved structure of the body casting gating system provided by the present utility model has the following beneficial effects:

[0015] (1) By providing a bottom gate, a bottom middle gate, and a side gate, the casting has multiple ingates for molten metal to enter during pouring. After the molten metal fills the mold, it will quickly fill the thin-walled parts of the water channels and air channels, enabling the thin-walled parts to be quickly filled and avoiding technical problems such as insufficient pouring of molten metal in the thin-walled parts and cold shuts; the setting of the bottom middle gate solves the problem that the molten metal cannot be filled in time due to the flow rate and distance of the side gate.

[0016] (2) A core bone with vent holes is added at the characteristic holes on the body, increasing the strength of the long sand core, enabling the gases generated during pouring to be discharged in time, and the hollow core bone taking away heat.

[0017] (3) Twelve chill blocks are added on the two side surfaces of the body. Without the chill blocks, the molten metal at this part solidifies last during pouring, causing the molten metal at this part to compensate for other parts, resulting in serious shrinkage porosity defects at this part. After adding twelve chill blocks, the flowing molten metal is sufficiently chilled, causing the molten metal at this part to quickly crust, solidify, and shrink, eliminating the shrinkage porosity defects at this part.

[0018] (4) The core sand one, core sand two, and core sand three are made by 3D printing without splitting, ensuring the overall shape and size of the main sand core and also ensuring the accuracy during mold assembly of the main sand core, enabling the casting size of the body to reach CT9 level, the wall thickness at the thin-walled parts to be uniform, and the quality and stability of the product to be greatly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 Schematic diagram of the improved structure of the body casting gating system of the present utility model;

[0020] Figure 2 Side view of the body casting structure;

[0021] Figure 3 Schematic diagram of the chill block structure;

[0022] Figure 4 Cross-sectional view of the long sand core structure;

[0023] Figure 5 Bottom view of the bottom gate and bottom middle gate structure;

[0024] Figure 6 Schematic diagram of the core tube structure;

[0025] Figure 7 Schematic diagram of the main sand core structure.

[0026] In the figure: 1, body casting; 11, chill; 111, arc mouth; 12, main sand core; 121, sand core one; 122, sand core two; 123, sand core three; 13, long sand core; 131, core bone; 132, exhaust hole; 14, horizontal runner; 141, liquid inlet; 15, bottom gate; 16, bottom middle gate; 17, side gate; 18, vertical runner; 181, exhaust port; 19, riser. DETAILED DESCRIPTION

[0027] In order to be able to understand the features and technical contents of the embodiments of the present disclosure in more detail, the implementation of the embodiments of the present disclosure is described in detail below in conjunction with the accompanying drawings. The attached drawings are for reference only and are not used to limit the embodiments of the present disclosure. In the following technical description, for the convenience of explanation, a full understanding of the disclosed embodiments is provided through multiple details. However, one or more embodiments can still be implemented without these details. In other cases, to simplify the drawings, well-known structures and devices can be simplified for display.

[0028] The terms "first", "second", etc. in the specification and claims of the embodiments of the present disclosure and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the terms used in this way can be interchanged where appropriate, so that the embodiments of the embodiments of the present disclosure described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions.

[0029] In the embodiments of the present disclosure, the terms "upper", "lower", "inside", "middle", "outside", "front", "back" and the like indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. These terms are mainly intended to better describe the embodiments of the present disclosure and their embodiments, and are not intended to limit the indicated devices, elements or components to have a specific direction, or to be constructed and operated in a specific direction. Moreover, in addition to being used to indicate directions or positional relationships, some of the above terms may also be used to indicate other meanings. For example, the term "upper" may also be used to indicate a certain dependency or connection relationship in certain circumstances. For those of ordinary skill in the art, the specific meanings of these terms in the embodiments of the present disclosure can be understood according to specific circumstances.

[0030] In addition, the terms "arranged", "connected", and "fixed" should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral structure; it can be a mechanical connection or an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, or there can be internal communication between two devices, components, or parts. For those of ordinary skill in the art, the specific meanings of the above terms in the embodiments of the present disclosure can be understood according to specific circumstances.

[0031] Unless otherwise specified, the term "plurality" means two or more.

[0032] It should be noted that, without conflict, the embodiments in the embodiments of the present disclosure and the features in the embodiments can be combined with each other.

[0033] Please refer to Figures 1-7 , a structure for improving the casting gating system of a body, including a body casting 1. On both sides of the top of the body casting 1, a number of chill blocks 11 are arranged. Inside the body casting 1, a main sand core 12 and a long sand core 13 are arranged. The main sand core 12 includes a sand core one 121, a sand core two 122, and a sand core three 123 that are integrally formed. At the bottom of the body casting 1, a cross runner 14 is arranged. On the top of the cross runner 14, a number of bottom gates 15 and a number of bottom intermediate gates 16 are arranged. Both the bottom gates 15 and the bottom intermediate gates 16 are in communication with the inside of the body casting 1. The long sand core 13 passes through the body casting 1 and both ends of the long sand core 13 extend to both sides of the body casting 1. Inside the long sand core 13, a core frame 131 is arranged. A number of vent holes 132 are arranged on the core frame 131. Through the arrangement of the liquid inlet 141, the cross runner 14, the bottom gates 15, the vertical runner 18, the side gates 17, the bottom intermediate gates 16, the chill blocks 11, the risers 19, the vent holes 132, the long sand core 13, the core frame 131, and the main sand core 12, the defects of shrinkage porosity, slag inclusion, and gas holes can be completely eliminated, and the qualified rate of this product can be increased to 90%, thereby improving the production efficiency and the finished product rate of this casting.

[0034] As a specific technical solution of this embodiment, the sand core one 121, the sand core two 122, and the sand core three 123 are made by means of 3D printing and molding without being split, which ensures the overall body size of the main sand core 12 and also ensures the accuracy during mold assembly of the main sand core 12, enabling the casting size of the body to reach CT9 level and obtaining a thin wall with uniform wall thickness, and the quality and stability of the product can be greatly improved.

[0035] As a specific technical solution of this embodiment, five cylinder holes are provided on both sides of the top of the body casting 1. The number of chill blocks 11 is twelve, and every six form a group. Each group of chill blocks 11 corresponds to five cylinder holes. Adjacent two chill blocks 11 do not contact each other, and an arc notch 111 avoiding the cylinder holes is provided between adjacent two chill blocks 11. The thickness of the chill block 11 is 20 mm. Since the two planes at the top of the engine body have extremely high requirements and are thicker than other parts of the body wall, shrinkage porosity is most likely to occur during casting, and feeding or chilling is required. Through experimental research, the chilling effect is better here. Therefore, two large chill blocks 11 are cut into twelve small pieces, and adjacent two chill blocks 11 do not contact each other, aiming to prevent the chill blocks 11 from undergoing large warping deformation during pouring, resulting in dimensional defects of the casting. If two large chill blocks 11 are designed, the deformation amount at both ends of the chill blocks 11 after heating is about 10 mm, and there will also be a dimensional error of about 10 mm on the surface of the casting. During the entire pouring process of the twelve chill blocks 11, the flowing molten metal is fully chilled, enabling the molten metal here to quickly crust, solidify, and shrink. The molten metal flowing through the side gate 17 will quickly supplement this place, thereby enabling the body casting 1 here to obtain better quality. The chill blocks 11 here are divided into twelve pieces, which can ensure that the chill blocks 11 generate a smaller deformation amount when heated, thereby ensuring the dimensional accuracy of the body casting 1 here.

[0036] As a specific technical solution of this embodiment, the runner 14 is in a grid shape. A number of the bottom middle gates 16 are arranged in a row at the middle position of the top of the runner 14. The height of the bottom middle gate 16 is greater than the height of the bottom gate 15. The diameter of the bottom middle gate 16 is greater than 90 mm. The cross-section of the runner 14 is rectangular, which facilitates the installation of the bottom gate 15 and the bottom middle gate 16. The bottom gate 15 is designed according to the bottom structure of the body casting 1 and is placed at a thicker part. The number of the bottom gates 15 is increased and the design size of the runner 14 is larger, making it easier to feed the lower part of the casting. The gas in the runner 14 during pouring will also be discharged through the riser 19 provided above; the design of the bottom middle gate 16 is to ensure smooth filling and effectively feed this place during low-pressure pouring.

[0037] As a specific technical solution of this embodiment, the present utility model further includes eleven side gates 17. Five of the side gates 17 are arranged on one side of the body casting 1, and the other six side gates 17 are arranged on the other side of the body casting 1. The side gates 17 are trapezoidal. The arrangement of the eleven side gates 17 not only supplements the molten metal but also has a large feeding effect on the part in contact with the body casting 1 when the molten metal solidifies.

[0038] As a specific technical solution of this embodiment, both sides of the cross-riser 14 protrude to both sides of the body casting 1, and two vertical risers 18 are provided at the top of both sides of the cross-riser 14. One end of the side gate 17 away from the body casting 1 is connected to one side of the vertical riser 18. An inlet 141 is provided at the middle position of the bottom of the cross-riser 14. Molten metal enters the inside of the cross-riser 14 through the inlet 141. Since the middle bottom gate 16 is higher than the bottom gate 15, the molten metal first fills the inner bottom of the body casting 1 through the bottom gate 15, and then the molten metal fills the mold cavity smoothly and rises to fill the inside of the body casting 1 through the middle bottom gate 16. The cross-sectional area of the middle bottom gate 16 is larger than that of the bottom gate 15, which can enable the part of the body casting 1 connected to the middle bottom gate 16 to be quickly filled, and can also effectively compensate for the part connected to the body casting 1 during the solidification stage of the molten metal.

[0039] As a specific technical solution of this embodiment, the long sand core 13 is formed by 3D printing. The inner hole diameter of the long sand core 13 is 21 mm, the diameter of the long sand core 13 is 38 mm, and the length of the long sand core 13 is greater than the length of the body casting 1. The core frame 131 is a hollow tube. When the length of the body casting 1 is 1 m, the length of the long sand core 13 is up to 1.2 m. For the long sand core 13 with a diameter of only 38 mm, the strength after suspension is surely insufficient. The long sand core 13 corresponds to an important feature hole on the engine body, and the feature hole must be cast. It is necessary to consider both the strength of the long sand core 13 and how to exhaust the gas generated by the long sand core 13. The long sand core 13 is made by 3D printing, and a 12-mm inner hole is left in the middle for passing the core frame 131. The multiple exhaust holes 132 on the core frame 131 are arranged staggeredly, and the core frame 131 is a hollow tube. When the air in the middle circulates, it also takes away part of the heat, making the temperature drop slightly faster here. At this time, the core frame 131 also acts as part of the chill 11, enabling the thin airway wall here to achieve sequential solidification and obtaining better results, and solving the problem that air holes are likely to occur in this part of the casting.

[0040] As a specific technical solution of this embodiment, several risers 19 are provided at the top of the body casting 1, and at least one exhaust port 181 is provided at the top of both the vertical riser 18 and the body casting 1. The function of the riser 19 during the entire filling process is to exhaust gas, enabling the gas in the mold cavity and the gas generated by the main sand core 12 being heated to be discharged smoothly during the filling process. The riser 19 can effectively compensate for the bosses above the body casting 1 when the body casting 1 solidifies. The exhaust port 181 on the vertical riser 18 facilitates the discharge of the gas in the runner during filling. Refer to Figure 1, the risers 19 are all arranged at the thick-wall parts and flat surfaces. In this way, the upper risers 19 can remove slag, exhaust gas, and perform feeding all at once, improving the quality of the upper castings. The horizontal runners 14 on both sides also have a significant feeding effect on both ends.

[0041] During use, the molten metal first enters from the inlet 141 and fills the horizontal runner 14 during filling, and then will respectively fill the bottom gate 15, the bottom middle gate 16, the vertical runner 18, and the side gates 17. When the molten metal fills the bottom gate 15, the bottom middle gate 16, the vertical runner 18, and the eleven side gates 17, the molten metal first fills the bottom of the body casting 1 from the bottom gate 15. Secondly, the molten metal fills the body casting 1 smoothly and rises, and fills the body casting 1 from the bottom middle gate 16. The cross-sectional area of the bottom middle gate 16 is larger than that of the bottom gate 15, enabling the part of the body casting 1 connected to the bottom middle gate 16 to be quickly filled, and also effectively feeding the part connected to the body casting 1 during the solidification stage of the molten metal; Secondly, the molten metal rises smoothly through the vertical runner 18 to the position of the side gate 17, and the molten metal fills the body casting 1 from the side gate 17, enabling the molten metal to quickly fill and supplement the molten metal; The setting of the eleven side gates 17 not only supplements the molten metal, but also has a significant feeding effect on the part connected to the body casting 1 when the molten metal solidifies. Finally, the molten metal is filled until the top surface of the riser 19, and the filling is completed. Then, pressure is applied for pressure holding for 20 minutes, and then the pressure is released. After the body casting 1 cools, the mold can be opened to remove the parts.

[0042] During the entire pouring process, the twelve chills 11 sufficiently chill the flowing molten metal, causing the molten metal here to quickly crust, solidify, and shrink. The molten metal flowing through the side gate 17 will quickly supplement this place, so that the body casting 1 here obtains better quality. The chills 11 here are divided into twelve pieces, which can ensure that the chills 11 produce smaller deformation amounts when heated, thus ensuring the dimensional accuracy of the body casting 1 here.

[0043] The function of the riser 19 during the entire filling process is to exhaust gas, enabling the gas in the cavity and the gas generated by the main core 12 being heated during the filling process to be discharged smoothly. The riser 19 can effectively feed the lugs above the body casting 1 when the body casting 1 solidifies.

[0044] In summary, the improved structure of the body casting gating system enables the casting to have multiple inlets for molten metal during pouring through the setting of the bottom gate 15, the bottom middle gate 16, and the side gates 17. After the molten metal fills, it will quickly fill the thin-wall parts of the water channels and air channels, enabling the thin-wall parts to be quickly filled, thus avoiding technical reasons such as insufficient pouring of the molten metal in the thin-wall parts and cold shuts. The setting of the bottom middle gate 16 solves the problem that the molten metal cannot be filled in time due to the flow rate and distance of the side gate 17.

[0045] The improved structure of the casting gating system of the body adds a core bone 131 with a vent hole 132 at the characteristic hole on the body, increasing the strength of the long core 13. The gas generated during pouring can also be discharged in time, and the hollow core bone 131 takes away heat.

[0046] The improved structure of the casting gating system of the body adds twelve chill blocks 11 on both side surfaces of the body. When the chill blocks 11 are not added, the molten metal at this position solidifies last during pouring, resulting in the molten metal at this position compensating for other parts and causing serious shrinkage porosity defects here. After adding twelve chill blocks 11, the flowing molten metal is sufficiently chilled, causing the molten metal here to quickly crust, solidify, and shrink, eliminating the shrinkage porosity defect here.

[0047] The improved structure of the casting gating system of the body makes the core one 121, core two 122, and core three 123 by 3D printing without splitting, ensuring the overall body dimensions of the main core 12 and the accuracy during mold assembly of the main core 12, enabling the casting dimensions of the body to reach CT9 level, the wall thickness at the thin-walled part to be uniform, and the quality and stability of the product to be greatly improved.

[0048] The above description and the drawings fully illustrate the embodiments of the present disclosure so that those skilled in the art can practice them. Other embodiments may include structural and other changes. The embodiments represent only possible variations. Unless explicitly required, individual components and functions are optional, and the order of operations may vary. Parts and features of some embodiments may be included in or substituted for parts and features of other embodiments. The embodiments of the present disclosure are not limited to the structures already described and shown in the drawings and can be modified and changed without departing from its scope. The scope of the present disclosure is limited only by the appended claims.

Claims

1. An improved structure of the casting gating system for the engine block, including the engine block casting (1), characterized in that: On both sides of the top of the body casting (1), a number of chill blocks (11) are provided. Inside the body casting (1), a main core (12) and a long core (13) are provided. The main core (12) includes a core one (121), a core two (122), and a core three (123) which are integrally formed. At the bottom of the body casting (1), a runner (14) is provided. At the top of the runner (14), a number of bottom gates (15) and a number of bottom intermediate gates (16) are provided. Both the bottom gates (15) and the bottom intermediate gates (16) are in communication with the inside of the body casting (1). The long core (13) passes through the body casting (1) and both ends of the long core (13) extend to both sides of the body casting (1). Inside the long core (13), a core frame (131) is provided, and a number of vent holes (132) are provided on the core frame.

2. The improved structure of the body casting gating system according to claim 1, characterized in that: On both sides of the top of the body casting (1), five cylinder holes are provided. The number of chill blocks (11) is twelve, and every six form a group. Each group of chill blocks (11) corresponds to five cylinder holes.

3. The improved structure of the casting gating system of the machine body according to claim 1, characterized in that: Adjacent two chill blocks (11) do not contact each other, and an arc opening (111) avoiding the cylinder holes is provided between adjacent two chill blocks (11). The thickness of the chill block (11) is 20 mm.

4. The improved structure of the casting gating system of the machine body according to claim 1, wherein: The runner (14) is in a grid shape. A number of the bottom intermediate gates (16) are arranged in a row at the middle position of the top of the runner (14). The height of the bottom intermediate gate (16) is greater than the height of the bottom gate (15).

5. The improved structure of the body casting gating system according to claim 1, characterized in that: It further includes side gates (17). The number of side gates (17) is eleven. Five of the side gates (17) are provided on one side of the body casting (1), and the other six side gates (17) are provided on the other side of the body casting (1).

6. The improved structure of the body casting gating system according to claim 5, characterized in that: Both sides of the runner (14) protrude to both sides of the body casting (1), and two risers (18) are provided at the top of both sides of the runner (14). One end of the side gate (17) far from the body casting (1) is connected to one side of the riser (18). At the middle position of the bottom of the runner (14), a liquid inlet (141) is provided.

7. The improved structure of the body casting gating system according to claim 1, wherein: The diameter of the bottom intermediate gate (16) is greater than 90 mm.

8. The improved structure of the casting gating system of the machine body according to claim 1, characterized in that: The long core (13) is formed by 3D printing. The inner hole diameter of the long core (13) is 21 mm. The diameter of the long core is 38 mm. The length of the long core (13) is greater than the length of the body casting (1). The core frame (131) is a hollow tube.

9. The improved structure of the body casting gating system according to claim 6, characterized in that: A number of risers (19) are provided at the top of the body casting (1). The riser (18) and the top of the body casting (1) are both provided with at least one vent port (181).

Images