Integrated casting model for cylinder body and cylinder cover
Through integrated casting model and 3D printing technology, the core forming process of the cylinder block and cylinder head is simplified, and the problems of complex operation and unstable quality in the existing technology are solved, and high-quality cylinder block and cylinder head castings are achieved efficiently.
Patent Information
- Application Number
- CN202422393830.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-30
- Publication Date
- 2025-07-22
- Estimated Expiration
- 2034-09-30
AI Technical Summary
In the existing cylinder block and cylinder head casting process, there are many sand cores and complex core forming processes, which leads to high operational difficulty and long production cycles, and is prone to inaccurate casting size and uneven wall thickness, which affects the quality of castings.
The integrated casting model is adopted to simplify the core forming process by supporting the combination of sand core and multiple sand cores, and connect the sand core with 3D printing technology to reduce operation difficulty. The open casting and sand core exhaust hole design are adopted to ensure smooth filling of metal liquid and gas discharge.
The core molding process is simplified, the difficulty of on-site operation and casting waste rate is reduced, the production efficiency and quality of castings are improved, and the accuracy and purity of castings are ensured.
Smart Images
Figure CN223129277U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of automobile engine castings, and more specifically, to an integrated casting model of a cylinder block and a cylinder head. Background Art
[0002] In the field of automobile engine manufacturing, the cylinder block and the cylinder head are the core components of the engine. Their quality and production efficiency directly affect the overall performance and manufacturing cost of the engine. Moreover, their product structures are very complex, the product size requirements are extremely high, and the wall thickness is within the range of 5-7 mm. Currently, the casting processes of the cylinder block and the cylinder head usually adopt separate independent casting, and generally use the traditional mold shaping and pouring process. The shaping materials used are furan resin sand, green sand, coated sand, etc. The core-making methods include manual core-making and core-making machine core-making. In the traditional process, multiple sand cores are required for the cylinder block and the cylinder head respectively to form their complex internal structures. For example, the cylinder head requires multiple sand cores such as a tray core, a water jacket core, an oil passage core, an intake passage core, an exhaust passage core, etc., and the cylinder block also requires multiple sand cores such as front and rear end cover sand cores, a crankcase sand core, a water jacket core, a cover core, etc. After assembling these sand cores into a whole, molten iron is poured and cooled to obtain the cylinder block blank and the cylinder head blank. In the core assembly process, the core assembly accuracy is generally controlled by using a special fixture combined with manual measurement. However, this method has the following disadvantages:
[0003] The number of sand cores is large, and these sand cores need to be accurately aligned during the core assembly process, resulting in an extremely complex core assembly and shaping process. The skill level requirements for on-site workers are high, which not only increases the labor intensity but also prolongs the production cycle. Moreover, the positioning error and cumulative error during the core assembly process are also likely to cause inaccurate casting dimensions and uneven wall thickness, thereby affecting the casting quality.
[0004] Therefore, how to provide an integrated casting model of a cylinder block and a cylinder head that can simplify the core assembly and shaping process, reduce the on-site operation difficulty and the casting rejection rate, and improve the production efficiency and quality of automobile engine castings is an urgent problem to be solved by those skilled in the art. Content of the Utility Model
[0005] In view of this, the utility model provides an integrated casting model of a cylinder block and a cylinder head, which can simplify the core assembly and shaping process, reduce the on-site operation difficulty and the casting rejection rate, and improve the production efficiency and quality of automobile engine castings.
[0006] In order to achieve the above purpose, the utility model adopts the following technical scheme:
[0007] An integrated casting model of a cylinder block and a cylinder head, comprising a mold body and a pouring assembly. The mold body includes a supporting sand core, a cylinder head shaping sand core, a first cylinder block shaping sand core, and a second cylinder block shaping sand core. An assembly groove is formed on the upper end surface of the supporting sand core, and the lower end of the pouring assembly is clamped in the assembly groove;
[0008] The cylinder head forming core, the first cylinder block forming core, and the second cylinder block forming core are tightly stacked on the support core in sequence from bottom to top, and the corresponding inner parts thereof are provided with a cylinder head forming cavity, a first cylinder block forming cavity, and a second cylinder block forming cavity that are interconnected. The cylinder head forming cavity is communicated with the pouring outlet of the pouring assembly. The lower inner wall surface of the cylinder head forming cavity correspondingly forms the lower end surface of the cylinder head, and the upper inner wall surface thereof correspondingly forms the top surface of the water jacket of the cylinder head; the upper inner wall surface of the first cylinder block forming cavity correspondingly forms the top flange surface of the cylinder block; the upper inner wall surface of the second cylinder block forming cavity correspondingly forms the cylinder port surface of the cylinder block.
[0009] Through the above technical solution, the present utility model provides an integrated casting model for a cylinder block and a cylinder head. It is supported by a support core, and the cylinder block and the cylinder head are integrally divided by the cylinder head forming core, the first cylinder block forming core, and the second cylinder block forming core. There is no need to separately cast the cylinder block and the cylinder head, and the combination of the cylinder block and the cylinder head can be directly cast, which simplifies the core assembly and molding process, reduces the requirements for the skill level of on-site workers and the operation difficulty, thereby reducing the casting rejection rate and improving the production efficiency and quality of automotive engine castings.
[0010] The setting of the above parting surface can better adapt to the shape of complex castings, facilitate manufacturing, can better adapt to the shape of complex castings, and improves the manufacturing precision and the quality of the castings.
[0011] The arrangement of the above parting surface and the cores forms a structure and a pouring direction in which the cylinder port of the cylinder block is upward and the cylinder head is downward. The setting of this structure helps the molten metal to fill the cavity more smoothly under the action of gravity. Since the structure of the cylinder block is relatively complex, the upward cylinder port can reduce the risk of gas entrainment and ensure the quality of the casting. At the same time, for the downward arrangement of the cylinder head, the pressure on the inner cavity core of the cylinder head during pouring is relatively small, reducing the possibility of core damage caused by excessive pressure.
[0012] Preferably, the support core includes a core body one formed by integral 3D printing and a bottom plate core. The core body one is arranged in a square hollow structure; the bottom plate core is formed at the center position of the upper end surface of the core body one and supports the lower wall surface of the cylinder head forming cavity; assembly grooves are formed on both sides of the core body one corresponding to the bottom plate core.
[0013] The assembly grooves can ensure that the molten metal can flow into the cavity smoothly and orderly, providing a good foundation for the forming of the casting; the bottom plate core provides a stable bottom support for the casting, ensuring the stability of the casting during the forming process.
[0014] The cylinder head forming core includes a core body two formed by integral 3D printing, an intake passage core, an exhaust passage core, and a water jacket core. The core body two is arranged in a square hollow structure and is clamped to the upper end of the core body one; the intake passage core and the exhaust passage core are respectively formed inside the core body two, and a first cavity is formed between the outer walls of the intake passage core and the exhaust passage core and the inner wall of the core body two. The lower inner wall surface of the first cavity correspondingly forms the lower end surface of the cylinder head. The bottom plate core is supported on the lower wall surface of the first cavity, and the pouring outlet of the pouring assembly is communicated with the first cavity;
[0015] The water jacket core is formed on the upper end surface of the core body two. There is a cavity one on the water jacket core. The lower end of the cylinder block forming core two extends into the cavity one, and a second cavity is formed between its outer wall and the inner wall of the cavity one. The second cavity is communicated with the first cavity, and the two form the cylinder head forming cavity. The upper inner wall surface of the second cavity correspondingly forms the water jacket top surface of the cylinder head.
[0016] The water jacket core is crucial for the cooling system of the casting, which can effectively control the temperature of the casting during the working process and improve the service life and performance of the casting; the intake passage core and the exhaust passage core provide channels for the intake and exhaust of the casting, ensuring the normal operation of the casting during the working process.
[0017] Furthermore, a core exhaust hole is horizontally opened at the lower end of the water jacket core.
[0018] The setting of the core exhaust hole greatly reduces the occurrence of the casting choking due to the exhaust of the resin burning inside the core during the casting process of the casting, improving the quality and yield of the casting.
[0019] The cylinder block forming core one includes a core body three formed by integral 3D printing, front and rear end cores, and a tappet core. The core body three is arranged in a hollow structure and is clamped to the upper end of the core body two. There is a cavity two opened in its center, and the upper end of the water jacket core extends into the cavity two;
[0020] The tappet core and the front and rear end cores are respectively formed on the inner wall of the cavity two corresponding to the upper end of the water jacket core, and there is a gap reserved between the two. The gap corresponds to and is communicated with the cavity one. The lower end of the cylinder block forming core two passes through the gap and is located in the cavity one. A third cavity is formed between the inner wall of the gap and the corresponding outer wall of the lower end of the cylinder block forming core two. A fourth cavity is formed between the outer walls of the tappet core and the front and rear end cores and the inner wall of the core body three. The third cavity and the fourth cavity form the cylinder block forming cavity one. The upper inner wall surfaces of the two are flush and correspondingly form the top flange surface of the cylinder head; the third cavity is communicated with the second cavity, and the fourth cavity is communicated with the first cavity.
[0021] The front and rear end cores provide a specific shape and structure for the front and rear ends of the casting, ensuring the accuracy and reliability of the casting during installation and use; the tappet core provides support and positioning for the tappet part in the casting, ensuring the normal movement of the tappet during the working process.
[0022] The second core for cylinder block forming includes a core body four formed integrally by 3D printing, a cylinder core, and a riser core. The core body four is arranged in a square hollow structure and is clamped to the upper end of the core body three. The cylinder core is formed at the lower end of the core body four and the through gap is located within the cavity one. The riser core is formed at the upper end of the core body four. A cylinder block forming cavity two is formed between the outer walls of the riser core and the cylinder core and the inner wall of the core body four, and the cylinder block forming cavity two is respectively communicated with the third cavity and the fourth cavity.
[0023] The riser core plays a role in feeding during the solidification of the casting, which can effectively prevent defects such as shrinkage cavities and porosity in the casting and improve the quality of the casting. The cylinder core provides the shape and structure for the cylinder part of the casting, ensuring the sealing performance and performance of the cylinder during operation.
[0024] This casting model is based on the completion of the three-dimensional modeling of the engine casting. Through 3D printing technology, while saving the mold making cost during casting production, the first-piece production verification of new products can be completed within two weeks, greatly promoting the R & D progress of new castings for automotive engines. At the same time, because 3D printing technology does not need to consider the problems of mold withdrawal and material removal, the cores of key parts of the cylinder block and cylinder head can be connected as a whole, thereby reducing the total number of cores, simplifying the core assembly and molding process, reducing the on-site operation difficulty, and reducing the casting rejection rate.
[0025] Preferably, the gating assembly includes a cross gate, a longitudinal gate, and an ingate. The cross gate is clamped in the assembly groove. One end of the longitudinal gate is communicated with the cross gate, and the other end thereof respectively penetrates upward through the core body two, the core body three, and the core body four and is located above the core body four. There are multiple ingates. One end of the ingate is fixed and communicated with the upper end surface of the cross gate, and the other end thereof is communicated with the first cavity.
[0026] The position of the gating assembly corresponding to the mold body forms a low-side injection open gating. This setting can enable the molten metal to enter the cavity smoothly, reduce turbulence and splashing, thereby reducing the generation probability of oxide inclusions. For extremely weak parts such as the water jacket core of the cylinder block and the inner cavity core of the cylinder head (the water jacket core of the cylinder block and the inner cavity core of the cylinder head are only 5 - 6 mm wide, extremely weak and prone to sand adhesion), smooth gating can reduce the impact on the core, reduce the risk of core deformation or damage, and reduce the risk of sand adhesion.
[0027] Furthermore, the gating assembly further includes a filter screen, and the filter screen is vertically installed on the inner wall of the longitudinal gate.
[0028] Furthermore, the pouring assembly further includes an oil bottle riser, which is arranged inside the riser core. This structure can provide additional molten metal during the solidification process of the casting, compensate for the shrinkage of the casting, and prevent defects such as shrinkage cavities and porosity. Placing it on top of the flange can utilize the gravitational force to make the molten metal in the riser more easily flow into the parts of the casting that need to be compensated for shrinkage. The oil bottle riser can also play the role of exhausting gas and collecting slag. During the pouring process, the gas and inclusions in the cavity can be discharged through the riser, improving the purity of the casting.
[0029] Preferably, it further includes a guiding and positioning assembly. The guiding and positioning assembly includes a plurality of ear handles and guiding rods. The plurality of ear handles are integrally formed on both sides of the first core body, the second core body, the third core body, and the fourth core body respectively, and the ear handles on the same side are arranged vertically corresponding to each other. Guide holes are provided on the ear handles, and the guide holes on the same side are arranged vertically corresponding to each other; the guiding rods vertically penetrate through the guide holes on the same side to position and assemble the cores.
[0030] Preferably, the circumferences of the upper end faces of the first core body, the second core body, and the third core body are all recessed downward to form frame-shaped recesses, and clamping frames adapted to the recesses are integrally formed at the positions corresponding to the recesses on the lower end faces of the second core body, the third core body, and the fourth core body.
[0031] The integrated casting model of a cylinder block and a cylinder head provided by the present invention has the following production steps:
[0032] ① Draw a cuboid block of 1500mm×800mm×800mm in 3D software, wrap the entire engine casting and the pouring assembly, and perform a subtraction operation to obtain a complete mold;
[0033] ② Perform further core splitting operations on the mold: Split the core from the lower end face position of the cylinder head to obtain a support core; split the core from the top surface position of the water jacket of the cylinder liner to obtain a cylinder head forming core; split the core from the top flange surface position of the cylinder block to obtain a first cylinder block forming core and a second cylinder block forming core;
[0034] ③ Assemble the cores: Place the support core on a relatively flat platform, which can be the ground or a steel pallet. Insert the guiding rod into the guiding hole of the support core, and place the cross runner of the pouring assembly in the assembly groove; Lift the cylinder head forming core through the ear handle of the cylinder head forming core, so that the guiding hole of the cylinder head forming core penetrates through the guiding rod to position and set the core of the cylinder head forming core, and clamp it through the recess on the upper end of the support core and the clamping frame on the lower end of the cylinder head forming core to prevent the molten metal from leaking from the parting surface during the pouring process; Repeat the above steps to operate on the first cylinder block forming core and the second cylinder block forming core to complete the assembly of the mold body;
[0035] ④ Bond the sprue at the upper end of the longitudinal runner and the riser for pouring, and the bare pouring method can be used.
[0036] As can be seen from the above technical solutions, compared with the prior art, the present utility model discloses an integrated casting model for a cylinder block and a cylinder head. Compared with the prior art, the present utility model is supported by a support core, and the cylinder block and the cylinder head are integrally divided by a cylinder head forming core, a cylinder block forming core I, and a cylinder block forming core II. There is no need to separately cast the cylinder block and the cylinder head, and the combination of the cylinder block and the cylinder head can be directly cast, which simplifies the core assembly molding process, reduces the requirements for the skill level of on-site workers and the operation difficulty, and further reduces the casting rejection rate, improving the production efficiency and quality of automotive engine castings; the setting of the core exhaust holes greatly reduces the occurrence of casting choking caused by the exhaust of the resin inside the core during the casting process of the casting, improving the quality and yield rate of the casting. Brief Description of the Drawings
[0037] In order to more clearly illustrate the technical solutions in the embodiments of the present utility model or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only the embodiments of the present utility model. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on the provided drawings.
[0038] Figure 1 It is a schematic structural diagram of an integrated casting model for a cylinder block and a cylinder head of the present utility model.
[0039] Figure 2 It is a schematic structural diagram of the support core provided by the present utility model.
[0040] Figure 3 It is a schematic structural diagram of the cylinder head forming core provided by the present utility model.
[0041] Figure 4 It is a cross-sectional view of the cylinder head forming core provided by the present utility model.
[0042] Figure 5 It is a schematic structural diagram of the cylinder block forming core I provided by the present utility model.
[0043] Figure 6 It is a schematic structural diagram of the cylinder block forming core II provided by the present utility model.
[0044] Figure 7 It is a cross-sectional view of the mold body provided by the present utility model.
[0045] Figure 8 It is a schematic structural diagram of the pouring assembly provided by the present utility model.
[0046] Figure 9 It is a connection diagram of the pouring assembly and the mold body provided by the present utility model.
[0047] Among them, 1 is the support core; 11 is the first core body; 12 is the bottom core; 13 is the assembly groove;
[0048] 2 is the cylinder head forming core; 21 is the second core body; 22 is the intake passage core; 23 is the exhaust passage core; 24 is the water jacket core; 241 is the first cavity; 25 is the core exhaust hole; 26 is the first cavity; 27 is the second cavity;
[0049] 3 is the first cylinder block forming core; 31 is the third core body; 311 is the gap; 32 is the front and rear end cores; 33 is the tappet core; 34 is the third cavity; 35 is the fourth cavity;
[0050] 4 is the second cylinder block forming core; 41 is the fourth core body; 42 is the riser core; 43 is the cylinder core; 44 is the second cylinder block forming cavity;
[0051] 5 is the pouring assembly; 51 is the cross runner; 52 is the longitudinal runner; 53 is the ingate;
[0052] 6 is the guiding and positioning assembly; 61 is the ear handle; 62 is the guiding hole; 63 is the guiding rod;
[0053] 7 is the recess; 8 is the clamping frame. Detailed implementation manners
[0054] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Apparently, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.
[0055] Refer to the appendix Figures 1-9 , the embodiments of the present invention disclose an integrated casting model for a cylinder block and a cylinder head, including a mold body and a pouring assembly 5. The mold body includes a support core 1, a cylinder head forming core 2, a first cylinder block forming core 3, and a second cylinder block forming core 4. An assembly groove 13 is provided on the upper end surface of the support core 1, and the lower end of the pouring assembly 5 is clamped in the assembly groove 13;
[0056] The cylinder head forming core 2, the first cylinder block forming core 3, and the second cylinder block forming core 4 are tightly stacked on the support core 1 in sequence from bottom to top, and the corresponding cylinder head forming cavity, the first cylinder block forming cavity, and the second cylinder block forming cavity 44 are provided inside and are interconnected. The cylinder head forming cavity is communicated with the pouring outlet of the pouring assembly 5. The lower inner wall surface of the cylinder head forming cavity correspondingly forms the lower end surface of the cylinder head, and the upper inner wall surface thereof correspondingly forms the water jacket top surface of the cylinder head; the upper inner wall surface of the first cylinder block forming cavity correspondingly forms the top flange surface of the cylinder block; the upper inner wall surface of the second cylinder block forming cavity 44 correspondingly forms the cylinder port surface of the cylinder block.
[0057] Specifically, the support core 1 includes a core body one 11 formed by integral 3D printing and a bottom plate core 12. The core body one 11 is arranged in a square hollow structure; the bottom plate core 12 is formed at the center of the upper end face of the core body one 11 and supports on the lower end wall surface of the cylinder head forming cavity; the assembly grooves 13 are formed on both sides of the core body one 11 corresponding to the bottom plate core 12.
[0058] The cylinder head forming core 2 includes a core body two 21 formed by integral 3D printing, an intake passage core 22, an exhaust passage core 23 and a water jacket core 24. The core body two 21 is arranged in a square hollow structure and is clamped on the upper end of the core body one 11; the intake passage core 22 and the exhaust passage core 23 are respectively formed inside the core body two 21, and a first cavity 26 is formed between the outer walls of the intake passage core 22 and the exhaust passage core 23 and the inner wall of the core body two 21. The lower end inner wall surface of the first cavity 26 correspondingly forms the lower end face of the cylinder head. The bottom plate core 12 supports on the lower end wall surface of the first cavity 26. The pouring outlet of the pouring assembly 5 is communicated with the first cavity 26;
[0059] The water jacket core 24 is formed on the upper end face of the core body two 21. The water jacket core 24 has a first cavity 241. The lower end of the cylinder block forming core two 4 extends into the first cavity 241, and a second cavity 27 is formed between its outer wall and the inner wall of the first cavity 241. The second cavity 27 is communicated with the first cavity 26 and the two together form the cylinder head forming cavity. The upper end inner wall surface of the second cavity 27 correspondingly forms the water jacket top surface of the cylinder head.
[0060] Wherein, a core exhaust hole 25 is horizontally opened at the lower end of the water jacket core 24.
[0061] The cylinder block forming core one 3 includes a core body three 31 formed by integral 3D printing, front and rear end cores 32 and a tappet core 33. The core body three 31 is arranged in a hollow structure and is clamped on the upper end of the core body two 21. A second cavity is opened in its center. The upper end of the water jacket core 24 extends into the second cavity;
[0062] The tappet core 33 and the front and rear end cores 32 are respectively formed on the inner wall of the second cavity corresponding to the upper end of the water jacket core 24, and a gap 311 is reserved between them. The gap 311 corresponds to and is communicated with the first cavity 241. The lower end of the cylinder block forming core two 4 passes through the gap 311 and is located in the first cavity 241. A third cavity 34 is formed between the inner wall of the gap 311 and the corresponding outer wall of the lower end of the cylinder block forming core two 4. A fourth cavity 35 is formed between the outer walls of the tappet core 33 and the front and rear end cores 32 and the inner wall of the core body three 31. The third cavity 34 and the fourth cavity 35 together form the first cylinder block forming cavity. The upper end inner wall surfaces of the two are flush and correspondingly form the top flange surface of the cylinder head; the third cavity 34 is communicated with the second cavity 27, and the fourth cavity 35 is communicated with the first cavity 26.
[0063] The second core for cylinder block forming 4 includes a core body four 41 formed by integral 3D printing, a cylinder core 43 and a riser core 42. The core body four 41 is arranged in a square hollow structure and is clamped at the upper end of the core body three 31; the cylinder core 43 is formed at the lower end of the core body four 41 and passes through the gap 311 and is located in the cavity one 241; the riser core 42 is formed at the upper end of the core body four 41; a cylinder block forming cavity two 44 is formed between the outer walls of the riser core 42 and the cylinder core 43 and the inner wall of the core body four 41, and the cylinder block forming cavity two 44 is respectively communicated with the third cavity 34 and the fourth cavity 35.
[0064] In some specific implementation examples, the gating assembly 5 includes a runner 51, a sprue 52 and an ingate 53. The runner 51 is clamped in the assembly groove 13; one end of the sprue 52 is communicated with the runner 51, and the other end of the sprue 52 respectively passes through the core body two 21, the core body three 31 and the core body four 41 upward and is located above the core body four 41; there are multiple ingates 53. One end of the ingate 53 is fixed and communicated with the upper end surface of the runner 51, and the other end of the ingate 53 is communicated with the first cavity 26.
[0065] Specifically, the gating assembly 5 further includes a filter screen, and the filter screen is vertically installed on the inner wall of the sprue 52.
[0066] Specifically, the pouring ratio can be selected as 1:2:2.5. The setting of this structure can, on the one hand, provide sufficient metal liquid supply to ensure the continuity of the pouring process. On the other hand, the size of the ingate is relatively large, which can control the inflow speed of the metal liquid and avoid the impact of too fast flow rate on the core. The open gating system has good exhaustibility, which can smoothly discharge the gas in the cavity and avoid the formation of defects such as pores in the casting. During the pouring process, the flow of the metal liquid is smoother, which is beneficial to improving the density and mechanical properties of the casting.
[0067] Specifically, the gating assembly 5 further includes an oil bottle riser, and the oil bottle riser is arranged in the riser core 42. The setting of this structure can provide additional metal liquid during the solidification process of the casting to compensate for the shrinkage of the casting and prevent defects such as shrinkage cavities and shrinkage porosity. Placing it on the top of the flange can utilize the gravity effect to make the metal liquid in the riser easier to flow into the part of the casting that needs to be compensated for shrinkage. The oil bottle riser can also play the role of exhaust and slag collection. During the pouring process, the gas and inclusions in the cavity can be discharged through the riser to improve the purity of the casting.
[0068] In some other specific implementation examples, it further includes a guiding and positioning component 6. The guiding and positioning component 6 includes a plurality of ear handles 61 and guiding rods 63. The plurality of ear handles 61 are integrally formed on both sides of the first core body 11, the second core body 21, the third core body 31, and the fourth core body 41 respectively, and the ear handles 61 on the same side are arranged vertically corresponding to each other. Guide holes 62 are formed in the ear handles 61, and the guide holes 62 on the same side are arranged vertically corresponding to each other. The guiding rods 63 vertically penetrate through the guide holes 62 on the same side for positioning and core assembly.
[0069] In some other specific implementation examples, the peripheral sides of the upper end faces of the first core body 11, the second core body 21, and the third core body 31 all sink downward to form a frame-shaped recess 7. At positions corresponding to the recess 7 on the lower end faces of the second core body 21, the third core body 31, and the fourth core body 41, a clamping frame 8 adapted to the recess 7 is integrally formed.
[0070] A one-piece casting mold for a cylinder block and a cylinder head provided by the present utility model has the following production steps:
[0071] ① Draw a cuboid block of 1500mm×800mm×800mm in 3D software, wrap the entire engine casting and the gating system, and perform a subtraction operation to obtain a complete mold.
[0072] ② Perform further core splitting operations on the mold: Split the core from the position of the lower end face of the cylinder head to obtain a support core; split the core from the position of the top surface of the water jacket of the cylinder liner to obtain a cylinder head forming core; split the core from the position of the top flange surface of the cylinder block to obtain a first cylinder block forming core and a second cylinder block forming core.
[0073] ③ Assemble the cores: Place the support core on a relatively flat platform, which can be the ground or a steel tray. Insert the guiding rod into the guiding hole of the support core, and place the cross runner of the gating system in the assembly groove. Lift the cylinder head forming core by the ear handle of the cylinder head forming core, so that the guiding hole of the cylinder head forming core penetrates through the guiding rod to position and lower the cylinder head forming core, and clamp it through the recess at the upper end of the support core and the clamping frame at the lower end of the cylinder head forming core to prevent the molten metal from leaking from the parting surface during pouring; Repeat the above steps to operate on the first cylinder block forming core and the second cylinder block forming core to complete the assembly of the mold body.
[0074] ④ Bond a sprue at the upper end of the longitudinal runner and the riser for pouring, and the bare pouring method can be adopted.
[0075] The integrated casting model of the cylinder block and cylinder head designed according to the present utility model is supported by a support core, and the cylinder block and cylinder head are integrally divided by a cylinder head forming core, a cylinder block forming core I, and a cylinder block forming core II. There is no need to separately cast the cylinder block and cylinder head, and the combination of the cylinder block and cylinder head can be directly cast, which simplifies the core assembly molding process, reduces the requirements for the skill level of on-site workers and the operation difficulty, thereby reducing the casting rejection rate and improving the production efficiency and quality of automotive engine castings; the setting of the core exhaust holes greatly reduces the occurrence of casting choking caused by the exhaust of the resin inside the core during the casting process of the casting, and improves the quality and yield of the casting.
[0076] The various embodiments in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments. For the same and similar parts among the various embodiments, reference can be made to each other.
[0077] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present utility model. Various modifications to these embodiments will be obvious to those skilled in the art. The general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present utility model. Therefore, the present utility model will not be limited to these embodiments shown herein, but will be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. An integrated casting model of a cylinder block and a cylinder head, characterized in that, It includes a mold body and a pouring assembly (5). The mold body includes a support core (1), a cylinder head forming core (2), a cylinder block forming core one (3), and a cylinder block forming core two (4). An assembly groove (13) is formed on the upper end surface of the support core (1). ， The lower end of the pouring assembly (5) is clamped in the assembly groove (13). The cylinder head forming core (2), the first cylinder block forming core (3) and the second cylinder block forming core (4) are tightly stacked on the support core (1) in sequence from bottom to top, and a cylinder head forming cavity, a first cylinder block forming cavity and a second cylinder block forming cavity (44) which are communicated with each other are correspondingly arranged inside them. The cylinder head forming cavity is communicated with the pouring outlet of the pouring assembly (5). The lower inner wall surface of the cylinder head forming cavity correspondingly forms the lower end surface of the cylinder head, and the upper inner wall surface thereof correspondingly forms the water jacket top surface of the cylinder head; the upper inner wall surface of the first cylinder block forming cavity correspondingly forms the top flange surface of the cylinder block; the upper inner wall surface of the second cylinder block forming cavity (44) correspondingly forms the cylinder port surface of the cylinder block.
2. The integrated casting model of a cylinder block and a cylinder head according to claim 1, characterized in that The support core (1) includes a first core body (11) formed by integral 3D printing and a bottom plate core (12). The first core body (11) is arranged in a square hollow structure; the bottom plate core (12) is formed at the center of the upper end surface of the first core body (11) and supports on the lower wall surface of the cylinder head forming cavity; the assembly groove (13) is formed on both sides of the first core body (11) corresponding to the bottom plate core (12).
3. The integrated casting model of a cylinder block and a cylinder head according to claim 2, characterized in that, The cylinder head forming core (2) includes a second core body (21), an intake passage core (22), an exhaust passage core (23) and a water jacket core (24) formed by integral 3D printing. The second core body (21) is arranged in a square hollow structure and is clamped on the upper end of the first core body (11); the intake passage core (22) and the exhaust passage core (23) are respectively formed inside the second core body (21), and a first cavity (26) is formed between the outer walls of the intake passage core (22) and the exhaust passage core (23) and the inner wall of the second core body (21). The lower inner wall surface of the first cavity (26) correspondingly forms the lower end surface of the cylinder head, and the bottom plate core (12) supports on the lower wall surface of the first cavity (26). The pouring outlet of the pouring assembly (5) is communicated with the first cavity (26); The water jacket core (24) is formed on the upper end surface of the second core body (21). The water jacket core (24) has a first cavity (241). The lower end of the second cylinder block forming core (4) extends into the first cavity (241), and a second cavity (27) is formed between its outer wall and the inner wall of the first cavity (241). The second cavity (27) is communicated with the first cavity (26), and the two together form the cylinder head forming cavity. The upper inner wall surface of the second cavity (27) correspondingly forms the water jacket top surface of the cylinder head.
4. An integrated casting model of a cylinder block and a cylinder head according to claim 3, characterized in that, The lower end of the water jacket core (24) is horizontally provided with a core exhaust hole (25).
5. An integrated casting model of a cylinder block and a cylinder head according to claim 3, characterized in that, The first cylinder block forming core (3) includes a third core body (31), front and rear end cores (32) and tappet cores (33) formed by integral 3D printing. The third core body (31) is arranged in a hollow structure and is clamped on the upper end of the second core body (21). A second cavity is formed in its center, and the upper end of the water jacket core (24) extends into the second cavity; The tappet core (33) and the front and rear end cores (32) are respectively formed on the inner wall of the second cavity and correspond to the upper end of the water jacket core (24). A gap (311) is reserved between them. The gap (311) corresponds to and communicates with the first cavity (241). The lower end of the cylinder block forming core two (4) passes through the gap (311) and is located in the first cavity (241). A third cavity (34) is formed between the inner wall of the gap (311) and the outer wall corresponding to the lower end of the cylinder block forming core two (4). A fourth cavity (35) is formed between the outer walls of the tappet core (33) and the front and rear end cores (32) and the inner wall of the core body three (31). The third cavity (34) and the fourth cavity (35) form the first cylinder block forming cavity. The upper inner wall surfaces of the two are flush and correspondingly form the top flange surface of the cylinder head. The third cavity (34) communicates with the second cavity (27), and the fourth cavity (35) communicates with the first cavity (26).
6. An integrated casting model of a cylinder block and a cylinder head according to claim 5, characterized in that, The cylinder block forming core two (4) includes a core body four (41), a cylinder core (43), and a riser core (42) integrally formed by 3D printing. The core body four (41) is arranged in a square hollow structure and is clamped to the upper end of the core body three (31). The cylinder core (43) is formed at the lower end of the core body four (41) and passes through the gap (311) and is located in the first cavity (241). The riser core (42) is formed at the upper end of the core body four (41). A second cylinder block forming cavity (44) is formed between the outer walls of the riser core (42) and the cylinder core (43) and the inner wall of the core body four (41), and the second cylinder block forming cavity (44) communicates with the third cavity (34) and the fourth cavity (35) respectively.
7. An integral casting model of a cylinder block and a cylinder head according to claim 6, characterized in that, The pouring assembly (5) includes a cross runner (51), a longitudinal runner (52), and an ingate (53). The cross runner (51) is clamped in the assembly groove (13). One end of the longitudinal runner (52) communicates with the cross runner (51), and the other end respectively passes through the core body two (21), the core body three (31), and the core body four (41) upward and is located above the core body four (41). There are multiple ingates (53). One end of each ingate (53) is fixed and communicates with the upper end surface of the cross runner (51), and the other end communicates with the first cavity (26).
8. An integrated casting model of a cylinder block and a cylinder head according to claim 7, characterized in that, The pouring assembly (5) further includes a filter screen, and the filter screen is vertically installed on the inner wall of the longitudinal runner (52).
9. An integrated casting model of a cylinder block and a cylinder head according to claim 6, characterized in that, It further includes a guiding and positioning component (6). The guiding and positioning component (6) includes a plurality of ear handles (61) and guiding rods (63). The plurality of ear handles (61) are integrally formed on both sides of the first core body (11), the second core body (21), the third core body (31), and the fourth core body (41) respectively, and the ear handles (61) on the same side are arranged corresponding to each other vertically. Guide holes (62) are formed in all the ear handles (61), and the guide holes (62) on the same side are arranged corresponding to each other vertically. The guiding rod (63) vertically penetrates through the guide holes (62) on the same side for positioning and core assembling.
10. The integrated casting model of a cylinder block and a cylinder head according to claim 6, characterized in that, On the peripheral sides of the upper end surfaces of the first core body (11), the second core body (21), and the third core body (31), frame-shaped recessed parts (7) are formed by downward depression. On the lower end surfaces of the second core body (21), the third core body (31), and the fourth core body (41), at positions corresponding to the recessed parts (7), clamping frames (8) adapted to the recessed parts (7) are integrally formed.