Exhaust manifold casting structure for improving process yield

Abstract

This utility model provides an exhaust manifold casting structure for improving process yield, belonging to the field of casting technology. The exhaust manifold casting structure of this utility model includes an inlet flange, an exhaust flange, an ingate, a sprue, a runner, and a baffle plate. The sprue, runner, and ingate are sequentially connected to form a gating system. The inlet flange is located at the end furthest from the gate and is designed without a riser. The inlet flange and the exhaust flange are arranged opposite each other along the length of the casting. The exhaust flange riser has a reduced-diameter riser, the volume of which is reduced by 6.5% ± 0.5% compared to a standard riser. The distance between the exhaust flange and the inlet flange is less than 150mm. The baffle plate is centrally located along the axis of the exhaust flange. This utility model enables uniform solidification of the casting, ensuring no shrinkage defects in the central area and flange, uniform microstructure, and stable mechanical properties.

Description

Technical Field

[0001] This utility model belongs to the field of casting technology, specifically relating to an exhaust manifold casting structure that improves the yield of the process. Background Technology

[0002] In the production process of silicon molybdenum exhaust pipes, several issues affect the yield rate. Currently, the riser size of the small flange is too large, resulting in low material utilization and negatively impacting the yield rate. At the same time, the uneven metallographic structure of the pipe wall between the inlet and exhaust flanges due to thermal deformation further affects product quality. The large volume and close proximity of the risers of the inlet and exhaust flanges not only reduce the yield rate but also cause the pipe wall between the two risers to be heated for too long, affecting the metallographic structure. Traditional designs have failed to effectively solve the problems of redundant outlet volume and unreasonable spacing.

[0003] In existing technologies, although attempts have been made to compensate for shrinkage by increasing the riser volume, the solidification sequence has not been effectively balanced, and it is difficult to balance the stability of yield and quality. These problems need to be improved to increase the process yield of exhaust manifolds, achieve uniform solidification of castings, ensure that there are no shrinkage defects in the middle area and flanges, uniform microstructure, and stable mechanical properties, and achieve efficient and low-cost casting production. Utility Model Content

[0004] The technical problem to be solved by this utility model is how to achieve uniform solidification of castings, ensure that there are no shrinkage defects in the middle area and flange, uniform microstructure, stable mechanical properties, significantly improve the process yield and reduce production costs. In view of the shortcomings of the existing technology, this utility model provides an exhaust manifold casting structure that improves the process yield.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: an exhaust manifold casting structure for improving process yield includes an inlet flange, an exhaust flange, an ingate, a sprue, a runner, and a partition. The sprue, runner, and ingate are connected in sequence to form a gating system. The inlet flange is located at the end away from the gate and is designed without a riser. The inlet flange and the exhaust flange are arranged opposite to each other along the length of the casting. The exhaust flange riser is provided with a reduced-diameter riser, the volume of which is reduced by 6.5% ± 0.5% compared to a standard riser. The distance between the exhaust flange and the inlet flange is less than 150mm. The partition is centrally located along the axis of the exhaust flange.

[0006] Optionally, the partition plate is thicker than 10 mm, and the exhaust flange can be extended laterally.

[0007] Compared to existing technologies, the beneficial effects of this utility model include: the exhaust manifold casting structure consists of an inlet flange, an exhaust flange, an ingate, a sprue, a runner, and a baffle plate; the sprue, runner, and ingate are sequentially connected to form a gating system; the gating system includes the sprue, runner, and ingate; by optimizing the gating dimensions and utilizing the principle of uniform solidification of ductile iron, the temperature field in the thicker areas of the casting is reduced, achieving the conditions for uniform solidification. Optimizing the gating dimensions and utilizing the principle of uniform solidification of ductile iron allows the molten iron to flow and solidify more evenly in the casting, reducing defects such as shrinkage porosity and shrinkage cavities caused by uneven temperature, improving the internal quality and overall performance of the casting, and ultimately... To improve process yield, the inlet flange is located at the end furthest from the gate and features a riserless design. The inlet and vent flanges are positioned opposite each other along the length of the casting. The vent flange riser has a reduced-bore riser, with its volume reduced by 6.5% ± 0.5% compared to a standard riser. The distance between the vent flange and the inlet flange is less than 150mm. The riserless design of the inlet flange, combined with the 6.5% reduction in riser volume, reduces material waste and lowers production costs. It also helps improve the solidification sequence of the casting, avoiding defects caused by riser-related issues, improving casting quality, and thus increasing process yield. The baffle is centrally located along the axis of the vent flange. Adjusting the flow obstruction by regulating the cross-sectional area of ​​the gating system allows for precise control of the water flow and temperature, providing a more stable environment for casting solidification, further ensuring casting quality, and positively impacting process yield. Attached Figure Description

[0008] The present invention will now be described in further detail with reference to the accompanying drawings.

[0009] Figure 1 : A schematic diagram of the structure of an exhaust manifold casting for improving process yield in an embodiment of this utility model;

[0010] Figure 2 This utility model embodiment presents a schematic diagram of the intake flange and exhaust flange structure of an exhaust manifold casting structure for improving process yield.

[0011] Among them: 1. Inlet flange; 2. Exhaust flange; 3. Inner runner; 4. Horizontal runner; 5. Vertical runner. Detailed Implementation

[0012] To better understand this utility model, the following embodiments further illustrate its content, but the scope of protection of this utility model is not limited to the embodiments described below. Numerous specific details are set forth in the following description to provide a more thorough understanding of this utility model. However, it will be apparent to those skilled in the art that this utility model can be practiced without one or more of these details.

[0013] It should be noted that the Z-axis in the attached figures represents the vertical direction, i.e., the up-down position, with the positive direction of the Z-axis representing upward and the negative direction representing downward; the Y-axis in the attached figures represents the horizontal direction and is designated as the front-back position, with the positive direction of the Y-axis representing the front and the negative direction representing the back; the X-axis in the attached figures represents the left-right position, with the positive direction of the X-axis representing the right and the negative direction representing the left. It should also be noted that the aforementioned representations of the Z, Y, and X axes are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0014] The term "comprising" and its variations as used herein are open-ended, meaning "including but not limited to"; the term "based on" means "at least partially based on"; the term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments"; and the term "optionally" means "optional embodiments". Definitions of other terms will be given in the following description. It should be noted that the concepts of "first," "second," etc., mentioned in this utility model are only used to distinguish different devices, modules, or units, and are not used to limit the order of functions performed by these devices, modules, or units or their interdependencies.

[0015] It should be noted that the terms "one" and "multiple" used in this utility model are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0016] In related technologies, the low process yield in the casting industry is a problem: the low process yield of existing products affects production efficiency, and the metallographic and performance of the thick areas in the middle of the casting are unqualified, making it difficult to guarantee product quality. In order to solve the above problems, an embodiment of this utility model provides an exhaust manifold casting structure to improve the process yield, including an inlet flange (1), an exhaust flange (2), an ingate (3), a sprue (5), a runner (4), and a partition. The sprue (5), the runner (4), and the ingate (3) are connected in sequence to form a gating system. The inlet flange (1) is located at the end away from the gate. The inlet flange (1) is designed without a riser. The inlet flange (1) and the exhaust flange (2) are arranged opposite each other along the length of the casting. The riser of the exhaust flange (2) is provided with a reduced diameter riser. The volume of the reduced diameter riser is reduced by 6.5% ± 0.5% compared with the standard riser. The distance between the exhaust flange (2) and the inlet flange (1) is less than 150mm. The partition is arranged in the center along the axis of the exhaust flange.

[0017] In this embodiment, as Figure 1 and Figure 2As shown, in order to improve the product yield and quality, the exhaust manifold casting structure is composed of an inlet flange (1), an exhaust flange (2), an ingate (3), a sprue (5), a runner (4), and a baffle. The sprue (5), the runner (4), and the ingate (3) are connected in sequence to form a gating system. The gating system includes the sprue (5), the runner (4), and the ingate (3). By optimizing the gating dimensions and utilizing the principle of uniform solidification of ductile iron, the temperature field in the thick area in the middle of the casting is reduced, achieving the conditions for uniform solidification. Optimizing the gating dimensions and utilizing the principle of uniform solidification of ductile iron can make the molten iron flow and solidify more evenly in the casting, reducing defects such as shrinkage porosity and shrinkage cavities caused by uneven temperature, improving the internal quality and overall performance of the casting, and ultimately improving the process yield. Flange (1) is located at the end furthest from the gate. The inlet flange (1) is designed without a riser. The inlet flange (1) and the exhaust flange (2) are set opposite each other along the length of the casting. The riser volume of the exhaust flange (2) is reduced by 6.5% of the original volume. The distance between the exhaust flange (2) and the inlet flange (1) is less than 150 mm. The inlet flange (1) adopts a riser-free design. The riser of the exhaust flange (2) is equipped with a reduced-diameter riser. The volume of the reduced-diameter riser is reduced by 6.5% ± 0.5% compared with the standard riser. The standard riser is determined by Magnia mold flow analysis, which can reduce material waste and reduce production costs. At the same time, it helps to improve the solidification sequence of the casting, avoid defects caused by riser-related problems, improve the casting quality, and thus improve the process yield. The baffle is set in the center along the axis of the exhaust flange (2). By adjusting the flow obstruction through the cross-sectional area of ​​the gating system, the water inflow and temperature can be precisely controlled, providing a more stable environment for the solidification of the casting, further ensuring the casting quality, and playing a positive role in improving the process yield.

[0018] Optionally, the partition thickness is greater than 10mm, and the exhaust flange (2) can be extended laterally.

[0019] In this optional embodiment, such as Figure 1 As shown, in order to improve the scalability of the exhaust manifold casting structure, when the baffle thickness is greater than 10mm, the casting can be extended laterally. For exhaust manifolds of different specifications, when the baffle thickness meets the strength requirements of greater than 10mm, the casting structure can be extended laterally so that the same mold or process scheme can be applied to multiple products, improve process versatility and mold utilization, and reduce production costs.

[0020] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model, as long as they do not depart from the spirit and scope of the technical solution of this utility model, should be covered within the scope of the claims of this utility model.

[0021] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A structure for an exhaust manifold casting that improves process yield, characterized in that: The casting includes an inlet flange, an vent flange, an ingate, a sprue, a runner, and a baffle plate. The sprue, runner, and ingate are connected in sequence to form a gating system. The inlet flange is located at the end away from the gate and is designed without a riser. The inlet flange and the vent flange are arranged opposite each other along the length of the casting. The vent flange riser is equipped with a reduced-diameter riser, the volume of which is reduced by 6.5% ± 0.5% compared to a standard riser. The distance between the vent flange and the inlet flange is less than 150 mm. The baffle plate is centrally located along the axis of the vent flange.

2. The exhaust manifold casting structure for improving process yield as described in claim 1, characterized in that: The thickness of the partition plate is greater than 10mm, and the exhaust flange can be extended laterally.

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