Melting furnace, die-casting machine and die-casting method

Abstract

The present application relates to the technical field of die casting, and relates to a melting furnace, a die-casting machine and a die-casting method. The melting furnace comprises a first cylinder and second cylinders, wherein the first cylinder is provided with a material melting cavity, which is configured to melt materials; each second cylinder is arranged in the material melting cavity and is provided with a liquid injection cavity, a feeding port and a discharging port, the feeding port and the discharging port each being in communication with the liquid injection cavity; and a molten material formed by means of melting in the material melting cavity flows into the liquid injection cavity via the feeding port and can also be discharged via the discharging port under the action of an external force. The present application can ameliorate the phenomenon of pores existing inside a die-cast product.

Description

Furnace, die casting machine and die casting method

[0001] Related applications

[0002] This application claims priority to Chinese patent application filed on August 26, 2024, application number 2024111820440, entitled "Furnace, Die Casting Machine and Die Casting Method", the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to the field of die casting technology, and in particular to a furnace, a die casting machine and a die casting method. Background Technology

[0004] Die casting is a metal casting process that uses the cavity of a mold to apply high pressure to molten metal. In related technologies, after the raw material is melted in a heating cylinder, it needs to be transferred to the injection chamber via a carrier. During the transfer process, the molten metal cools down due to contact with air, preventing it from being injected into the mold cavity at its highest temperature. Furthermore, it needs to be injected into the mold cavity at high speed, resulting in the product containing air bubbles. Summary of the Invention

[0005] Based on this, a furnace, a die-casting machine, and a die-casting method are provided.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0007] In a first aspect, embodiments of this application provide a furnace, including:

[0008] The first cylinder body is provided with a melting chamber for material melting.

[0009] At least one second cylinder body, each second cylinder body is disposed in the melting chamber, and each second cylinder body is provided with a liquid injection chamber, a feed inlet and a discharge outlet, the feed inlet and the discharge outlet being respectively connected to the liquid injection chamber;

[0010] The molten material formed by melting in the melting chamber flows into the injection chamber through the feed port and can also be discharged through the discharge port under the action of external force.

[0011] In one embodiment of the first aspect, each second cylinder is disposed in the melting chamber so as to keep the second cylinder warm by the molten material formed by melting in the melting chamber.

[0012] In one embodiment of the first aspect, the furnace further includes a heating element disposed within the melting chamber for melting the material in the first cylinder and for heat preservation of the molten material in the second cylinder.

[0013] In one embodiment of the first aspect, the second cylinder further includes an extruder that slides through the injection chamber and is in contact with the inner wall of the injection chamber, with the inlet and outlet respectively located on different sides of the extruder.

[0014] In one embodiment of the first aspect, the extruder has a first preset position and a second preset position relative to the injection cavity;

[0015] When the extrusion is in the first preset position, the feed port is open and the feed port, the liquid injection chamber and the discharge port are interconnected.

[0016] When the extruder is in the second preset position, the extruder seals the feed inlet, and the injection chamber is connected to the discharge outlet.

[0017] In one embodiment of the first aspect, the extruder includes a push rod and a plunger, the plunger being connected to one end of the push rod and slidably disposed in the injection chamber, for extruding the molten material in the injection chamber from the outlet when the extruder moves from a first preset position to a second preset position.

[0018] In one embodiment of the first aspect, the injection chamber includes a first chamber and a second chamber that are independent of each other. The first chamber is in communication with the second chamber. The inlet is located on one side of the first chamber and is in communication with the first chamber. The outlet is located on one side of the second chamber and is in communication with the second chamber. The extruder slides through the first chamber.

[0019] In one embodiment of the first aspect, the second cylinder further includes a liquid injection pipe, one end of which is sealed to the discharge port.

[0020] Secondly, embodiments of this application also provide a die-casting machine, including the furnace in any of the above embodiments.

[0021] Thirdly, this application also provides a die-casting method, employing the furnace or die-casting machine described in any of the above embodiments. The die-casting method includes:

[0022] Add material into the molten material chamber of the first cylinder;

[0023] The heating element is activated to bring the melting chamber to the preset melting temperature of the material, thus obtaining the molten material.

[0024] Adjust the extruder to the first preset position to open the feed port of the second cylinder and add the molten material into the injection chamber of the second cylinder;

[0025] The extruder presses the molten material in the injection cavity and blocks the feed port, so that the molten material is injected into the mold cavity through the discharge port;

[0026] The extrusion part returns to the first preset position, the feed port opens, and some of the molten material flows back into the injection chamber.

[0027] Compared to related technologies, the advantages of this application are as follows: This application provides a furnace, a die-casting machine, and a die-casting method, which can be used for metal die casting. The furnace includes a first cylinder and a second cylinder, wherein the first cylinder is provided with a molten material chamber for melting materials. In this way, during the die-casting process, the molten material in the first cylinder is added to the second cylinder and injected into the mold cavity from the outlet of the second cylinder, allowing the molten material to be injected into the mold at its highest temperature without increasing the injection speed, thus improving the phenomenon of porosity inside the die-cast product. Attached Figure Description

[0028] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the disclosed drawings without creative effort.

[0029] Figure 1 is a schematic diagram of the initial state structure of the furnace in some embodiments of this application;

[0030] Figure 2 is a schematic diagram of the structure of the second cylinder in some embodiments of this application;

[0031] Figure 3 is a schematic diagram of the feeding state structure of the second cylinder in some embodiments of this application;

[0032] Figure 4 is a schematic diagram of the feeding state structure of the second cylinder in some embodiments of this application;

[0033] Figure 5 is a schematic diagram of the die-cast state structure of the second cylinder block in some embodiments of this application;

[0034] Figure 6 is a schematic diagram of the structure of the first cavity and the second cavity in some other embodiments of this application;

[0035] Figure 7 is a schematic flowchart of the die-casting method in some embodiments of this application.

[0036] Explanation of reference numerals in the attached drawings: 100, furnace; 110, first cylinder; 111, melting chamber; 120, second cylinder; 121, liquid injection chamber; 1211, first cavity; 1212, second cavity; 122, feed inlet; 123, discharge outlet; 124, extrusion component; 1241, push rod; 1242, plunger; 125, partition plate; 130, heating component. Detailed Implementation

[0037] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] In die casting, raw materials are shaped into blocks or other forms, melted in a heating cylinder, and then transferred to an injection chamber. However, during this transfer, the molten metal comes into contact with external air, causing cooling and making it difficult to maintain the maximum temperature before injection into the mold cavity. Furthermore, to prevent cooling, the molten metal needs to be injected into the mold cavity at high speed, making it difficult for air to escape quickly. This results in residual gas in the molten metal, leading to porosity in the product and low density (typically only 90%-98%), with mechanical properties far below the specifications of the raw material. Moreover, grinding after forming exposes these internal pores, causing poor appearance and surface defects. This hinders surface treatment processes such as anodizing, painting, powder coating, electroplating, micro-arc oxidation, and electrophoretic painting, negatively impacting product yield and increasing costs.

[0039] Therefore, embodiments of this application provide a furnace 100 that can improve the phenomenon of porosity inside die-cast products.

[0040] Referring to Figure 1, the furnace 100 includes a first cylinder 110 and at least one second cylinder 120.

[0041] Referring again to Figure 2, the first cylinder 110 is provided with a melting chamber 111 for melting materials; each second cylinder 120 is provided with a liquid injection chamber 121, a feed inlet 122, and a discharge outlet 123, with the feed inlet 122 and discharge outlet 123 respectively connected to the liquid injection chamber 121. The molten material formed in the melting chamber 111 flows into the liquid injection chamber 121 through the feed inlet 122 and can also be discharged through the discharge outlet 123 under external force.

[0042] Furthermore, the second cylinder 120 also includes a liquid injection pipe, one end of which is sealed to the discharge port 123.

[0043] For example, one end of the injection pipe is connected to the outlet 123 and the other end is connected to the injection port of the mold, so that the molten liquid is in a fully sealed state during the injection process, reducing air contact, maintaining the temperature of the molten liquid, and reducing the generation of porosity in the die-cast product.

[0044] In summary, the furnace 100 provided in this application embodiment is in a fully sealed state during the die casting process, with full pipeline feeding, filling the cavity at low speed, and using a pressing method to maintain the product surface pressure and stress balance during molding.

[0045] In some embodiments, each second cylinder 120 is disposed in the melting chamber 111 so as to keep the second cylinder 120 warm by the molten material formed in the melting chamber 111.

[0046] For example, the first cylinder 110 can be a high-temperature resistant metal container. The first cylinder 110 has a melting chamber 111 inside, and an opening on one side to facilitate the installation of the second cylinder 120 into the melting chamber 111 from the opening side, and the addition of raw materials to be melted from the opening side. It is understood that an openable and closable cover structure can be provided at the opening to control the feeding state of the melting chamber 111.

[0047] The second cylinder 120 can be made of the same high-temperature resistant material as the first cylinder 110. The second cylinder 120 has an injection chamber 121. By placing the second cylinder 120 inside the molten material chamber 111 of the first cylinder 110, a structure similar to a mother-daughter cylinder is formed. The temperature of the molten material chamber 111 of the first cylinder 110 provides some insulation for the second cylinder 120. After the molten material inside the first cylinder 110 is added to the second cylinder 120, the molten material is injected into the mold cavity through an injection device. This ensures that the molten material is injected into the mold cavity at its highest temperature, thus eliminating the need to avoid heat loss during the transfer process and to deliberately increase the injection speed, thereby improving the die-casting quality of the product and mitigating the problem of internal porosity.

[0048] It should be noted that at least one index in this application is a natural number greater than zero. The number of second cylinder blocks 120 in this application can be one, two, three, four, etc., which can be selected according to actual needs, and can meet the simultaneous die-casting operations of multiple molds.

[0049] It should be noted that in this embodiment, the second cylinder 120 and the first cylinder 110 can be integrally formed. In other embodiments, the second cylinder 120 and the first cylinder 110 can also be separately provided, and the second cylinder 120 can be installed in the first cylinder 110 simply by installing the workpiece, which can satisfy the die-casting effect of this application.

[0050] In other embodiments, the second cylinder 120 is not limited to being installed only inside the first cylinder 110, but may also be disposed on the side of the first cylinder 110 or separately disposed on the outside of the first cylinder 110, all of which can realize the function of injecting molten liquid into the mold at its highest temperature.

[0051] In some embodiments, the furnace 100 further includes a heating element 130, which is disposed in the melting chamber 111 and is used to keep the molten material in the first cylinder 110 and the molten material in the second cylinder 120 warm.

[0052] For example, the heating element 130 can heat the interior of the molten material chamber 111, thereby bringing the interior of the molten material chamber 111 to a preset temperature value for material melting. Specifically, the preset temperature value can be set according to different raw materials, such as the melting point of iron (1538℃), cobalt (1495℃), and nickel (1455℃). The heating element 130 can heat and melt the material, and during the die-casting process, it can further maintain the temperature of the first cylinder 110 and the second cylinder 120, thus keeping the molten liquid at a high temperature and ensuring the die-casting quality of the molten liquid and the workpiece.

[0053] In some embodiments, a temperature sensor may be installed inside the melting chamber 111, and a corresponding temperature threshold may be set according to the material. When the temperature inside the melting chamber 111 is lower than the preset temperature threshold, the heating element 130 automatically starts heating, which can reduce the energy consumption of the heating element 130 to a certain extent, while ensuring that the high temperature of the melt is maintained.

[0054] In some embodiments, the heating element 130 is an electromagnetic heater, which includes an electromagnetic coil wound around the periphery of the second cylinder 120.

[0055] For example, an electromagnetic heater can convert electrical energy into heat energy through the principle of electromagnetic induction. This conversion eliminates the need for an intermediate medium, thus avoiding energy loss. It also features rapid and accurate temperature control, allowing for precise control of the heated substance. Furthermore, it produces no waste gas or wastewater, and is flameless and odorless, making it safer than traditional heating methods using fuels such as coal gas.

[0056] However, electromagnetic heaters require the material being heated to have metallic conductivity; therefore, the embodiments in this application are not limited to electromagnetic heating. For non-magnetic metals, such as aluminum and titanium, resistance heating, electron beam heating, laser heating, and other methods can still be used.

[0057] In some embodiments, the second cylinder 120 further includes an extruder 124, which is slidably disposed in the injection chamber 121 and is in contact with the inner wall of the injection chamber 121. The inlet 122 and the outlet 123 are respectively disposed on different sides of the extruder 124.

[0058] For example, the extruder 124 can perform a reciprocating pushing operation under the action of external force. By fitting the extruder 124 against the inner wall of the injection chamber 121, the molten liquid in the injection chamber 121 is pushed out from the discharge port 123 during the extrusion process, preventing the molten liquid from seeping out from the side of the extruder 124 during the pushing process. At the same time, during the pushing process, the extruder 124 blocks the feed port 122 to prevent the molten liquid from flowing back.

[0059] Referring again to Figures 3 and 4, in some embodiments, the extruder 124 has a first preset position and a second preset position relative to the injection chamber 121. When the extruder 124 is in the first preset position, the inlet 122 is open, and the inlet 122, the injection chamber 121, and the outlet 123 are interconnected. When the extruder 124 is in the second preset position, the extruder 124 seals the inlet 122, and the injection chamber 121 is connected to the outlet 123.

[0060] For example, the first preset position is the initial position of the extruder 124. At this time, the plunger 1242 is located above the first cavity 1211, and the feed port 122 is located in the middle of the first cavity 1211 and is in an open state, so that the molten material can be added into the first cavity 1211 through the feed port 122. The second preset position is the position where the extruder 124 reaches the maximum displacement. At this time, the plunger 1242 is located at the bottom of the first cavity 1211, so that the molten material is injected into the second cavity 1212 and injected into the mold cavity through the discharge port 123. At the same time, the outer wall of the push rod 1241 is in contact with the wall of the first cavity 1211, thereby blocking the feed port 122 located on one side of the wall of the first cavity 1211 and preventing the molten material from flowing back during the extrusion process.

[0061] In some embodiments, the extruder 124 includes a push rod 1241 and a plunger 1242. The plunger 1242 is connected to one end of the push rod 1241 and is slidably disposed in the injection chamber 121. When the extruder 124 moves from the first preset position to the second preset position, the molten material in the injection chamber 121 is extruded from the outlet 123.

[0062] For example, the plunger 1242 can be similar to a piston structure. Driven by the push rod 1241, the plunger 1242 can reciprocate within the first cavity 1211, thereby injecting the molten material in the first cavity 1211 into the mold cavity.

[0063] In some embodiments, the injection chamber 121 includes a first chamber 1211 and a second chamber 1212 that are independent of each other. The first chamber 1211 is connected to the second chamber 1212. The inlet 122 is disposed on one side of the first chamber 1211 and is connected to the first chamber 1211. The outlet 123 is disposed on one side of the second chamber 1212 and is connected to the second chamber 1212. The extruder 124 is slidably inserted through the first chamber 1211.

[0064] For example, the first cavity 1211 is a feeding cavity and is connected to the feeding port 122, and the second cavity 1212 is a discharging cavity and is connected to the discharging port 123, so that the molten liquid is added into the first cavity 1211 through the feeding port 122, and then discharged from the second cavity 1212 and the discharging port 123 under the extrusion of the extruder 124.

[0065] A feed hopper is provided at the end of the feed inlet 122 away from the first cavity 1211. The feed hopper has a conical structure, which facilitates the addition of molten liquid to the feed hopper during feeding, and allows it to flow into the feed inlet 122 and the first cavity 1211 along the hopper wall.

[0066] In this application, the flow direction of the first cavity 1211 and the second cavity 1212 can be set according to actual needs, and is not specifically limited here. For example, the injection direction of the first cavity 1211 can be from top to bottom or from bottom to top.

[0067] Referring to Figure 6, the first cavity 1211 and the second cavity 1212 can be connected at a certain angle, thereby adjusting the direction of the discharge port 123 and allowing for injection of molten metal from different directions. This also extends the flow length of the molten metal within the cavity, reduces the molten metal feeding speed, and allows sufficient time for residual air and molten metal to escape, thus improving the die-casting performance of the product.

[0068] In some embodiments, the second cylinder 120 further includes a partition 125, which divides the injection chamber 121 into a first chamber 1211 and a second chamber 1212.

[0069] For example, both the first cavity 1211 and the second cavity 1212 are vertically arranged, and the partition 125 separates the first cavity 1211 and the second cavity 1212. The bottom ends of the first cavity 1211 and the second cavity 1212 are connected to form a U-shaped structure. When the surface pressure of the molten liquid inside the two cavities is the same, the height of the molten liquid in the two cavities is the same.

[0070] Embodiments of this application also provide a die-casting machine, including the furnace 100 in any of the above embodiments.

[0071] For example, the die-casting machine may also include a thrust device, with one end of the extruded part 124 away from the first cavity 1211 connected to the output end of the thrust device, so that under the drive of the thrust device, the push rod 1241 drives the plunger 1242 to perform reciprocating pressing operations.

[0072] In addition, the thrust device can be a pneumatic cylinder, hydraulic cylinder, linear motor or other device with telescopic function. The specific choice can be made according to actual needs, and no specific limitation is made here.

[0073] This embodiment includes the furnace 100 of any of the above embodiments, and therefore has all the beneficial effects of the furnace 100 of any of the above embodiments, which will not be described in detail here.

[0074] Referring to Figure 7, an embodiment of this application also provides a die-casting method, which employs the furnace 100 or die-casting machine in any of the above embodiments.

[0075] Die casting methods include:

[0076] S10, add material into the melting chamber 111 of the first cylinder 110.

[0077] Referring to Figure 1, for example, the cover of the first cylinder 110 can be opened to expose the melting chamber 111, allowing material to be added to the melting chamber 111. Specifically, material can be manually shoveled and poured in, or solid raw materials can be added to the melting chamber 111 of the first cylinder 110 via a conveying device, thus achieving automatic material feeding.

[0078] S20, start the heating element 130 to make the melting chamber 111 reach the preset melting temperature of the material and obtain the molten material.

[0079] For example, after the material is added, the heating element 130 is activated to heat the melting chamber 111, so that the temperature inside the melting chamber 111 reaches the preset melting temperature of the material, and the material is completely melted to obtain a molten material.

[0080] S30, the extruder 124 is adjusted to the first preset position, so that the feed port 122 of the second cylinder 120 is opened, and the molten material is added into the injection chamber 121 of the second cylinder 120.

[0081] Referring to Figure 3, for example, when adding molten material to the second cylinder 120, the extruder 124 is located at the top of the first cavity 1211, and the feed inlet 122 is open. The feeding operation can be performed using a transfer device, such as a spoon. Specifically, an industrial camera and a robotic arm can work together. The spoon is mounted on the working end of the robotic arm, and the robotic arm uses the industrial camera to obtain the corresponding feeding position, thereby controlling the spoon to feed material into the feed inlet 122.

[0082] Since the first cavity 1211 and the second cavity 1212 form a U-shaped connection structure, when molten material is added to the first cavity 1211, the second cavity 1212 can also maintain the same level of molten material as the first cavity 1211, which facilitates subsequent pressing and injection.

[0083] S40, the extruder 124 presses the molten material in the injection chamber 121 and blocks the feed port 122, so that the molten material is injected into the mold cavity through the discharge port 123.

[0084] Referring to Figure 4, exemplarily, after feeding is completed, the extruder 124, driven by the thrust device, presses down on the molten material in the first cavity 1211. The plunger 1242 is pressed down to the second preset position at the bottom, and the molten material in the second cylinder 120 is discharged from the outlet 123 and injected into the mold cavity. At the same time, the push rod 1241 fits against the wall of the first cavity 1211, blocking the feed inlet 122 to prevent the molten material from flowing back during the extrusion process.

[0085] S50, the extrusion part 124 is reset to the first preset position, the feed port 122 is opened, and part of the molten material flows back to the injection chamber 121.

[0086] Referring to Figure 5, for example, when the extruder 124 reaches the second preset position of its maximum descent height, the thrust device drives the extruder 124 to reset and return to the first preset position. The feed port 122 is then open, allowing for the next feeding and pressing operation. This cycle repeats to complete the production of the die-cast workpiece.

[0087] The die-casting method provided in this application embodiment involves a solution in a semi-liquid and semi-solid state during the pressing process. The resulting die-cast workpiece has high density and low stress, and even small, precise areas can be molded into products with perfect appearance. It possesses the anodized appearance and mechanical properties of CNC (Computerized Numerical Control) machined sheets. The product's density can exceed 98%, reducing defects caused by porosity or high-speed injection.

[0088] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0089] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A furnace, comprising: A first cylinder body, the first cylinder body being provided with a melting chamber, the melting chamber being used for material melting; At least one second cylinder body, each second cylinder body is provided with a liquid injection chamber, a feed inlet and a discharge outlet, the feed inlet and the discharge outlet being respectively connected to the liquid injection chamber; The molten material formed by melting in the melting chamber flows into the injection chamber through the feed port and can also be discharged through the discharge port under the action of external force.

2. The furnace according to claim 1, wherein, Each of the second cylinders is disposed in the melting chamber so as to keep the second cylinders warm by the molten material formed by melting in the melting chamber.

3. The furnace according to claim 2, wherein, The furnace also includes a heating element disposed inside the melting chamber for maintaining the temperature of the molten material in the first cylinder and the molten material in the second cylinder.

4. The furnace according to any one of claims 1-3, wherein, The second cylinder also includes an extrusion member, which is slidably disposed in the injection cavity and fits against the inner wall of the injection cavity. The inlet and outlet are respectively disposed on different sides of the extrusion member.

5. The furnace according to claim 4, wherein, The extrusion member has a first preset position and a second preset position relative to the injection cavity; When the extruder is located in the first preset position, the feed port is in the open state, and the feed port, the injection chamber and the discharge port are interconnected. When the extruder is in the second preset position, the extruder seals the feed port, and the injection chamber is connected to the discharge port.

6. The furnace according to claim 5, wherein, The extrusion component includes a push rod and a plunger. The plunger is connected to one end of the push rod and is slidably disposed in the injection chamber. When the extrusion component moves from the first preset position to the second preset position, it extrudes the molten material in the injection chamber and discharges it from the outlet.

7. The furnace according to any one of claims 4-6, wherein, The injection chamber includes a first chamber and a second chamber that are independent of each other. The first chamber is connected to the second chamber. The inlet is located on one side of the first chamber and is connected to the first chamber. The outlet is located on one side of the second chamber and is connected to the second chamber. The extruder slides through the first chamber.

8. The furnace according to any one of claims 1 to 7, wherein, The second cylinder also includes a liquid injection pipe, one end of which is sealed to the discharge port.

9. A die-casting machine comprising the furnace according to any one of claims 1 to 8.

10. A die-casting method, employing the furnace of any one of claims 1 to 8 or the die-casting machine of claim 9, the die-casting method comprising: Material is added to the molten material chamber of the first cylinder; The heating element is activated to bring the melting chamber to the preset melting temperature of the material, thereby obtaining the molten material. The extruder is adjusted to the first preset position, so that the feed port of the second cylinder is opened, and the molten material is added into the injection chamber of the second cylinder; The extruder presses down on the molten material in the injection chamber and blocks the inlet, so that the molten material is injected into the mold cavity through the outlet. The extruder is reset to the first preset position, the feed port is opened, and part of the molten material flows back to the injection chamber.

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