Flaskless Molding Machine Sand Flow Uniformity
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Solution Overview
Problem
In flaskless molding machines, the non-uniform flow of mold sand due to misalignment of communication ports in the sand tanks can lead to sand clogging, requiring the use of mold sand with low compactability, which compromises mold quality and casting product performance.
Innovation Solution
The machine divides the lower sand tank into two independently movable tanks, allowing the adjustment of communication port heights to ensure uniform sand flow, using permeation members for improved fluidity and incorporating movable guides for stable operation, and adjustable nozzles for conforming to model shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the communication ports in the sand tanks are misaligned, then sand flow becomes non-uniform, but this causes sand clogging and requires using mold sand with low compactability which compromises mold quality
Solution Approach 1:
The communication ports are made adjustable rather than fixed, allowing dynamic alignment adjustment to maintain uniform sand flow while using optimal compactability mold sand for high-quality mold production
Solution Approach 2:
The height position of communication ports is changed as a variable parameter that can be adjusted to optimize both sand flow uniformity and mold quality, rather than being fixed at a single position
2Device complexity
If a single lower sand tank is used, then the structure is simple, but the communication port height cannot be adjusted leading to sand clogging
Solution Approach 1:
The single lower sand tank is divided into two separate sand tanks, allowing independent adjustment of communication port heights to ensure uniform sand flow while maintaining reasonable structural complexity
Solution Approach 2:
The divided sand tanks with adjustable communication ports provide dynamic adaptability to maintain reliable sand flow, outweighing the increased structural complexity
3Ease of operation
If the lower flask moves a large distance, then sand can be supplied to the lower molding space, but the machine height increases
Solution Approach 1:
Dividing the sand supply system into multiple tanks with adjustable ports allows sand supply without requiring large vertical movement of the lower flask, thereby reducing machine height
Solution Approach 2:
The adjustable communication ports act as intermediaries that facilitate sand supply through optimized flow paths, reducing the need for large mechanical movements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration prevents sand clogging, allows the use of optimal mold sand for moldability and casting quality, reduces machine height, and enhances model-stripping performance by stabilizing the movement of components and optimizing sand distribution.
Implementation Method 1
an upper sand tank disposed above the upper flask, communicating with a compressed air source
Implementation Method 2
The compressed air blown from the compressed air source supplies the upper blow head with the mold sand stored in the upper sand tank
Implementation Method 3
an upper sand tank disposed above the upper flask, communicating with a compressed air source, being open at a lower end thereof, and internally storing mold sand
Implementation Method 4
The upper squeeze cylinder applies a downward pressure to the mold sand in the upper molding space, and the lower squeeze cylinder applies an upward pressure to the mold sand in the lower molding space. Accordingly, the hardness of the mold sand is increased.
Data Source
Figure 1
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AI summary
A flaskless molding machine includes: an upper flask and a lower flask that can clamp a match plate; an upper sand tank that is disposed above the upper flask, is open at a lower end, and internally stores mold sand; an upper plate that is attached to a lower end of the upper sand tank, with a supply port being formed in the upper plate, and can enter and be retracted from the inside of the upper flask; a first lower sand tank that internally stores the mold sand, and has a first communication port for discharging the mold sand; a second lower sand tank that is disposed below the lower flask, is open at an upper end thereof, has a second communication port capable of communicating with the first communication port of the first lower sand tank, and stores the mold sand; a lower plate that is attached to an upper end of the second lower sand tank, with a supply port being formed in the lower plate, and can enter and be retracted from the inside of the lower flask; a drive unit that moves the second lower sand tank in a vertical direction; and an adjustment drive unit that moves the first lower sand tank in the vertical direction.