CN111822658A - Forming die of automobile exhaust manifold and implementation method thereof - Google Patents

Forming die of automobile exhaust manifold and implementation method thereof Download PDF

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Publication number
CN111822658A
CN111822658A CN202010597530.4A CN202010597530A CN111822658A CN 111822658 A CN111822658 A CN 111822658A CN 202010597530 A CN202010597530 A CN 202010597530A CN 111822658 A CN111822658 A CN 111822658A
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CN
China
Prior art keywords
riser
die
module
exhaust manifold
pouring
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Pending
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CN202010597530.4A
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Chinese (zh)
Inventor
刘刚
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Jiangyin Hongchuang Kinetic Energy Technology Co ltd
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Jiangyin Hongchuang Kinetic Energy Technology Co ltd
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Application filed by Jiangyin Hongchuang Kinetic Energy Technology Co ltd filed Critical Jiangyin Hongchuang Kinetic Energy Technology Co ltd
Priority to CN202010597530.4A priority Critical patent/CN111822658A/en
Publication of CN111822658A publication Critical patent/CN111822658A/en
Pending legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/22Moulds for peculiarly-shaped castings
    • B22C9/24Moulds for peculiarly-shaped castings for hollow articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082Sprues, pouring cups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/088Feeder heads

Abstract

The invention relates to a forming die of an automobile exhaust manifold and an implementation method thereof, wherein the forming die comprises an upper die and a lower die, the upper die is used for printing an upper die cavity on an upper sand box, the lower die is used for printing a lower die cavity on a lower sand box, and the upper die cavity and the lower die cavity are combined to form a pouring system of the automobile exhaust manifold; the upper pouring system of the upper mold comprises a side riser module, a heating block is arranged on the side riser module, and when the upper mold stamps a side riser on the upper sand box, the heating block is separated from the side riser module and transferred to the top of the side riser for rapidly heating molten iron in the side riser, so that a temperature field for an isolated hot spot is formed. The difficult problem of isolated hot spot department of exhaust manifold produces the shrinkage cavity of shrinkage porosity easily has been solved to this application, and the molten iron casting system that this forming die corresponds has saved chill, the feeding runner of traditional big flange department, reduces the feeding riser, improves the utilization ratio of molten iron and has improved the yield promptly, simplifies the follow-up finishing operation of casting blank.

Description

Forming die of automobile exhaust manifold and implementation method thereof
Technical Field
The invention relates to a forming die and a forming method of an automobile exhaust manifold.
Background
Automotive exhaust manifolds are important components in automobiles and are normally screwed into the cylinder block or head and communicate downwardly with the exhaust pipe. The exhaust manifold of the automobile serves to collect exhaust gas discharged from each cylinder and to discharge the exhaust gas to the atmosphere through an exhaust pipe and a muffler. The main requirement of the exhaust manifold of the automobile is to reduce exhaust resistance when exhausting, and when a certain pipe exhausts outwards, the pipe collides with the incoming unpurified exhaust gas from other cylinders, so that the exhaust resistance is generated. Therefore, the cylinders of the exhaust manifold need to be branched, and the cylinders are separated as much as possible, so that the exhaust resistance is reduced, and the output power of the engine is not influenced. At present, two types of cast iron exhaust manifolds and stainless steel exhaust manifolds exist in the machining process. Of which cast iron exhaust manifolds are relatively widely used.
Patent document No. CN111215579A discloses a casting process for preventing internal continuous thermal joint shrinkage cavity, which comprises the following steps of 1, manufacturing a sand shell by using precoated sand as a raw material; step 2, baking the sand shell, and then pouring the smelted molten steel into the sand shell; step 3, immediately placing the sand shell on a steel grid after the pouring is finished, introducing cold air or compressed air into the lower part of the grid, forcibly cooling the bottom and the inner cavity of the sand shell, and taking down the casting; and 4, performing shot blasting, riser cutting, heat treatment, secondary shot blasting and finishing on the casting to obtain a blank product. After the pouring is finished, the sand shell is quickly placed on the steel grating, cold air or compressed air is introduced into the lower part of the grating to forcibly cool the bottom and the inner cavity of the sand shell, so that continuous heat close to the bottom and the middle can be quickly solidified in an energy-saving manner, and shrinkage cavities and shrinkage porosity in the sand shell are eliminated.
The patent document of publication No. CN206794676U discloses a casting model structure for thin-wall exhaust pipe products, which is characterized in that the casting model structure consists of a sprue cup, a vertical sprue, a horizontal sprue, a slag filter, a water inlet sheet, an inner cavity sand core, a riser and a casting cavity; a vertical pouring gate is connected below the pouring cup, and the output end of the vertical pouring gate is connected with a horizontal pouring gate; a slag filter is arranged in the cross pouring gate; the part of the cross gate behind the slag filter is divided into two cross gates, and the two shunted molten irons are respectively input into a riser from a lower die through a water inlet sheet; the water inlet sheet adopts a wedge-shaped water inlet sheet; the inner cavity sand core is arranged in the casting cavity. The utility model has the advantages that: the utility model discloses the model structure can produce effective feeding to the position of entrying through the design of wedge income water piece and prevent shrinkage porosity, gas leakage, reduces the casting defect that the product caused because shrinkage porosity, gas leakage etc to reduce the waste of manpower, material resources, financial resources.
The publication number CN205904387U discloses a high nickel ductile iron exhaust pipe casting system, which comprises a sprue, cross runners arranged on two sides of the lower part of the sprue, and ingates arranged on two sides of the cross runners; the tail end of the ingate is connected with a feeding head, the feeding head is connected with the air inlet flange surfaces at two sides of the exhaust pipe body through a short-circuit ingate, the exhaust pipe body is provided with a heat-insulating feeding head in the middle of the air inlet flange surface, and the air outlet flange of the exhaust pipe body is provided with a heat-insulating feeding head; when the utility model is adopted to cast the exhaust pipe of the type, the process yield is improved to 42 percent from the original 33 percent; meanwhile, the use of a ceramic slag avoiding net is cancelled, so that the phenomenon that the root of the air outlet flange is shrunk and air is leaked is solved; the product percent of pass is improved from 69 percent to 94 percent.
The exhaust manifold consists of a main pipe and a plurality of branch pipes, wherein the branch pipes are provided with independent small flanges, the branch pipes are converged to the main pipe, and the main pipe is provided with a large flange. The waste gas from a plurality of branch pipes is gathered and discharged outside through the large flange, the large flange is subject to severe working conditions, so the requirement on the structural strength is high, and when the large flange is molded in a cast iron mode, the molding structure is in a concave-convex shape due to the isolated hot spots corresponding to the large flange, so that shrinkage porosity and shrinkage cavity are easily generated at the isolated hot spots. The shrinkage porosity and shrinkage cavity forming principle is that in the process of cooling and solidifying molten iron, because gaps between iron atoms are gradually reduced along with the temperature of the molten iron to form smaller and smaller molten iron shrinkage, the shrinkage porosity and shrinkage cavity can be formed under the condition that the molten iron shrinkage in the isolated heat node center area cannot be compensated.
In the prior art, riser feeding is mostly adopted to solve shrinkage porosity and shrinkage cavity, molten iron is fed to an isolated hot spot of a casting through an ingate and is fed to the isolated hot spot by the riser, and the corresponding feeding principle is that the molten iron is fed by utilizing a temperature field of which the temperature of the riser is higher than that of the isolated hot spot. The solution of publication No. CN205904387U is the riser feeding principle adopted. In addition, the publication No. CN206794676U adopts a wedge-shaped water inlet sheet to change the molten iron flow structure to realize feeding, and the publication No. CN111215579A adopts a forced cooling mode to realize feeding. The riser feeding is adopted, the molten iron utilization rate can be reduced due to the arrangement of the riser and the ingate, two chilling blocks are generally arranged at the large flange, the chilling blocks at the large flange have small recovery rate, chilling block recovery operation is additionally added, and the production efficiency is not beneficial.
Disclosure of Invention
The invention aims to provide a forming die of an automobile exhaust manifold, which is used for casting the exhaust manifold by using a sand box formed by the forming die, can solve the problem that an isolated hot spot of the exhaust manifold is easy to produce shrinkage porosity, and a molten iron casting system corresponding to the forming die saves cold iron and a feeding runner at the traditional large flange, reduces a feeding head, improves the utilization rate of molten iron, namely improves the yield, and simplifies the subsequent finishing operation of a casting blank.
The technical scheme for realizing the aim of the invention is as follows: a forming die of an automobile exhaust manifold comprises an upper die and a lower die, wherein the upper die is used for printing an upper die cavity on an upper sand box, the lower die is used for printing a lower die cavity on a lower sand box, and after the upper sand box and the lower sand box are closed, the upper die cavity and the lower die cavity are closed to form a pouring system of the automobile exhaust manifold; the upper die comprises an upper die plate, an upper die formed on the surface of the upper die plate and matched with the upper part of the automobile exhaust manifold, and an upper pouring system, wherein the upper die is communicated with the upper pouring system; the lower die comprises a lower template, a lower model which is formed on the surface of the lower template and is matched with the lower model of the automobile exhaust manifold, and a lower pouring system, wherein the lower model is communicated with the lower pouring system; the upper casting system comprises a side riser module, the side riser module is positioned at the downstream of a large flange of the upper model, a clamping groove is formed in the side riser, a heating block is arranged in the clamping groove, and when the side riser module molds the side riser on an upper sand box, the heating block is separated from the side riser module and is suspended at the top of the side riser for rapidly heating molten iron in the side riser, so that a temperature field of the side riser to an isolated hot spot on the large flange side is formed; the lower casting system comprises a side filling chamber module, the side filling chamber module is positioned at the downstream of the isolated hot spot of the lower mold, and the side filling chamber module is vertically communicated with the side riser in a side filling chamber printed on the upper mold of the lower mold box and used for storing molten iron and feeding the molten iron to the isolated hot spot on the large flange side under the action of the temperature field.
Furthermore, the upper pouring system further comprises a plurality of riser modules, the number of the riser modules is the same as that of the branch pipes of the automobile exhaust manifold, the riser modules are arranged at the upstream of the branch pipes in a one-to-one correspondence mode, and risers formed on the upper sand box of the riser modules are used for feeding small flanges of the branch pipes. And each small flange independently feeds through a riser without mutual interference.
Furthermore, the upper pouring system further comprises a plurality of upper filling chamber modules, the number of the upper filling chamber modules is the same as that of branch pipes of the automobile exhaust manifold, the upper filling chamber modules are connected with the end faces of the small flanges of the upper model in a one-to-one correspondence mode, and the riser modules are arranged above the upper filling chamber modules in a one-to-one correspondence mode. The lower pouring system further comprises a plurality of lower filling chamber modules, the number of the lower filling chamber modules is the same as that of the branch pipes of the automobile exhaust manifold, the lower filling chamber modules are connected with the end face of the small flange of the lower mold in a one-to-one correspondence mode, and the lower filling chambers formed on the lower sand box by the lower filling chamber modules correspond to the upper filling chambers formed on the upper sand box by the upper filling chamber modules in an up-and-down correspondence mode. The upper and lower filling chambers are jointed to form a complete filling chamber, and molten iron is poured into each branch pipe through the filling chambers respectively.
Furthermore, the upper pouring system further comprises an upper pouring gate module, an inner pouring gate module and a sprue module, the riser modules are sequentially connected through the inner pouring gate module, the sprue module is connected with the inner pouring gate module, and the upper pouring gate module is not connected with the sprue module. The lower pouring system further comprises a lower horizontal pouring gate module and a sprue bottom module, the lower horizontal pouring gate module is connected with the sprue bottom module, the sprue bottom module corresponds to the sprue module from top to bottom, and the lower horizontal pouring gate module is connected with the end part of the upper horizontal pouring gate module on the upper and lower projection surfaces.
The molten iron poured from the sprue is received through the bottom of the sprue, is guided downwards through the lower cross gate and then flows into the upper cross gate, and is guided to the ingate through the cross gate, the molten iron is uniformly distributed to a plurality of risers through the ingate and enters the sand core and the die cavity, and the tail end of the riser is a side filling chamber and a side riser.
Preferably, the forming die is provided with a plurality of casting units of the automobile exhaust manifold, the casting units share one sprue, and the casting units are symmetrically arranged by taking the sprue as a center.
The implementation method of the forming die of the automobile exhaust manifold comprises the following steps:
the method comprises the following steps: designing a mould according to a three-dimensional model of an automobile exhaust manifold, wherein the automobile exhaust manifold comprises a plurality of branch pipes and a main pipe, the branch pipes are communicated with the main pipe, pipe orifices of the branch pipes are small flanges, a pipe body of the main pipe is provided with a large flange, and the part of the main pipe close to the large flange corresponds to an isolated hot spot during cast iron molding; when a pouring system is designed, the flow direction of molten iron is designed according to the sequence of a small flange, a plurality of branch pipes, a main pipe, an isolated hot junction and a large flange, so that the distribution of a sprue, a cross runner and an ingate is determined; when designing the upper die and the lower die, the upper die and the lower die of the automobile exhaust manifold are required to be matched in a complementary mode.
Step two: preparing an upper sand box and a lower sand box, correspondingly stamping an upper die cavity and a lower die cavity on the upper sand box and the lower sand box by utilizing an upper die and a lower die, ensuring that a heating block in a side riser is in place for the upper die cavity, then placing a prepared sand core between the upper die cavity and the lower die cavity, enabling the shape of the sand core to be matched with the shape of an inner cavity of an automobile exhaust manifold, and then combining and locking the upper sand box and the lower sand box;
step three: preheating a sand box, pouring hot molten iron into a pouring system through a sprue, receiving the molten iron poured from the sprue through the bottom of the sprue, downwards guiding the molten iron through a lower sprue, then overflowing into an upper sprue, guiding the molten iron to an inner sprue through the upper sprue, uniformly distributing the molten iron to four risers and a filling chamber through the inner sprue, entering a gap between a sand core and a die cavity, and finally reaching a side filling chamber and a side riser. The small flange is fed by using a temperature field of the riser to the small flange, a heating block of the side riser is detonated and combusted after encountering molten iron, and then the molten iron in the side riser and the side filling chamber is reheated, the temperature difference of the side riser compared with the molten iron of the isolated hot link reaches 40-120 ℃, so that the side riser forms a temperature field to the isolated hot link, and the isolated hot link is fed;
step four: and after the molten iron in the casting system is completely solidified, opening the upper sand box and the lower sand box again, removing the sand cores, cutting off risers, and finishing the casting blank.
Compared with the prior art, the invention has the advantages that: a more reasonable forming die is designed for an automobile exhaust manifold, a mode of a heating block at a side riser position is developed for the shrinkage porosity and shrinkage cavity problems of the isolated hot spot at the side of the large flange, and the isolated hot spot is fed through the heating block and a side filling chamber.
The traditional feeding of the isolated hot spot mainly depends on a side riser, an independent side cross runner is arranged for the side riser, and an independent molten iron branch is led from the cross runner to the side riser through the side cross runner, so that the temperature drop of molten iron in the side riser is reduced. Because the temperature of the molten iron is gradually reduced in the process of flowing in the die cavity, and the side riser is positioned at the downstream of the large flange, the temperature of the molten iron reaching the side riser through the die cavity is particularly reduced, and the requirement of a feeding temperature field is difficult to meet, so that a side cross pouring gate is required to be arranged to directly guide the molten iron to the side riser. And further designing a chilling block at the large flange for cooling. Therefore, the temperature difference of the temperature field is improved, and feeding is realized. The cold iron, the side cross gate and the side riser can reduce the utilization rate of molten iron and improve the processing complexity and difficulty of the casting blank after being taken out of the box.
Compared with the traditional method, the method saves chill and side cross runners, the heating block is arranged at the side riser to replace the side riser to store high-temperature molten iron, the reheating temperature of the heating block to the molten iron is higher than that of the traditional side riser, the high temperature difference of a feeding temperature field is larger, and the feeding effect is better. Because the recovery rate of the chill is about 70 percent generally, the chill and a side cross gate are saved, the dependence degree of a side riser is reduced, the utilization rate of molten iron is obviously improved, the subsequent treatment difficulty of casting blanks is simplified, and the operation convenience of casting finishing is improved.
Drawings
FIG. 1 is a schematic structural view of an exhaust manifold of an automobile according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of an alternative perspective view of an automotive exhaust manifold according to an embodiment of the present invention;
FIG. 3 is a schematic structural diagram of an alternative perspective view of an automotive exhaust manifold according to an embodiment of the present invention;
FIG. 4 is a schematic structural diagram of an upper mold according to an embodiment of the present invention;
FIG. 5 is a schematic structural diagram of a lower mold according to an embodiment of the present invention;
FIG. 6 is an enlarged view of a portion of the upper die of an embodiment of the present invention;
FIG. 7 is a schematic structural view of an upper mold of a comparative example of the present invention;
FIG. 8 is a schematic structural view of a lower die of a comparative example of the present invention;
in the figure, 1 branch pipe, 2 main pipes, 3 large flanges, 4 small flanges, 5 isolated hot sections, 6 riser modules, 7 upper filling chamber modules, 7 ' lower filling chamber modules, 8 side riser modules, 9 heating blocks, 10 sprue modules, 10 ' sprue bottom modules, 11 upper runner modules, 11 ' lower runner modules, 12 inner runner modules, 13 side filling chamber modules, 15 side runner modules, 16 traditional side risers and 17 chills.
Detailed Description
The present invention will be described in further detail below with reference to the embodiments of the drawings, which are illustrative and intended to be illustrative of the present invention and are not to be construed as limiting the present invention. In the embodiment, the upstream and the downstream are positions relative to a reference object according to the flowing direction of the molten iron.
Example 1
Referring to fig. 1-3, the automobile exhaust manifold according to the embodiment includes four branch pipes 1 and a main pipe 2, the four branch pipes 1 are communicated with the main pipe 2, the pipe openings of the branch pipes 1 are small flanges 4, the pipe body of the main pipe is provided with a large flange 3, the large flange 3 is different from the branch pipes 1, the four branch pipes 1 are aligned in a straight line, and the main pipe part near the large flange 3 corresponds to an isolated thermal joint 5 during cast iron molding.
Referring to fig. 4 to 6, the mold for forming the exhaust manifold of the automobile includes an upper mold and a lower mold, wherein an upper mold is formed on the surface of the upper mold and a lower mold is formed on the surface of the lower mold by using the symmetrical planes of the four branch pipes 1 as parting planes. And simultaneously, in order to realize molten iron pouring, an upper pouring system and a lower pouring system are formed on the surface of the upper die, the upper pouring system is matched with the upper die, and the lower pouring system is matched with the lower die. The specific distribution structure is as follows:
the upper pouring system comprises a side riser module 8, the side riser module 8 is located at the downstream of a large flange of the upper mold, a clamping groove is formed in the side riser module 8, a heating block 9 is arranged in the clamping groove, and when the side riser module 8 molds a side riser on an upper sand box, the heating block 9 is separated from the side riser module 8 and two side risers are fixed to the top of the upper sand box. The feeder comprises four feeder modules 6, the feeder modules 6 are arranged at the upper parts of the four branch pipes 1 in a one-to-one correspondence mode, and feeders formed on the feeder modules 6 on the cope flask are used for feeding the small flanges 4 of the branch pipes 1. And each small flange independently feeds through a riser without mutual interference. The feeder head structure is characterized by further comprising four upper filling chamber modules 7, wherein the upper filling chamber modules 7 are connected with the end faces of the four small flanges 4 in a one-to-one correspondence mode, and the feeder head modules 6 are arranged above the upper filling chamber modules 7 in a one-to-one correspondence mode.
The lower pouring system comprises a side filling chamber module 13, the side filling chamber module 13 is positioned at the downstream of an isolated hot spot of the lower mold, the side filling chamber module 13 is vertically communicated with a side riser of an upper flask in a side filling chamber printed on an upper mold of the lower flask, is used for storing high-temperature molten iron and feeds the molten iron to the isolated hot spot 5 at the large flange 3 side under the action of a temperature field. The sand box mould also comprises four lower filling chamber modules 7 ', the lower filling chamber modules 7 ' are correspondingly connected with the end surface of the small flange of the lower mould one by one, and the lower filling chambers formed on the lower sand box by the lower filling chamber modules 7 ' are vertically corresponding to the upper filling chambers formed on the upper sand box by the upper filling chamber modules 7. The upper and lower filling chambers are jointed to form a complete filling chamber, and the risers respectively pour molten iron into each branch pipe through the filling chambers.
The upper pouring system further comprises an upper pouring gate module 11, an inner pouring gate module 12 and a sprue module 10, the four riser modules 6 are sequentially connected through the inner pouring gate module 12, the sprue module 11 is connected with the inner pouring gate module 12, and the upper pouring gate module 11 is not connected with the sprue module 10. The lower pouring system further comprises a lower cross gate module 11 'and a sprue bottom module 10', the lower cross gate module 11 'is connected with the sprue bottom module 10', the sprue bottom module 10 'corresponds to the sprue module 10 up and down, and the lower cross gate module 11' is connected with the end part of the upper cross gate module 11 on the upper and lower projection surfaces, so that the formed upper and lower cross gates are connected up and down.
As shown in the figure, the forming die of the embodiment can form two automobile exhaust manifolds at a time, and the gating systems of the two automobile exhaust manifolds are in central symmetry of a sprue. Molten iron flows in the die cavity according to the sequence of the small flange, the plurality of branch pipes, the main pipe, the isolated heat node and the large flange.
The method for forming the automobile exhaust manifold in the embodiment comprises the following steps of:
the method comprises the following steps: designing a forming die according to a three-dimensional model of an automobile exhaust manifold, and preparing the forming die, an upper sand box, a lower sand box and a sand core.
Step two: an upper die cavity and a lower die cavity are correspondingly stamped on an upper sand box and a lower sand box by utilizing an upper die and a lower die, the upper die cavity ensures that a heating block is in place in a side riser, then a prepared sand core is placed between the upper die cavity and the lower die cavity, the shape of the sand core is matched with the shape of an inner cavity of an automobile exhaust manifold, a gap between the sand core and the die cavity is an automobile exhaust manifold body, and the upper sand box and the lower sand box are combined and locked;
step three: preheating a sand box, pouring hot molten iron into a pouring system through a sprue, receiving the molten iron poured from the sprue through the bottom of the sprue, downwards guiding the molten iron through a lower sprue, then overflowing into an upper sprue, guiding the molten iron to an inner sprue through the upper sprue, uniformly distributing the molten iron to four risers and a filling chamber through the inner sprue, entering a gap between a sand core and a die cavity, and finally reaching a side filling chamber and a side riser. And feeding the small flange by using a riser to the temperature field of the small flange. The heating block of the side riser is detonated and combusted after encountering molten iron, so that the temperature of the molten iron in the side filling chamber is increased, and a high temperature difference to an isolated hot spot is formed, thereby realizing the feeding of the isolated hot spot.
Step four: and after the molten iron in the casting system is completely solidified, opening the upper sand box and the lower sand box again, removing the sand cores, cutting off risers, and finishing the casting blank.
Comparative example
As shown in figures 7-8, in the conventional forming die for the same automobile exhaust manifold, the conventional compensation for isolated hot spots mainly depends on the conventional side feeder 16, and a separate side runner 15 is arranged for the side feeder, and an independent molten iron branch is led from the upper runner to the side feeder 16 through the side runner 15, so that the temperature drop of molten iron in the side feeder is reduced, and in addition, cold irons 17 are designed at two ends of a large flange for cooling the large flange. The temperature field of the side riser to the isolated hot spot is formed by the two means, and the isolated hot spot is fed.
Compared with the comparative example, the embodiment omits a chill and a side cross pouring gate, reduces the dependence on a side riser and is beneficial to improving the utilization rate of molten iron. The specific comparison is as follows
In addition, a cold iron is arranged at a large flange of the pain-creating process, because the cold iron is small and is difficult to recover, basically, the recovery rate of the cold iron is about 70%, the cost of the cold iron is increased, 4.3 yuan is required for each cold iron, and 4 cold irons are required for each type. Meanwhile, four chills are formed, so that the operation steps are increased, and the production efficiency is reduced.
The yield of the embodiment is improved to 40.6%, and the chill is eliminated. The method has the advantages of improving the yield, the utilization rate of molten iron, the yield improvement and the operation convenience, particularly obviously reducing the cost, and reducing the cost by 1331 yuan per ton of castings. By contrast, the method has obvious advantages compared with the traditional process.
Although preferred embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that modifications and variations of the present invention are possible to those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (9)

1. The utility model provides a forming die of car exhaust manifold which characterized in that: the upper mould and the lower mould are closed to form a pouring system of the automobile exhaust manifold after the upper and the lower sand boxes are closed;
the upper die comprises an upper die plate, an upper die formed on the surface of the upper die plate and matched with the upper part of the automobile exhaust manifold, and an upper pouring system, wherein the upper die is communicated with the upper pouring system;
the lower die comprises a lower template, a lower model which is formed on the surface of the lower template and is matched with the lower model of the automobile exhaust manifold, and a lower pouring system, wherein the lower model is communicated with the lower pouring system;
the upper casting system comprises a side riser module, the side riser module is located at the downstream of a large flange of the upper model, a clamping groove is formed in the side riser module, a heating block is arranged in the clamping groove, and when the side riser module molds a side riser on an upper sand box, the heating block is separated from the side riser module and transferred to the top of the side riser for rapidly heating molten iron in the side riser, so that a temperature field of the side riser to an isolated hot spot on the large flange side is formed;
the lower casting system comprises a side filling chamber module, the side filling chamber module is positioned at the downstream of the isolated hot spot of the lower mold, and the side filling chamber module is vertically communicated with the side riser in a side filling chamber printed on the upper mold of the lower mold box and used for storing molten iron and feeding the molten iron to the isolated hot spot on the large flange side under the action of the temperature field.
2. The mold for molding an exhaust manifold for an automobile according to claim 1, wherein: the upper pouring system further comprises a plurality of riser modules, the number of the riser modules is the same as that of the branch pipes of the automobile exhaust manifold, the riser modules are arranged at the upstream of the branch pipes in a one-to-one correspondence mode, and risers formed on the upper sand box of the riser modules are used for feeding small flanges of the branch pipes.
3. The forming die for an automobile exhaust manifold according to claim 2, characterized in that: the upper pouring system further comprises a plurality of upper filling chamber modules, the number of the upper filling chamber modules is the same as that of branch pipes of the automobile exhaust manifold, the upper filling chamber modules are connected with the end faces of the small flanges of the upper model in a one-to-one correspondence mode, and the riser modules are arranged above the upper filling chamber modules in a one-to-one correspondence mode.
4. The mold for molding an exhaust manifold for an automobile according to claim 3, wherein: the lower pouring system further comprises a plurality of lower filling chamber modules, the number of the lower filling chamber modules is the same as that of the branch pipes of the automobile exhaust manifold, the lower filling chamber modules are connected with the end face of the small flange of the lower mold in a one-to-one correspondence mode, and the lower filling chambers formed on the lower sand box by the lower filling chamber modules are vertically corresponding to the upper filling chambers formed on the upper sand box by the upper filling chamber modules.
5. The forming die for an automobile exhaust manifold according to claim 2, characterized in that: the upper pouring system further comprises an upper pouring gate module, an inner pouring gate module and a sprue module, the riser modules are sequentially connected through the inner pouring gate module, the sprue module is connected with the inner pouring gate module, and the upper pouring gate module is not connected with the sprue module.
6. The mold for molding an exhaust manifold for an automobile according to claim 5, wherein: the lower pouring system further comprises a lower horizontal pouring gate module and a sprue bottom module, the lower horizontal pouring gate module is connected with the sprue bottom module, the sprue bottom module corresponds to the sprue module from top to bottom, and the lower horizontal pouring gate module is connected with the end part of the upper horizontal pouring gate module on the upper and lower projection surfaces.
7. The forming die for an automobile exhaust manifold according to any one of claims 1 to 6, wherein: the forming die is provided with a plurality of casting units of the automobile exhaust manifold, the casting units share one sprue, and the casting units are symmetrically arranged by taking the sprue as a center.
8. The method of implementing the molding die according to any one of claims 1 to 6, wherein: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
the method comprises the following steps: designing a mould according to a three-dimensional model of an automobile exhaust manifold, wherein the automobile exhaust manifold comprises a plurality of branch pipes and a main pipe, the branch pipes are communicated with the main pipe, pipe orifices of the branch pipes are small flanges, a pipe body of the main pipe is provided with a large flange, and the part of the main pipe close to the large flange corresponds to an isolated hot spot during cast iron molding; when a pouring system is designed, the flow direction of molten iron is designed according to the sequence of a small flange, a plurality of branch pipes, a main pipe, an isolated hot junction and a large flange, so that the distribution of a sprue, a cross runner and an ingate is determined; when designing an upper die and a lower die, the upper die and the lower die of the automobile exhaust manifold are subjected to complementary matching;
step two: preparing an upper sand box and a lower sand box, correspondingly stamping an upper die cavity and a lower die cavity on the upper sand box and the lower sand box by utilizing an upper die and a lower die, ensuring that a heating block in a side riser is in place for the upper die cavity, then placing a prepared sand core between the upper die cavity and the lower die cavity, enabling the shape of the sand core to be matched with the shape of an inner cavity of an automobile exhaust manifold, and then combining and locking the upper sand box and the lower sand box;
step three: preheating a sand box, pouring hot molten iron into a pouring system through a sprue, carrying the molten iron poured from the sprue through the bottom of the sprue, leading the molten iron downwards through a lower horizontal runner, then overflowing into an upper horizontal runner, leading the molten iron to an inner runner through the upper horizontal runner, uniformly distributing the molten iron to four risers and filling chambers through the inner runner, entering gaps between a sand core and a die cavity, and finally reaching a side filling chamber and a side riser, and feeding the temperature field of the small flange to the small flange by using the risers; and feeding the small flange by using a riser to the temperature field of the small flange. The heating block of the side riser is detonated and combusted after encountering molten iron to increase the temperature of the molten iron in the side filling chamber, so that a high temperature difference to an isolated hot spot is formed, and thus the isolated hot spot is fed;
step four: and after the molten iron in the casting system is completely solidified, opening the upper sand box and the lower sand box again, removing the sand cores, cutting off risers, and finishing the casting blank.
9. The implementation method according to claim 8, characterized in that: in the third step, the temperature field means that the high temperature difference of the side riser compared with the isolated hot spot is 40-120 ℃.
CN202010597530.4A 2020-06-28 2020-06-28 Forming die of automobile exhaust manifold and implementation method thereof Pending CN111822658A (en)

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CN104999036A (en) * 2015-08-21 2015-10-28 广东富华铸锻有限公司 Process for solving problem of shrinkage of differential housing castings
CN205904387U (en) * 2016-08-15 2017-01-25 西峡县内燃机进排气管有限责任公司 Nickelic magnesium iron blast pipe the gating system
CN107584076A (en) * 2016-07-06 2018-01-16 科华控股股份有限公司 It is a kind of to set heating block to prevent the structure that rising head binds at the top of casting pressing port
CN108296451A (en) * 2018-01-26 2018-07-20 共享智能铸造产业创新中心有限公司 The parting and its parting scheme of automobile engine exhaust manifold
CN108856650A (en) * 2017-05-15 2018-11-23 科华控股股份有限公司 The accurate pre-buried location structure of the heating block of casting mould exothermic riser
CN208357746U (en) * 2018-06-04 2019-01-11 江阴宏创动能科技有限公司 A kind of effective casting mould of diesel exhaust gas for facilitating casting metal liquid to be vented

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN204135295U (en) * 2014-09-24 2015-02-04 河南省西峡汽车水泵股份有限公司 A kind of high-nickel austenite nodular cast iron blast pipe casting die
CN104999036A (en) * 2015-08-21 2015-10-28 广东富华铸锻有限公司 Process for solving problem of shrinkage of differential housing castings
CN107584076A (en) * 2016-07-06 2018-01-16 科华控股股份有限公司 It is a kind of to set heating block to prevent the structure that rising head binds at the top of casting pressing port
CN205904387U (en) * 2016-08-15 2017-01-25 西峡县内燃机进排气管有限责任公司 Nickelic magnesium iron blast pipe the gating system
CN108856650A (en) * 2017-05-15 2018-11-23 科华控股股份有限公司 The accurate pre-buried location structure of the heating block of casting mould exothermic riser
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CN208357746U (en) * 2018-06-04 2019-01-11 江阴宏创动能科技有限公司 A kind of effective casting mould of diesel exhaust gas for facilitating casting metal liquid to be vented

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