CN114453559A - Time-delay pouring method for large casting - Google Patents

Time-delay pouring method for large casting Download PDF

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Publication number
CN114453559A
CN114453559A CN202210102543.9A CN202210102543A CN114453559A CN 114453559 A CN114453559 A CN 114453559A CN 202210102543 A CN202210102543 A CN 202210102543A CN 114453559 A CN114453559 A CN 114453559A
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pouring
casting
time
gating system
gate
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CN114453559B (en
Inventor
裴志勇
薛吉庆
殷立坤
杨继伟
郑永杰
钱红武
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Dalian Huarui Heavy Industry Casting Co ltd
Dalian Huarui Heavy Industry Group Co Ltd
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Dalian Huarui Heavy Industry Casting Co ltd
Dalian Huarui Heavy Industry Group Co Ltd
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    • 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
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D35/00Equipment for conveying molten metal into beds or moulds
    • B22D35/04Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D37/00Controlling or regulating the pouring of molten metal from a casting melt-holding vessel

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Continuous Casting (AREA)

Abstract

The invention provides a time-delay pouring method of a large casting, which comprises the steps of determining parameters of an inner pouring gate according to the structure of the casting and the amount of molten iron required by the casting, obtaining an original pouring system, calculating the vertical height between the inner pouring gate at the lowest point and the inner pouring gate at the highest point, and calculating the time required by the casting to be filled in the height; if the used time exceeds 20s, a delay gating system is established to gate the casting, the inner gates near the inner gate at the highest point are divided into a class, an independent gating system is established for the class, and the rest inner gates are main gating systems; and determining the time T for the independent gating system to delay opening. The invention solves the problems that the large casting with a large number of inner gates and height difference is easy to have cold shut, insufficient casting and other defects when the traditional gating system is adopted, and can realize reasonable casting and stable iron liquid filling, thereby avoiding major quality hidden dangers and reducing the rejection risk of large casting products.

Description

Time-delay pouring method for large casting
Technical Field
The invention relates to the technical field of large casting pouring, in particular to a time-delay pouring method for a large casting.
Background
The large-scale steel castings and iron castings which are cast by sand molds usually adopt a bottom pouring type pouring system, namely, an ingate is arranged at the bottom of the castings, and molten metal is introduced into a cavity from the bottom of the castings through a sprue, a cross runner and the ingate, so that the method has the advantages of uniform and stable mold filling, reduction of oxidation and splashing of the molten metal, benefit for exhaust and the like. In actual production, the molten iron amount of a large casting is large (often exceeding 60t), the structure is complex, and dozens of inner gates need to be arranged at different positions of the bottom of the casting at the same time to meet pouring requirements. When the bottom of the mold with the inner sprue is large in outline size and is not horizontal, the inner sprue at different positions has height difference. At this time, in the same set of gating system, according to the principle of a communicating vessel, the molten iron rising plane is at the same height, the ingate at the lower part enters the molten iron first, and for the ingate at the higher part, the molten iron stagnates for a long time in the ingate ceramic tube until the whole molten iron liquid level rises to the same height, and the molten iron can be introduced into the cavity. In the process, because the size of the ingate is small (the diameter is about 50mm or 60mm), the temperature of a small amount of molten iron standing at a high position in the ingate can be reduced very quickly, and when the liquid level rises to the extent that the molten iron can be introduced into the cavity in the later period, the low-temperature molten iron in the standing state flows into the cavity, so that the risk of cold shut of the local part of the casting is caused. If the height difference of the ingate is extremely large and the rising speed of the liquid level is slow, the stagnant molten iron in the ingate at the high position is in a liquid-solid coexisting state or a solidification state seriously, so that the molten iron is prevented from being injected, and the risk of insufficient pouring is caused.
Therefore, a time delay pouring method for a large casting needs to be developed to solve the above problems caused by the fact that the traditional pouring system has a large height difference between the inner gates.
Disclosure of Invention
According to the technical problem, the delay pouring method for the large casting is provided.
The technical means adopted by the invention are as follows:
a time delay pouring method for a large casting comprises the following steps:
determining the number, position and size of the inner gates according to the structure of the casting and the amount of molten iron required by the casting;
determining the sizes and the quantities of a pouring box, a cross pouring channel and a straight pouring channel used in the pouring process according to the molten iron amount, the distribution of the inner pouring gates and the technological parameters required by casting pouring to obtain an original pouring system;
calculating the vertical height between the ingate positioned at the lowest point and the ingate positioned at the highest point in the plurality of ingates, calculating the weight of molten iron required by the casting in the height, and obtaining the time for filling the molten iron of the part of the casting according to the weight of the molten iron;
if the used time does not exceed 20s, the original pouring system is adopted to pour the casting;
if the used time exceeds 20s, a delay gating system is established to gate the casting, and the establishment mode of the delay gating system is as follows: dividing the inner gates near the inner gate at the highest point into one type, establishing an independent gating system for the inner gates, taking the other inner gates as a main body gating system, re-confirming the sizes and the numbers of the pouring gate boxes, the cross runners and the straight runners used by the independent gating system, re-confirming the sizes and the numbers of the pouring gate boxes, the cross runners and the straight runners used by the main body gating system on the basis of the original gating system, and combining the main body gating system and the independent gating system into a time delay gating system;
and determining the time T required by the independent casting system to delay the opening, wherein T is T1-T2, T1 is the time required by the main casting system to be cast to the lowest ingate of the independent casting system, T1 comprises two parts, one part is the time required by the main casting system to fill, and the other part is the time required by the ingate at the lowest point of the independent casting system to be filled after molten iron enters the casting mold. T2 is only the time required for the independent gating system to fill itself; the mold filling time of T1 and T2 in the formula is obtained according to the weight of the molten iron filled in each part.
And carrying out three-dimensional modeling on the delayed pouring system, carrying out simulation by using simulation software, verifying the accuracy of the time of filling, delaying opening and the like of the delayed pouring system, and optimizing and correcting the deviation. The simulation software is Magma.
Compared with the prior art, the invention has the following advantages:
1. the problem of the large-scale foundry goods that the quantity is many, and have the difference in height easily take place cold shut, water defects such as not enough when adopting traditional gating system is solved, can realize the reasonable pouring of foundry goods and the iron liquid fills the type steadily to avoid great quality hidden danger, reduce large-scale foundry goods product and scrap the risk.
2. The method and the theoretical basis for calculating the delay time of the independent gating system are provided, and the verification is carried out through simulation software, so that the rationality and the accuracy of the prenatal preparation technical scheme are greatly improved, the development period of a new product is shortened, and the development risk is reduced.
3. The method of the invention has the advantages of clear product characteristics, wide application range, and strong popularization and application.
Based on the reasons, the invention can be widely popularized in the fields of large casting pouring and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a graph of a distribution of gate locations in an original gating system in accordance with an embodiment of the present invention;
FIG. 2 is a schematic view of an original gating system in an embodiment of the present invention;
FIG. 3 is a graph illustrating an analysis of a height difference of an in-gate in an original runner system in accordance with an embodiment of the present invention;
FIG. 4 is a graph of a pattern of ingate locations in a delayed casting system in accordance with an embodiment of the present invention;
FIG. 5 is a schematic view of a delayed runner system according to an embodiment of the present invention;
FIG. 6 is a schematic diagram illustrating time calculation of a delayed gating system according to an embodiment of the present invention;
FIG. 7 shows the result of a mold filling simulation of the original gating system in an embodiment of the present invention;
FIG. 8 shows the simulation result (35s) of the start of filling of the independent casting system itself according to the embodiment of the present invention;
FIG. 9 shows the result of a mold filling simulation (40s) performed on a mold by the independent casting system according to the embodiment of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless it is specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. Any specific values in all examples shown and discussed herein are to be construed as exemplary only and not as limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present invention, it is to be understood that the orientation or positional relationship indicated by the directional terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc., are generally based on the orientation or positional relationship shown in the drawings, and are used for convenience of description and simplicity of description only, and in the absence of any contrary indication, these directional terms are not intended to indicate and imply that the device or element so referred to must have a particular orientation or be constructed and operated in a particular orientation, and therefore should not be considered as limiting the scope of the present invention: the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "above … … surface," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of the present invention should not be construed as being limited.
As shown in fig. 1 to 9, a method for delayed pouring of a large casting includes:
1. confirming the inner pouring gate parameters: the estimated molten iron amount of the casting is 84-88 tons, the diameter size of phi 60 is selected as the inner gate, the initial number is set to be 44, and the positions are uniformly distributed at the bottom of the casting, as shown in FIG. 1.
2. And (3) estimating parameters of other components of the pouring system: preliminarily estimating parameters of each component of an original pouring system, and planning to select 2 pouring boxes of 45 tons and 2 straight pouring channels according to the molten iron quantity value; and determining the sizes of the sprue gate as phi 120 and the side gate as phi 110 and phi 70 according to the distribution of the inner gate and the parameters required by the open type gating system. The sum proportion of the sectional areas of all the components is sigma-delta: e, horizontal movement: Σ inner ═ 1:1.18:5.5 as shown in fig. 2.
3. Analysis of height difference of inner pouring gate: the vertical height between the lowest point and the highest point in the ingate position is calculated to be about 700mm, and the weight of the molten iron occupied by the ingate at the height is calculated to be about 20.5 tons (as shown in figure 3). And (3) under the design of the original gating system preset in the step (2), calculating the partial mold filling time, wherein the formula is as follows: t ═ T1 ═ T2'. Wherein T' is the molten iron filling time of the high and low difference casting part; t1' is the time needed when the molten iron is filled to the highest point of the inner pouring gate; t2' is the time required for the mold to fill the mold to the lowest point of the ingate.
Through calculation, when the molten iron is filled to the lowest point of the inner pouring gate, the amount of the molten iron flowing into the pouring gate is about 6.2 tons, and the filling time T2' is 10 s; when the molten iron is filled to the highest point of the inner sprue, the molten iron flows into the inner sprue for 26.7 tons, and the filling time T1' is 44 s; therefore, the molten iron filling time T ═ T1 ═ T2 ═ 34s >20s of the high and low difference casting parts, certain cold shut and insufficient pouring risks exist, and the delayed pouring system in the invention needs to be adopted to solve the problem.
4. Establishing a delay gating system: according to the analysis result, determining to adopt a delay gating system, wherein the establishment mode of the delay gating system is as follows:
(1) firstly, optimizing the final position of the inner pouring gate, and dividing the inner pouring gate near the inner pouring gate at the highest point to establish a set of independent pouring system. After calculation and analysis, the amount of molten iron in the casting is corrected to 84 tons, the number of the inner gates is set to 42, after local modification of the distribution mode, the positioning points of 13 inner gates (14 inner gates are calculated) near the highest point inner gate are set to be independent gating systems, as shown in fig. 4.
(2) The parameters of each component of the independent gating system are confirmed according to the divided 14 ingates. Through calculation, 1 gate box with 35 tons, 1 straight gate channel with phi 120 and 2 cross gate channels with phi 100 are determined and selected. The sum proportion of the sectional areas of all the components of the independent pouring system is sigma-delta: e, horizontal movement: Σ inner is 1:1.39:3.5 as shown in fig. 5.
(3) And recalculating and checking parameters of the rest of the ingates on the basis of the original gating system, and updating the sizes and the number of the selected gating boxes, the cross runners, the straight runners and the like to obtain the main body gating system. After the parameters are corrected, the main body gating system needs to use 2 gate boxes of 30 tons, 2 sprues of phi 110, and fixed gate seats of the transverse pouring channels. The sum proportion of the cross sections of the straight pouring channel and the inner pouring channel of the main body pouring system is sigma-straight: Σ inner is 1:4.17 as shown in fig. 5.
(4) After the design is finished, the integral structure of the delay pouring system is formed, and the ingate groups at the high point and the low point are divided into an independent pouring system and a main pouring system which are controlled and controlled respectively, so that basic conditions are created for delay pouring. Wherein, the independent gating system is planned to flow 28 tons of molten iron, and the main body gating system flows 56 tons of molten iron.
5. The independent gating system needs to delay the calculation of the open time T: the delay time calculation formula is T1-T2, which is as follows:
(1) calculating the time T1 needed by the main body pouring system to pour into the lowest inner pouring gate of the independent pouring system, wherein the inflow of the molten iron is composed of two parts, the first part is the time needed by the main body pouring system to fill the mold, and the inflow of the molten iron in the time is about 4.35 tons; the second part is the time required for filling the mold to the ingate at the lowest point of the independent pouring system after the molten iron enters the casting mold, and the inflow of the molten iron in the time is about 16.85 tons; therefore, the total amount of molten iron inflow was about 21.2 tons, and T1 was obtained as 40s from the amount of molten iron inflow, as shown in fig. 6.
(2) And calculating the time T2 required by the self-filling of the independent pouring system, wherein the weight of the self-required molten iron filling of the independent pouring system is about 1.68 tons, so that the time T2 required by the self-filling is 5 s.
(3) And calculating the time T (T1-T2) for opening the independent gating system in a delayed manner, namely T35 s.
6. Filling simulation and simulation verification: and performing three-dimensional modeling according to the structure of the delayed pouring system and the calculated parameters of each component, performing mold filling simulation by using simulation software, and verifying the mold filling condition, the accuracy of the delay time and the like of the delayed pouring system. The simulation software is Magma.
Proved by verification, the original pouring system has an obvious mold filling problem, in the early stage of mold filling, molten iron at the highest position of an ingate cannot be introduced into a cavity, but is retained in the ingate for a long time until the molten iron is filled to the position after 44S, the retained molten iron enters the cavity, the temperature of the retained molten iron is about 1200 ℃ at the moment, the temperature is 100 ℃ higher than that of molten iron in other areas, and a large cold shut risk exists, as shown in fig. 7.
After the delayed pouring system is applied, the main pouring system is opened preferentially and molten iron is poured, the main pouring system rises along with the liquid level of the molten iron, the independent pouring system is opened 35 th s after pouring is started and the molten iron is poured (as shown in fig. 8), the molten iron in the independent pouring system 40 th s is introduced into the cavity and is converged with the liquid level of the molten iron poured in advance, the temperature of the poured molten iron is about 1340 ℃, the temperature difference with other regional water temperatures is within 10 ℃, the verification effect is very ideal, and calculation data do not need to be corrected again, as shown in fig. 9.
7. In actual production, a time delay pouring system is adopted according to the calculation and analysis results. The product is verified by NDT inspection, has compact structure and no cold shut defect, and is an example of successful application of the invention.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.

Claims (5)

1. A time delay pouring method for a large casting comprises the following steps:
determining parameters of an inner pouring gate according to the structure of the casting and the amount of molten iron required by the casting;
determining parameters of other components used in the pouring process according to the molten iron amount, the parameters of the inner pouring gate and the technological parameters required by casting pouring to obtain an original pouring system, and the method is characterized by further comprising the following steps:
calculating the vertical height between the ingate positioned at the lowest point and the ingate positioned at the highest point in the plurality of ingates, calculating the weight of molten iron required by the casting in the height, and obtaining the time for filling the molten iron of the part of the casting according to the weight of the molten iron;
if the used time does not exceed 20s, the original pouring system is adopted to pour the casting;
if the used time exceeds 20s, a delay gating system is established to gate the casting, and the establishment mode of the delay gating system is as follows: dividing the inner gates near the inner gate at the highest point into one type, establishing an independent gating system for the inner gates, taking the other inner gates as a main body gating system, re-confirming the parameters of other components used by the independent gating system, re-confirming the parameters of other components used by the main body gating system on the basis of the original gating system, and combining the main body gating system and the independent gating system into a time delay gating system;
determining the time T that the independent gating system needs to be delayed for opening, wherein T is T1-T2, T1 is the time required by the main body gating system to be poured to the lowest inner gate of the independent gating system, and T2' is the time required by the independent gating system to fill;
and carrying out three-dimensional modeling on the delayed pouring system, carrying out simulation by using simulation software, verifying the accuracy of the time of filling, delaying opening and the like of the delayed pouring system, and optimizing and correcting the deviation.
2. The delayed pouring method for the large casting according to claim 1, wherein T1 comprises two parts, one part is the time required by the main pouring system to fill the mold, and the other part is the time required by the inner pouring gate from the lowest point of the independent pouring system after the molten iron enters the mold.
3. The delay pouring method for the large casting according to claim 1 or 2, wherein the simulation software is Magma.
4. The time-lapse pouring method for the large casting according to claim 1, wherein the parameters of the in-gates comprise the number, the positions and the sizes of the in-gates.
5. The delayed pouring method for the large casting according to claim 1, wherein the parameters of other components comprise the size and the number of a sprue box, a cross gate and a sprue.
CN202210102543.9A 2022-01-27 2022-01-27 Time-delay pouring method for large castings Active CN114453559B (en)

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