CN117444176A - Low-pressure casting die for aluminum alloy motor shell and using method thereof - Google Patents
Low-pressure casting die for aluminum alloy motor shell and using method thereof Download PDFInfo
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- CN117444176A CN117444176A CN202311800042.9A CN202311800042A CN117444176A CN 117444176 A CN117444176 A CN 117444176A CN 202311800042 A CN202311800042 A CN 202311800042A CN 117444176 A CN117444176 A CN 117444176A
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- 238000005266 casting Methods 0.000 title claims abstract description 84
- 238000000034 method Methods 0.000 title claims abstract description 22
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 9
- 238000001816 cooling Methods 0.000 claims abstract description 152
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 50
- 239000010959 steel Substances 0.000 claims abstract description 50
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 27
- 229910052751 metal Inorganic materials 0.000 claims description 21
- 239000002184 metal Substances 0.000 claims description 21
- 238000004088 simulation Methods 0.000 claims description 6
- 238000007711 solidification Methods 0.000 claims description 5
- 230000008023 solidification Effects 0.000 claims description 5
- 238000004458 analytical method Methods 0.000 claims description 4
- 238000005058 metal casting Methods 0.000 abstract description 2
- 230000000694 effects Effects 0.000 description 13
- 230000010354 integration Effects 0.000 description 10
- 238000009826 distribution Methods 0.000 description 9
- 238000010586 diagram Methods 0.000 description 8
- 239000000498 cooling water Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000013461 design Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 238000000465 moulding Methods 0.000 description 3
- 238000005086 pumping Methods 0.000 description 3
- 238000007664 blowing Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000005670 electromagnetic radiation Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/64—Electric machine technologies in electromobility
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The application relates to the technical field of metal casting molds and forming processes, in particular to a low-pressure casting mold of an aluminum alloy motor shell and a use method thereof. Wherein, this low pressure casting mould includes: the die block, the upper die and the four opening and closing side dies are combined to form a casting blank cavity of the motor shell; the center position of the bottom die is provided with a unique pouring gate, and the die is free of other pouring gates or riser feeding systems; the steel core, the side die and the bottom die are respectively hollowed to form a thin-wall structure, and the steel core, the side die and the hollowed part of the bottom die are respectively provided with a first air cooling mechanism, a second air cooling mechanism and a third air cooling mechanism.
Description
Technical Field
The application relates to the technical field of metal casting molds and forming processes, in particular to a low-pressure casting mold of an aluminum alloy motor shell and a use method thereof.
Background
The motor is the main power source of new energy automobile, and the motor casing is the shell of motor, is the important part of guaranteeing its safe and stable operation, and the main roles of motor casing include: (1) The internal components of the motor are protected, and external sundries, dust, moisture and the like are prevented from entering the motor; (2) Heat dissipation and cooling are carried out, so that the normal working temperature of the motor is maintained, and overheating is prevented; (3) Mechanical support is provided, vibration and resonance phenomena are reduced, and normal operation of the motor is ensured; (4) Electromagnetic shielding prevents electromagnetic radiation from the motor from interfering with other electronic equipment and vehicle systems.
In the related art, the processing of the motor shell is mostly finished through casting production, and gravity casting is a conventional casting process for producing aluminum alloy motor shells and similar products, and the main process scheme is as follows: the shell is vertically arranged, and pouring channels are independently arranged on one side of the casting and are used for injecting molten metal into the bottom of the casting; along with the rise of the filling height of the molten metal, a plurality of transverse pouring channels can be arranged on the pouring channels and the side surfaces of the castings, and high-temperature molten metal is continuously injected into the castings; a circle of riser with a larger modulus is arranged on the flange surface at the top of the casting and is used for feeding molten metal in the solidification process of the casting. The mold structure corresponding to such processes is typically: the metal bottom die is matched with front, back, left and right opening and closing side dies, and the inner cavity and the top riser of the casting are molded by using sand cores due to the influence of equipment and demoulding. The limitations of the above process and die structure are: the casting process has low yield, a large amount of materials are used for casting and riser systems, the subsequent sawing process is tedious, and the beat is long; the cycle beat of the casting process is longer, the production efficiency is low, the qualification rate of the casting is low, the riser feeding is easy to cause internal quality defects at the corresponding position of the casting, and the requirement on process control is high.
It should be noted that the information disclosed in this background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art that is well known to a person skilled in the art.
Disclosure of Invention
The utility model provides a low pressure casting mould of aluminum alloy motor casing and application method thereof, this low pressure casting mould single gate design does not have other complicated pouring to fill type system or riser feeding system to the current state of the art of above-mentioned, has realized the order solidification of foundry goods through the thin wall structural design and the multiple spot forced air cooling system of mould, can improve the shaping quality and the technology yield of casing foundry goods greatly when simplifying the gating system.
In order to achieve the above purpose, the present application adopts the following technical scheme:
in a first aspect, the present application provides a low pressure casting mold for an aluminum alloy motor housing, comprising: the die comprises a bottom die, an upper die, four opening and closing side dies matched with the upper die, and a steel core, wherein the bottom die, the upper die and the four side dies are combined and combined with the steel core to form a casting blank cavity of the motor shell; wherein, the steel core is utilized to form the inner cavity of the motor shell, and the sand core is utilized to form the cavity structure inside the side wall of the motor shell; the center position of the bottom die is provided with a single pouring gate, and in addition, the low-pressure casting die has no other pouring gates or riser feeding systems;
the steel core is hollow in the inside to form a thin-wall structure in the height direction, and the hollow part of the steel core is provided with a first air cooling mechanism, the first air cooling mechanism comprises a plurality of annular or spiral first air cooling pipes which are arranged at intervals along the height direction, a plurality of first air cooling holes are formed in the direction of the side wall of the steel core towards the first air cooling pipes, and a plurality of first air cooling holes are used for forming multipoint air cooling for the steel core.
Further, one side of the side die, which is away from the blank cavity, is hollowed out to form a thin-wall structure; and a second air cooling mechanism is arranged on the hollowed side of the side die, and a plurality of second air cooling points are formed on the surface of the side die by the second air cooling mechanism.
Further, the bottom die comprises a die frame and a die core arranged at the center of the die frame; the pouring gate is arranged at the center of the mold core, one side, deviating from the blank cavity, of the mold core is hollowed out to form a thin-wall structure, a third air cooling mechanism is arranged on the hollowed-out side of the mold core, and a plurality of third air cooling points are formed on the surface of the mold core by the third air cooling mechanism.
Further, the steel core forms uniform wall thickness in the height direction, and the wall thickness of the steel core is between 25 and 35 mm.
Further, the number and layout positions of the second air cooling points are obtained according to simulation analysis of the casting process.
Further, the sand core is installed on the insert through the sand core head, the insert is installed on the bottom die, and a water cooling mechanism is arranged on the insert to realize cooling.
Further, the third air cooling points uniformly radiate and extend in the radial direction with the gate as the center.
Further, the upper die is provided with ejector rod holes for installing ejector rods, each ejector rod is provided with a plurality of first exhaust structures, a first gap is formed between the first exhaust structures and the ejector rod holes, and feeding and exhausting of molten metal in the blank cavity are achieved through the first gap.
Further, a push rod sleeve is arranged between the push rod hole and the push rod, and a second exhaust structure is arranged on the push rod sleeve; the first gap is formed between the ejector rod and the ejector rod sleeve, the second gap is formed between the ejector rod sleeve and the ejector rod hole, and the exhaust feeding of molten metal in the blank cavity is realized through the first gap and the second gap.
In a second aspect, the present application provides a method for using the low-pressure casting mold of the first aspect, including the following steps:
(1) Fixing a bottom die on a die bottom plate, mounting an insert on the bottom die, mounting a sand core on the insert, placing a steel core, and driving four side dies and an upper die to act through an equipment oil cylinder respectively to enable the bottom die, the upper die and the four side dies to form a blank cavity with the steel core;
(2) Starting low-pressure casting equipment to enable molten metal to be filled into a blank cavity through a pouring gate;
(3) Starting the first air cooling mechanism, the second air cooling mechanism, the third air cooling mechanism and the water cooling mechanism to cool the die and the insert, so that the molten metal in the blank cavity is sequentially solidified;
(4) After the casting is solidified, the four side dies are driven by the equipment oil cylinder to move and leave the surface of the casting; after the four side dies are opened in place, the steel core moves together with the upper die under the drive of the equipment oil cylinder under the condition of locking the casting, and the casting and the sand core inside the casting are brought out of the bottom die;
(5) After the upper die is lifted, the ejection mechanism acts to eject the casting and the sand core out of the upper die.
The beneficial effects of this application are: compared with the traditional gravity casting process, the low-pressure casting die greatly improves the casting forming quality and the process yield of the motor shell, simplifies the structure of a pouring system, shortens the subsequent processing procedures of castings, reduces the operation difficulty of equipment, improves the production efficiency of the motor shell, and has important significance for realizing high-precision and mass production of the new energy motor shell.
Drawings
FIG. 1 illustrates a schematic structural view of a low pressure casting mold for a motor housing, according to some embodiments of the present application;
FIG. 2 illustrates a cross-sectional view of a mold, according to some embodiments of the present application;
FIG. 3 illustrates a schematic structural view of a steel core+a first air cooling mechanism, according to some embodiments of the present application;
FIG. 4 illustrates a cross-sectional view of FIG. 3, according to some embodiments of the present application;
FIG. 5 illustrates a schematic diagram of a side mold + second air cooling mechanism, according to some embodiments of the present application;
FIG. 6 illustrates a schematic structural view of a mold core+a third air cooling mechanism, according to some embodiments of the present application;
FIG. 7 illustrates a schematic diagram of a sand core, inserts, and water cooling mechanism, according to some embodiments of the present application;
FIG. 8 illustrates a schematic structural view of a carrier rod, according to some embodiments of the present application;
FIG. 9 is a schematic diagram showing the mating structure of the ejector pin and the upper die according to some embodiments of the present application;
FIG. 10 illustrates a schematic structural view of a push rod+push rod sleeve, according to some embodiments of the present application;
FIG. 11 illustrates a schematic diagram of the mating structure of a ram, ram sleeve, and upper die according to some embodiments of the present application;
reference numerals illustrate:
101. an upper die; 102. a bottom die; 102a, a mold frame; 102b, a mold core; 102c, a third air cooling point; 103. a side mold; 103a, side mold frames; 103b, templates; 103c, a second cavity; 103d, a second air cooling point; 104. a steel core; 104a, a first cavity; 104b, sidewalls; 105. a first air cooling mechanism; 105a, a first air inlet; 105b, a first pipeline integration module; 105c, a first air inlet pipe; 105d, a first air-cooled tube; 105e, a first air distribution pipe; 105f, a first air outlet; 106. a second air cooling mechanism; 106a, a second air inlet; 106b, a second pipeline integration module; 106c, a second air inlet pipe; 106d, a second air distribution pipe; 107. a gate; 108. a third air cooling mechanism; 108a, a third air inlet pipe; 108b, a third air-cooled tube; 108c, a third air distribution pipe; 109. an insert; 110. a water cooling mechanism; 110a, a water inlet pipe; 110b, a water outlet pipe; 110c, a fourth pipeline integration module; 111. a main oil cylinder of the equipment; 112. a material ejection mechanism; 113. a side-pumping oil cylinder; 114. a push rod; 114a, a first exhaust structure; 115. a first gap; 116. a push rod sleeve; 116a, a second exhaust structure; 116b, exhaust holes; 117. a second gap; 200. a sand core; 210. a sand core head; 300. and (5) blank cavity.
Detailed Description
The technical features and advantages of the present application are described in more detail below with reference to the accompanying drawings so that the advantages and features of the present application may be more readily understood by those skilled in the art, thereby making clear and defining the scope of the present invention.
It should be noted that, in the description of the present application, terms such as "upper," "lower," "left," "right," "inner," "outer," and the like indicate directions or positional relationships based on the directions or positional relationships shown in the drawings, which are merely for convenience of description, and do not indicate or imply that the apparatus or elements must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the invention.
The terms "first," "second," and "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implying an importance of the illustrated technical features.
Furthermore, it should be noted that, in the description of the present application, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those skilled in the art according to the specific circumstances.
Referring to fig. 1-2, a schematic structural diagram of a low-pressure casting mold for an aluminum alloy motor housing of a new energy automobile in an embodiment of the present application is shown, where the low-pressure casting mold structurally includes: the upper die 101, the bottom die 102, the four opening and closing side dies 103 and a steel core 104 are combined to form a casting blank cavity 300 of the motor shell by combining the bottom die 102, the upper die 101 and the four side dies 103 with the steel core 104; the upper die 101 is used for forming the upper end face of the motor shell, the steel core 104 is used for forming the inner cavity structure of the motor shell, the four side dies 103 are jointly used for forming the outer side wall structure of the motor shell, the bottom die 102 is used for forming the lower end face and the bottom runner structure of the motor shell, and the unique pouring gate 107 is arranged at the central position of the bottom die 102. During pouring, molten metal enters the mold from the bottom gate 107, and gradually fills the blank cavity 300 from bottom to top. In addition, the hollow structure inside the side wall of the motor housing is formed by a sand core 200.
Because no complex pouring system and riser feeding structure are designed, in order to obtain good casting molding quality and process yield in the low-pressure casting process, the embodiment of the application performs special cooling design on the steel core 104, the side die 103 and the bottom die 102 so as to realize sequential solidification of molten metal in the blank cavity 300.
Referring to fig. 3-4, in order to achieve good cooling of the steel core 104, the interior of the steel core 104 is hollowed out to form a first cavity 104a, the side wall 104b of the steel core 104 forms a uniform wall thickness D in the height direction, and a first air cooling mechanism 105 is disposed inside the first cavity 104 a. The first air cooling mechanism 105 may include a plurality of annular first air cooling pipes 105d arranged at intervals along the height direction, each first air cooling pipe 105d is communicated with a first air inlet 105a through a first air inlet pipe 105c, and the first air inlet 105a is communicated with an external air source to realize air inlet; in order to facilitate centralized management of the multiple paths of first air inlet pipes 105c, the first air cooling mechanism 105 may further include a first pipeline integration module 105b, and the multiple paths of first air inlet pipes 105c are installed in a centralized manner through the first pipeline integration module 105b and marked with corresponding identifiers, so that an operator can conveniently connect and control pipelines; a plurality of first air cooling holes (not shown in the figure) are formed in the first air cooling pipe 105d towards the side wall 104b of the steel core 104, and the plurality of first air cooling holes are used for carrying out multi-point air cooling on the side wall 104b of the steel core 104, so that the plurality of first air cooling holes can be uniformly distributed at intervals along the length direction of the first air cooling pipe 105d, and uniform cooling can be realized on the side wall 104b in the cross section direction; the plurality of first air cooling ducts 105d arranged at intervals in the height direction may form uniform cooling in the height direction to the side wall 104b of the steel core 104. Referring to fig. 4, considering that the bottom of the steel core 104 corresponds to the thick end face structure of the bottom of the casting, a plurality of first air distribution pipes 105e are arranged on the first air cooling pipe 105d at the lowest part towards the bottom surface of the casting, the bottom of the first air distribution pipes 105e forms a first air outlet 105f, and multi-point air blowing cooling is performed towards the thick bottom surface of the casting through the plurality of first air outlets 105 f. The inside of the steel core 104 is hollowed, on one hand, the first air cooling mechanism 105 can be arranged in the hollow inside of the steel core 104, and the integration level of the die is improved; on the other hand, the wall thickness and the quality of the steel core 104 can be reduced, so that the air cooling effect is improved.
In some other embodiments, the first air cooling tube 105d may also be designed into an annular spiral tube structure extending along the height direction, wherein a plurality of first air cooling holes are formed on one side of the spiral tube towards the side wall 104b, and a plurality of first air outlets 105f are formed towards the bottom surface of the steel core 104; the layout position of the first air cooling pipe 105d, the outlet gas flow rate of the first air cooling hole/the first air outlet 105f, the pitch and other parameters can be determined by casting simulation analysis software, so as to obtain the optimal cooling effect on the steel core 104.
In order to obtain a good cooling effect while ensuring strength, the wall thickness D of the side wall 104b of the steel core 104 may be controlled between 25 and 35 mm.
Further, in order to improve the cooling effect of the side mold 103, the four side molds 103 are also designed to be a thin-wall+multipoint air-cooled structure. Referring to fig. 2, each side mold 103 includes a side mold frame 103a and a mold plate 103b, wherein the side mold frame 103a is used for forming an outer sidewall structure of the housing, and the mold plate 103b is used for connecting the side oil pumping cylinder 113 to realize opening and closing driving of the side mold 103. And a second air cooling mechanism 106 is correspondingly arranged on each side die 103 to realize cooling of the side die.
Referring to fig. 5, a schematic structural diagram of a side mold frame 103a and a second air cooling mechanism 106 is shown, wherein a side of the side mold frame 103a, which is away from the blank cavity 300, is hollowed out to form a second cavity 103c, the hollowed-out structure enables a side of the side mold frame 103a, which is close to the blank cavity 300, to form a thin-wall structure, and the side mold frame 103a is designed into the thin-wall structure, so that the air cooling effect can be improved; in addition, the second cavity 103c between the side frame 103a and the mold plate 103b may also be used to install the second air cooling mechanism 106, so as to further improve the integration level of the mold.
A plurality of second air cooling points 103d are formed on the hollowed side surface of the side mold frame 103a at intervals through a second air cooling mechanism 106; the second air cooling mechanism 106 comprises a plurality of second air distribution pipes 106d which are in one-to-one correspondence with the second air cooling points 103d, a second air cooling hole is formed in one side, facing the side die frame 103a, of the second air distribution pipes 106d, the second air inlet 106a is communicated with the second air inlet 106a through the second air inlet pipe 106c to realize external air inlet, and then the second air cooling holes are used for blowing air to each second air cooling point 103d to realize multi-point air cooling of the side die frame 103 a. In this embodiment, the number, layout position and outlet wind speed of the second air cooling points 103d on the side mold frame 103a can be obtained by analysis of the casting simulation analysis software.
For convenient observation and operation, a second duct integration module 106b may be further disposed in the second air cooling mechanism 106, for centralized installation and management of the plurality of second air inlet ducts 106 c.
Referring to fig. 2, the bottom mold 102 of the present embodiment includes a mold frame 102a and a mold core 102b, and the mold core 102b is located at a center position of the mold frame 102a for laying out the gate 107. The gate 107 is located at the point where molten metal enters the blank cavity 300 and is the region of the entire mold where the temperature is highest. To cool this high temperature region, a third air cooling mechanism 108 is disposed on the mold core 102 b. Referring to fig. 6, a schematic structural diagram of the mold core 102b and the third air cooling mechanism 108 is shown, wherein a plurality of third air cooling points 102c are formed on the surface of the mold core 102b at intervals by the third air cooling mechanism 108, and the plurality of third air cooling points 102c may be disposed around the gate 107 and radially extend around the gate 107. The third air cooling mechanism 108 may include a plurality of annular third air cooling pipes 108b arranged around the gate 107, a plurality of third air distribution pipes 108c are arranged on one side, facing the mold core 102b, of each third air cooling pipe 108b, a third air cooling hole is formed in one side, facing the mold core 102b, of each third air distribution pipe 108c, the third air cooling holes are in one-to-one correspondence with the third air cooling points 102c, the third air cooling pipes 108b are communicated with the third air inlet pipes 108a to achieve external air inlet, and air is blown to the third air cooling points 102c through the third air cooling holes to achieve multi-point air cooling of the mold core 102 b. The number, layout position and outlet wind speed of the third air cooling points 102c on the mold core 102b can be obtained through simulation analysis by casting simulation analysis software. In this embodiment, in order to achieve a better cooling effect on the mold core 102b, a denser number of third air-cooling points 102c are arranged on the mold core 102b, and according to the structural characteristics of the mold core 102b and the gate 107, three circles of third air-cooling points 102c which are coaxial with the gate 107 and are in annular layout are sequentially arranged from inside to outside to achieve uniform cooling of the mold core 102 b; in other embodiments, the third air cooling tube 108b may be configured as a spiral tube extending outward around the gate 107, or may be configured in other manners, as long as the third air cooling points 102c are uniformly spaced around the surface of the mold core 102 b. In order to further improve the cooling effect on the mold core 102b, a side of the mold core 102b away from the blank cavity 300 may be hollowed out, and the hollowed-out position is used for laying out a plurality of third air cooling points 102c, so that on one hand, the wall thickness of the mold core 102b may be reduced to improve the air cooling effect, and on the other hand, the hollowed-out position is also convenient for arranging the third air cooling mechanism 108, so as to improve the integration level of the mold.
Through carrying out the design of drawing out + multiple spot forced air cooling to the mold core 102b of steel core 104, side form 103 and die block 102, can realize better cooling effect to whole mould.
In this embodiment, the sand core 200 is used to mold a cavity structure inside the side wall of the motor housing. Referring to fig. 7, the sand core 200 is fixed on the insert 109 by the sand core head 210, and in combination with the structural features of the process scheme of this embodiment, the insert 109 needs to be mounted on the mold core 102b or the mold frame 102a of the bottom mold 102, in this embodiment, three inserts 109 are designed to mount the sand core 200, wherein two inserts 109 need to be mounted on the mold core 102 b. The temperature of the insert 109 associated therewith is also higher due to the higher temperature of the core 102 b. However, the overall volume of the insert 109 is small, and good cooling effect cannot be achieved by using an air cooling structure. Thus, a water cooling mechanism 110 is disposed on each insert 109 connected to the core 102 b.
Referring to fig. 7, in this embodiment, a schematic diagram of the matching structure of the sand core 200, the insert 109 and the water cooling mechanism 110 is shown. Each water cooling mechanism 110 comprises a water inlet pipe 110a and a water outlet pipe 110b, wherein the water inlet pipe 110a is communicated with an external water source to realize water inlet, the water inlet pipe 110a is used for introducing cooling water into the insert 109, a cooling water channel is designed in the insert 109, and the cooling water flows through the cooling water channel to uniformly cool the insert 109 and then is introduced from the water outlet pipe 110 b. For easy installation and observation, the water cooling mechanism 110 is provided with a fourth pipeline integration module 110c for installing the water inlet pipe 110a and the water outlet pipe 110b and performing corresponding identification to avoid wrong connection to the water inlet and outlet pipelines.
In casting molds, water cooling and air cooling are two common cooling means for controlling the mold temperature to ensure high quality casting manufacture. The water cooling efficiency is higher, the cooling is more intense, and the cost is slightly higher; air cooling is mild, but cooling efficiency is low, and temperature control is relatively poor. In the embodiment, aiming at the characteristics of the die structure, a thin-wall structure and multipoint air cooling are designed for the steel core 104, the side die 103 and the bottom die 102 with larger volume, so that a milder and uniform cooling effect is realized, and meanwhile, the cost of a cooling system is reduced; for the insert 109 with small volume and high temperature, a water cooling structure is designed to realize efficient cooling; by combining the cooling modes, the mold is uniformly cooled, and the method is an important condition for obtaining good casting molding quality.
The low-pressure casting mold of the embodiment comprises the following using method:
(1) Fixing a bottom die 102 on a die bottom plate, installing three inserts 109 on the bottom die 102, installing a sand core 200 on the inserts 109, placing a steel core 104, and respectively driving a front side die 103, a rear side die 103, a left side die 103, a right side die 103 and an upper die 101 to act through a main oil cylinder 111 and a side oil pumping cylinder 113 of the equipment to enable the bottom die 102, the upper die 101, the four side dies 103 and the steel core 104 to form a blank cavity 300;
(2) Starting the low-pressure casting equipment to enable molten metal to be filled into the blank cavity 300 through the pouring gate 107;
(3) Starting the first air cooling mechanism 105, the second air cooling mechanism 106, the third air cooling mechanism 108 and the water cooling mechanism 110, performing multi-point air cooling on the die through each air cooling pipe, and performing water cooling on the insert 109 through cooling water, so that the molten metal in the blank cavity 300 is sequentially solidified;
(4) After the casting is solidified, the four side dies 103 are driven by the side oil cylinders 113 to move forwards, backwards, leftwards and rightwards and leave the surface of the casting; after the four side dies 103 are opened in place, the steel core 104 moves together with the upper die 101 under the drive of the equipment master cylinder 111 under the condition of locking the casting, and the casting and the internal sand core 200 are brought out of the bottom die 102;
(5) After the upper die 101 is lifted, the ejection mechanism 112 acts to eject the casting and the sand core 200 out of the upper die 101.
In the pressure casting mold of the present embodiment, since the rest of the riser feeding structure is not designed except the gate 107, in order to realize the exhaust during the solidification of molten metal filling, an exhaust structure is designed on the ejector mechanism 112.
Referring to fig. 8-9, in this embodiment, a portion of the ejector pin 114 matching with the ejector pin hole is designed with a plurality of first exhaust structures 114a along the axial direction, wherein the first exhaust structures 114a may be exhaust bar structures formed on the columnar ejector pin 114, and when the ejector pin 114 matches with the ejector pin hole of the upper mold 101, a first gap 115 is formed between the first exhaust structures 114a and the ejector pin hole, so as to be used for exhausting molten metal in the cavity.
In some preferred embodiments, referring to fig. 10-11, in order to further enhance the exhaust effect, a mandrel sleeve 116 is disposed between the mandrel 114 and the mandrel hole, the mandrel sleeve 116 is sleeved between the mandrel 114 and the mandrel hole, a first exhaust structure 114a is disposed on the mandrel 114, a plurality of second exhaust structures 116a and exhaust holes 116b are disposed on the mandrel sleeve 116, when the mandrel 114 is matched with the exhaust holes of the upper die 101 through the mandrel sleeve 116, a first gap 115 is formed between the first exhaust structure 114a and the mandrel sleeve 116, a second gap 117 is formed between the second exhaust structure 116a and the mandrel hole, and the gas in the cavity can be exhausted through the first gap 115, the second gap 117 and the exhaust holes 116 b.
Through the low-pressure casting die of the embodiment, good cooling effect can be realized on the die and molten metal in the casting process, the prepared motor shell is high in process yield, obvious quality defects are avoided in the casting, and the molding quality requirement of the product is met.
In the description of the present specification, reference to the terms "some embodiments," "exemplary," "example," "preferred," or "further" etc. means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The foregoing description is only exemplary embodiments of the present application and is not intended to limit the scope of the present application, and all equivalent structures or equivalent processes using the descriptions and the drawings of the present application, or direct or indirect application in other related technical fields are included in the scope of the present application.
Claims (10)
1. A low pressure casting die for an aluminum alloy motor housing, comprising: the die comprises a bottom die (102), an upper die (101) and four opening and closing side dies (103) matched with the bottom die, and further comprises a steel core (104), wherein the bottom die (102), the upper die (101) and the four side dies (103) are combined and combined with the steel core (104) to form a casting blank cavity (300) of the motor shell; wherein, the inner cavity of the motor shell is formed by the steel core (104), and the cavity structure inside the side wall of the motor shell is formed by a sand core (200); a single pouring gate (107) is arranged at the central position of the bottom die (102), and besides, the low-pressure casting die has no other pouring gate or riser feeding system;
the steel core (104) is internally hollowed to form a thin-wall structure in the height direction, a first air cooling mechanism (105) is arranged at the hollowed part of the steel core (104), the first air cooling mechanism (105) comprises a plurality of annular or spiral first air cooling pipes (105 d) which are arranged at intervals in the height direction, the first air cooling pipes (105 d) face the side wall direction of the steel core (104) to form a plurality of first air cooling holes, and the first air cooling holes are used for forming multi-point air cooling for the steel core (104).
2. The low-pressure casting die according to claim 1, characterized in that a side of the side die (103) facing away from the blank cavity (300) is hollowed out to form a thin-walled structure; and a second air cooling mechanism (106) is arranged on the hollowed side of the side die (103), and a plurality of second air cooling points (103 d) are formed on the surface of the side die (103) by the second air cooling mechanism (106).
3. The low pressure casting mold according to claim 1, characterized in that the bottom mold (102) comprises a mold frame (102 a) and a mold core (102 b) arranged at the center of the mold frame (102 a); the pouring gate (107) is arranged at the center of the mold core (102 b), one side of the mold core (102 b) facing away from the blank cavity (300) is hollowed out to form a thin-wall structure, a third air cooling mechanism (108) is arranged at the hollowed-out side of the mold core (102 b), and a plurality of third air cooling points (102 c) are formed on the surface of the mold core (102 b) by the third air cooling mechanism (108).
4. The low-pressure casting die according to claim 1, characterized in that the steel core (104) is formed with a uniform wall thickness in the height direction, the wall thickness of the steel core (104) being set between 25 and 35 mm.
5. The low pressure casting mold according to claim 2, characterized in that the number and layout positions of the second air-cooled spots (103 d) are obtained from a simulation analysis of the casting process.
6. The low pressure casting mold according to claim 1, characterized in that the sand core (200) is mounted on an insert (109) by a sand core head (210), the insert (109) is mounted on the bottom mold (102), and a water cooling mechanism (110) is arranged on the insert (109) to realize cooling.
7. A low pressure casting mould according to claim 3, characterized in that a plurality of said third air-cooled spots (102 c) extend radially uniformly radiating around said gate (107).
8. The low-pressure casting mold according to claim 1, wherein the upper mold (101) is provided with ejector rod holes for installing ejector rods (114), each ejector rod (114) is provided with a plurality of first exhaust structures (114 a), a first gap (115) is formed between the first exhaust structures (114 a) and the ejector rod holes, and feeding and exhausting of molten metal in the blank cavity (300) is realized through the first gap (115).
9. The low-pressure casting mold according to claim 1, wherein the upper mold (101) is provided with ejector rod holes for mounting ejector rods (114), and each ejector rod (114) is provided with a plurality of first exhaust structures (114 a); a mandril sleeve (116) is further arranged between the mandril hole and the mandril (114), and a second exhaust structure (116 a) is arranged on the mandril sleeve (116); a first gap (115) is formed between the ejector rod (114) and the ejector rod sleeve (116), a second gap (117) is formed between the ejector rod sleeve (116) and the ejector rod hole, and the exhaust feeding of molten metal in the blank cavity (300) is jointly realized through the first gap (115) and the second gap (117).
10. The method of using a low pressure casting mold according to claim 6, comprising the steps of:
(1) Fixing a bottom die (102) on a die bottom plate, mounting an insert (109) on the bottom die (102), mounting a sand core (200) on the insert (109), placing a steel core (104), and driving four side dies (103) and an upper die (101) to act through equipment cylinders respectively to enable the bottom die (102), the upper die (101) and the four side dies (103) to form a blank cavity (300) with the steel core (104);
(2) Starting the low-pressure casting equipment to enable molten metal to be filled into a blank cavity (300) through a gate (107);
(3) Starting a first air cooling mechanism (105), a second air cooling mechanism (106), a third air cooling mechanism (108) and a water cooling mechanism (110) to cool a die and an insert (109) so as to realize sequential solidification of molten metal in a blank cavity (300);
(4) After the casting is solidified, the four side dies (103) move under the drive of the equipment oil cylinder and leave the surface of the casting; after the four side dies (103) are opened in place, the steel core (104) moves together with the upper die (101) under the drive of an equipment oil cylinder under the condition of locking the casting, and the casting and the sand core (200) inside are taken out of the bottom die (102);
(5) After the upper die (101) is lifted, the ejection mechanism (112) acts to eject the casting and the sand core (200) out of the upper die (101).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311800042.9A CN117444176A (en) | 2023-12-26 | 2023-12-26 | Low-pressure casting die for aluminum alloy motor shell and using method thereof |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311800042.9A CN117444176A (en) | 2023-12-26 | 2023-12-26 | Low-pressure casting die for aluminum alloy motor shell and using method thereof |
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| CN117444176A true CN117444176A (en) | 2024-01-26 |
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| CN202311800042.9A Pending CN117444176A (en) | 2023-12-26 | 2023-12-26 | Low-pressure casting die for aluminum alloy motor shell and using method thereof |
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Cited By (1)
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| CN118122996A (en) * | 2024-05-07 | 2024-06-04 | 象山同家模具制造有限公司 | Low-pressure casting mold |
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