GB2578945A

GB2578945A - Gravity casting simulation test bench

Info

Publication number: GB2578945A
Application number: GB1911055.0A
Authority: GB
Inventors: Wang Chengjun; Dou Haishi; Zheng Yan; Li Long; Guo Yongcun; Shen Yuzhe; Yu Hanwei
Original assignee: Anhui University of Science and Technology
Current assignee: Anhui University of Science and Technology
Priority date: 2017-10-09
Filing date: 2017-10-31
Publication date: 2020-06-03
Anticipated expiration: 2037-10-31
Also published as: CN107478800A; WO2019071666A1; CN107478800B; GB201911055D0; GB2578945B

Abstract

A gravity casting simulation test bench comprises: a base (1), a ladle frame (2), a test ladle (3), a pouring device (4), a vibration table (5), a simulated sand box (6) and a measuring device (7). The device can utilize water, mud or glycerin as media to simulate liquid metal, and is mainly used for hydraulic simulation testing, casting law simulation testing and vibration casting simulation testing of a filling process in a casting process. The test ladle (3) is driven by the pouring device (4) to execute gravity casting, and a filling test can be carried out by installing different gating systems and molds in the simulated sand box (6). Test results are obtained by sensors installed in the measuring device (7), the vibration table (5), the simulated sand box (6) and the test ladle (3), and test parameters are automatically collected and converted by a computer. The device can develop a test plan according to different working conditions, gating systems and molds to obtain objective conclusions, and has many advantages such as allowing research independent of environmental and site constraints, being easy to operate, low in cost etc.

Description

GRAVITY CASTING SIMULATION TEST BENCH

Technical Field

The present invention belongs to the technical field of casting test devices, and in particularly relates to a gravity casting simulation test bench.

Background Art

In the traditional process of casting production, the parameters in casting process such as the coefficient of the quantity of flow and the flow rate and the reasonable gating system are currently still determined based on experience, which is insufficient and unscientific for some large-size, complex and large batch of castings products, with a high casting reject ratio and a significant economic loss. In the process of casting production, during the casting, the molten iron or molten steel needs to be transferred to the production line by means of a casting ladle, aligned to the spate gate the molten iron or molten steel in the casting ladle can be poured into the spruc cup of the casting workpiece, the casting pieces can be achieved after cooling and shakeout operating. Currently, during molten iron or molten steel pouring, the heavy casting ladle is lifted and carried by the workers manually or hanging-lifted and transferred by bridge cranes, when the casting ladle having collected the molten iron or molten steel from the high-frequency electric furnace, then the casting ladle filled with the molten iron or molten steel being carried or transferred to the casting site, two or more people cooperating to slowly incline the ladle so that the molten iron or molten steel in the ladle can be poured into the spree gate of the workpiece. Such a method is inconvenient for the on-the-spot teaching or test research, and the main constraint factors includes: (I) due to the limitation of electricity consumption, the process of casting production is generally carried out in the night, this is inconvenient for a relatively large number of participants attending the teaching or test research which requiring adjustment; (2) the casting scene is poor in working environment, where the temperature of the molten iron or molten steel reaches up to about 1500°C, and the temperature of the working environment is at more than 40°C, which resulting in a large hidden security risk; (3) the working environment is dangerous, where the workers on the scene need to be careful about the splashing molten iron or molten steel all the time and there is very high hidden danger risk for personal safety guarantee thereof; (4)it takes a relatively long period for the whole process of the casting, and the casting speed is slow; and (5) the cost of the cast-in-place test is high.

In the teaching and research relating to the casting process, the teaching of the aspect in casting moulding is based on the dictation of teachers or masters and referred teaching video, few students can actually experience the casting process, and thus they stay only in the armchair stage for learning a lot of knowledge about casting. Moreover, the site visit is subject to many constraints such as the visit time arrangement, conditions available for the site visit, security management, and traffic, and each teaching often costs much time and labour in preparation and organization. Accordingly, not only are the working amount of the organization and preparation and the teaching cost increase, but also a certain hidden security danger and a management difficulty exist in the on-the-spot teaching of casting. Therefore, the numerical simulation and the physically similar simulation test mainly adopting the hydraulic simulation become main means substituting for the cast-in-place test to perform the teaching and scientific research test. in addition, with the development of the technology of casting production, the application of testing technology and computers in the casting production and research, and the improved requirements for the casting quality, it is urgent to perform accurate measurement for the main processes of the casting production-the mould filling process and the solidification process by means of the methods of physical simulation and mathematical simulation in the laboratory, to research the rules of the methods and obtain qualitative and quantitative mathematical formulas. Therefore, some unknown phenomena can be detected, and the rules obtained in the laboratory can be used to guide and control the producing process, so as to improve the quality and output of the casting pieces and thus achieve a better economic benefit.

The computer-based numerical simulation method has a certain reference value, but the error is relatively large, and many parameters in the process cannot be obtained by means of the computer simulation method. For the process of producing large-size, complex and large batch number of casting pieces, some foreign factories have begun to generally research the mould filling process and gating system firstly by hydraulic simulation method in the laboratory since I 970s, to find out the rules for the process and system and determine the most reasonable process solution, then performing production to achieve the best economic effects.

The hydraulic simulation technology has become a common research method in the optimization design of the casting process of a casting, and the ideal casting process design can effectively reduce the tendency of air entrapment and inclusion during the liquid metal mould filling. With the development of modem computer technology, image processing technology and laser technology, the research process lies not only in the display of the flow process and the supplement to the computer-based numerical simulation process, but also in the quantitative research on the obtained flow field images performed by use of the fluid flow field visualization technology such as PIV and by use of the high-speed and effective algorithms in the computer graphics. However, there is a higher requirement for the similarity between the hydraulic simulation process and the liquid metal mould filling process, and a higher requirement is put forward for the design of the hydraulic simulation test bench, so as to improve the accuracy of the hydraulic simulation test result.

For the research on aspects in the casting experiment simulation apparatus and method, the existing documents also disclose some solutions. For example, the Chinese patent application CN 201210591733.8 discloses a system real-time displaying the important data in a molten steel casting process, comprises of a weighing unit, a receiver, an industrial personal computer, an on-site large screen and a wireless remote control box, wherein a weight change for the molten steel is continuously measured by means of an analogue sensor during the casting process, the analogue signal of the sensor is converted into a digital signal, which is continuously transmitted to the site via a wireless digital transmission module, and the system is applicable to on-site production of a heavy casting but is not applicable to a test research having a multi-parameter measurement requirement. The Chinese patent application CN 201410482876.4 discloses a small-sized laboratory simulation machine for a mobile heating and stirring of pouring asphalt, comprises a machine body, a wheel, a stirring shaft, a stirring tank, a stirring blade, a connecting arm, a motor, and a transmission, wherein the simulation machine is suitable for producing a small amount of mixture and in-door measuring performance parameters such as fluidity, hardness, and dynamic stability of the MA asphalt mixture in the laboratory tests. The Chinese utility model application CN 201621049701.5 discloses a model test apparatus for simulating a pouring process of a cast-in-place pile, comprising a metal frame platform, a metal funnel, a conduit, and a pile body member, wherein the model test apparatus is used to simulate a pouring process in which the concrete is poured under initially poured concrete and jacks up the initially poured concrete and slurry or water thereon, so as to form a uniform and compact concrete pile body. The Chinese utility model application CN 200920110535.9 discloses a high-pressure crack grouting simulation test bench, which is mainly used for the research of process parameters of high-pressure grouting for deep stratum cracks. In 1992, Chen LIU and Zupei GUO from Wuhan Institute of Technology published a paper titled "Development of Experiment Bench for SMSJ-44A Hydraulic Simulation Gating System" in "Experimental Technology and Management", introducing an experiment bench for the SMSJ-44A hydraulic simulation gating system, wherein the experiment bench comprises a water tank, a water tank console, a pouring workbench, and a measuring water tank, the control portion of the experiment bench consists of a liquid level controller, a temperature controller, and a chronograph for use in any combination in the experiment, all members adopt parts and components such as an integrated package, digital display and numerical code dial switches, this test bench can simulate a casting process of a casting to observe a flow situation of a metal liquid, a defect, and the like in the casting process, thereby providing a basis for formulation of a process plan and design work, but only the flow rate, flow amount, and casting time can be measured. Huiguang WANG, Rongmao YE, and Dong WANG from Harbin Institute of Technology published a paper titled " Hydraulic Simulation Test of Filling Rule and Structural Effect of Vertical Slit Gating System in Low-pressure Casting" in the fifth issue of "Hot Working Technology" in 1986, introducing a simple casting test apparatus made of polymethyl methacrylate and provided with a slit gating system, wherein the test apparatus comprises a pressurized liquid storage tank, a riser tube, a vertical cylinder, and a transparent simulated casting mold provided with a mold cavity; a hydraulic simulation method is used to observe a process of the thin-wall mold cavity being filled with molten metal, a fluid particle motion rule and a filling sequence of the cavities of the casting mold during the filling process in low-pressure casting production during use of the slot gating system, and to research impacts of related factors such as a mold filling speed, a structure and size of each unit of the gating system, the thickness of the mold cavity wall, and fluid viscosity on the filling process; and the test apparatus can be used for only vertical slit gating test simulation. Zhaohao DENG, Entao ZHANG, Fuquan Ll et al. from Dalian Institute of Technology published a paper titled "Hydraulic Simulation Experiment of Gating System-Flow Coefficient u of Gating System" in the "Foundry Engineering" magazine in May 1981, introducing a method for the hydraulic simulation experiment, wherein the flow coefficient of the gating system is determined by means of four polymethyl methacrvlate molds according to a proposed mathematical formula for the flow coefficient of the gating system, and a flow coefficient curve is drawn by means of an electric simulation method in cooperation with the hydraulic simulation experiment. Zhongxing ZHAO, Guang JIN, Yongchen WANG, Lianqi WANG et al. published a paper titled "Development of Multifunctional Hydraulic Simulation Test Bench" in the second issue of "Hot Processing Technology" in 2003, introducing a hydraulic simulation test bench comprising a workbench, a low-pressure casting water tank, a primary water tank, a water supply pump, a secondary water tank, a measuring water tank, a circulating water pump, a pouring water tank, a flow regulating tube, a lifting mechanism, mobile trolley, and a flow rate meter, wherein the mobile trolley and the water tank thereon can move forward-rearward and leftward-rightward, lifting-up and putting-down of the pouring water tank are manually implemented by means of a lead screw and a nut provided with a rotary wheel, and the test bench can be used for measurement of a flow coefficient and performing a mold filling test, but cannot be used for a simulation test for casting ride.

The prior art has the following obvious disadvantages: lacking an effective laboratory gravity casting simulation test apparatus, especially lacking a comprehensive test bench which can be used for carrying out the gravity casting rule simulation test, the hydraulic simulation test of the filling process, and the vibration casting test; and being significantly affected by the environment, and having relatively less measurable parameters, and being inconvenient in operation. Thus, the prior art cannot satisfy the requirements for the gravity casting simulation test of casting molding and test and research solutions cannot be pertinently formulated according to various different working conditions.

Summary of the Invention

In view of the defects of the prior art, the present invention is aimed to provide a gravity casting simulation test bench, which can be used for the simulation teaching and test research of gravity casting in a casting molding process, wherein the teaching and the test can be carried out in a classroom or a laboratory and are not affected by the environment, time and site, thereby ensuring both the reality of the test and success of the teaching or the test, with extremely high economic efficiency and security and reduced test costs. The defects of the prior art can be overcome.

The problem to be solved by the present invention is implemented by the following technical solution.

A gravity casting simulation test bench, comprises: a base, a ladle frame, a test ladle, a pouring apparatus, a vibration table, a simulation sand box, and a measuring apparatus. The ladle frame is located at the middle of the base and is fixed connected to the base by means of screws; the test ladle is mounted on the ladle frame with the two sides of the test ladle being connected to the ladle frame by means of hinges; the pouring apparatus is located at the rear of the base, the bottom of the pouring apparatus is fixed mounted on the base, the front end of the pouring apparatus is connected to the test ladle by means of hinges; the vibration table is located at the front end of the base and is fixed connected to the base: the simulation sand box is fixed mounted on the top of the vibration table; the measuring apparatus is located at the side of the front of the base, and the measuring apparatus is fixed mounted on the base by means of sliding block(s) and can move forwardly and backwardly along the base.

The ladle frame, for supporting and mounting the test ladle, comprises center pillars, top beams, cross beams and lifting means. There are four center pillars symmetrically and fixed mounted on the base by means of corner connectors and screws, the top beam is fixedly mounted on the top of the pair of the corresponding left and right center pillars, the beam is mounted between the pair of the corresponding front and rear pillars, the beam is connected to the center pillars by means of a sliding pair and can slide upwardly and downwardly along the center pillars, a rotation pin used for connecting the test ladle is further disposed at the middle of each cross beam; there are two lifting means symmetrically arranged at the left and right sides of the base and used for driving the cross beams and the test ladle moving upwardly and downwardly along the center pillar; the bottom of the lifting means are fixedly connected to the base, the top of the lifting means are connected to the cross beams by means of hinges; Three-dimensional force sensor and an angle sensor are further disposed on the rotation pins of the cross beams and are used for measuring force applied by the test ladle and the pouring apparatus to the cross beam. The lifting means can be linear actuators, hydraulic cylinders, electrohydraulic cylinders, or air cylinders.

A ladle mouth is disposed on the front top of the test ladle, fixed pin sleeves are disposed on both sides of the middle part of the test ladle; an upper side T-shaped groove and a lower side T-shaped groove are respectively disposed at upper and lower sides of each fixed pin sleeve, an upper movable pin sleeve and a lower movable pin sleeve are respectively fixedly mounted outside each upper side T-shaped groove and each lower side T-shaped groove, both the upper movable pin sleeves and the lower movable pin sleeves are connected to the test ladle by means of T-shaped screws; a rear upper T-shaped groove and a rear lower T-shaped groove are further disposed respectively on the rear side of the test ladle; an upper lug and a lower lug are respectively fixedly mounted outside the rear upper T-shaped groove and the rear lower T-shaped groove, and both the upper lug and the lower lug are connected to the test ladle by means of T-shaped screws; the test ladle is connected to the rotation pin on the cross beams by means of the fixed pin sleeves, the upper movable pin sleeves, or the lower movable pin sleeves; and a temperature sensor, an electrical heater, and an electrical heating temperature controller are disposed in the test ladle. All of the fixed pin sleeves, the upper movable pin sleeves, and the lower movable pin sleeves can cooperate with the rotation pin on the cross beams. The upper movable pin sleeves and the lower movable pin sleeves can respectively slide for adjustment and be fixed in the upper side T-shaped grooves and the lower side T-shaped grooves to adjust the position of the rotation axis of the test ladle during pouring, so as to research the impacts of different rotation axes of the test ladle on the casting morphology and the mold filling effect of liquid metal, and the impacts of different rotation axes of the test ladle on the structure of the pouring apparatus and driving force. The upper lug and the lower lug can also respectively slide for adjustment and be fixed in the rear upper T-shaped groove and the rear lower T-shaped groove to adjust the positions of the upper and lower connecting hinges between the pouring apparatus and the test ladle, thereby further adjusting the angle of pouring force applied to the test ladle by the pouring apparatus, so as to research the impacts of parameters such as manner, direction, and dimension of the force applied by the pouring apparatus on pouring casting of the test ladle, and to perform comprehensive, analytic, and optimizing researches and tests for a mechanism type of the pouring apparatus.

The pouring apparatus comprises a rear pillar, an upper telescopic rod and a lower telescopic rod which used for driving the test ladle to rotate about the axis of the rotation pin, so as to implement the pouring casting. The rear pillar is used for mounting and supporting the upper telescopic rod and the lower telescopic rod, the bottom of the rear pillar is fixedly mounted on the base by means of corner connectors and screws, a scale ruler is disposed on the front surface of the rear pillar and is used for calibrating and measuring mounting positions of the rear ends of the upper telescopic rod and the lower telescopic rod on the rear pillar; the rear end of the upper telescopic rod is connected to the rear pillar by means of a hinge, the front end of the upper telescopic rod is connected to the upper lug by means of a hinge; and the rear end of the lower telescopic rod is connected to the rear pillar by means of a hinge, the front end of the lower telescopic rod is connected to the lower lug by means of a hinge. The upper telescopic rod and the lower telescopic rod can be linear actuators, hydraulic cylinders, clectrohydraulic cylinders, or air cylinders.

The simulation sand box is used for substituting for a sand box and casting mold in a casting molding test, and different types of test-used gating systems and casting molds can be mounted in the simulation sand box, so as to research the impacts of different types of gating systems and casting molds on the mold filling process of the liquid metal. A sprue cup is disposed on the middle top of the simulation sand box, two symmetrically arranged open risers are disposed on the front top of the simulation sand box, test-used replaceable gating systems and casting molds are disposed in the simulation sand box, and a flow rate meter is disposed in the sprue cup and is used for measuring the flow rate and the flow quantity parameter during pouring of a medium such as water, slurry, or glycerine for simulating the liquid metal in the test process. All of the simulation sand box, the sprue cup, the open risers, and the gating systems and the casting molds mounted in the simulation sand box are made of transparent polymethyl methacrylate materials or completely transparent acrylic materials, for ease of a tester to perform visual observation or photography by using a high-speed camera during the test.

The measuring apparatus comprises a measuring support, a high-speed camera, and a laser displacement sensor. The bottom of the measuring support is fixedly mounted on the base by means of sliding block(s) and is used for mounting the high-speed camera, the laser displacement sensor, or other measuring instalments which are temporarily required to be mounted; the measuring support can move forwardly and backwardly along the base, so as to adjust the measuring positions in the forward and backward directions; and lock screws are further disposed on the bottom of the measuring support for fixing the measuring support. The high-speed camera is mounted on the upper end of the measuring support and is used for measuring the displacement and tracking the movement of the medium such as water, slurry, or glycerine for simulating the liquid metal and an inclusion during the casting process; the high-speed camera is connected to the measuring support by means of a supporting base with an adjustable inclination angle, and a shooting angle of the high-speed camera can be adjusted by means of the supporting base with an adjustable inclination angle. The laser displacement sensor is located below the high-speed camera and is used for measuring the position and thickness information of the medium such as water, slurry, or glycerine and inclusion which are used for simulating the liquid metal during the casting process; and the laser displacement sensor is mounted on the measuring support by means of T-shaped lockable screw(s) on the tail thereof, for ease of adjusting the height thereof on the measuring support. A scale ruler is disposed on the side of the base where the measuring support is mounted and is used for measuring and marking the position of the measuring support on the base.

The vibration table comprises telescopic supporting legs, a working table, and vibration motors. There arc four telescopic supporting legs symmetrically arranged on the base and used for supporting and adjusting the height of the working table; and the bottom of each telescopic supporting kg is fixedly connected to the base by means of screw(s), the top of each telescopic supporting leg is connected to the working table by means of a spherical hinge. There are two vibration motors, both of which are fixedly mounted on the bottom of the working table and provide excitation power for vibrating the working table; a weighing sensor is disposed on the top of the working table and is used for measuring the change of the weight of the simulation sand box mounted on the working table and the weight of the medium poured into the simulation sand box for simulating the liquid metal; and an acceleration sensor is further disposed below the working table and is used for real-time measuring the displacement, the speed, and the acceleration of the working table. Axes of the two vibration motors are parallel to each other, specifications and models of the two vibration motors are completely identical, and the two vibration motors keep synchronously rotating in opposite directions during working. The telescopic supporting legs can be double-action hydraulic cylinders, double-action elcctrohydraulic cylinders, or double-action air cylinders, and such a design makes the telescopic supporting legs to further provide the function as a shock absorber.

An electric cabinet is thither disposed outside the mechanical body of the present invention, wherein a data acquisition card, a controller, and a computer arc disposed and used for collecting, analyzing, and processing sensing information obtained by each sensor.

During the use, different types of medium for formulating the liquid metal and heating temperature of the test ladle are firstly selected according to different test contents, the positions of the front and rear ends of the upper telescopic rod and the lower telescopic rod in the pouring apparatus on the test ladle and the rear pillar need to be respectively adjusted according to specific test requirements, the position of the upper movable pin sleeve in the upper side T-shaped groove or the position of the lower movable pin sleeve in the lower side T-shaped groove is determined and is locking fixed, the position of the measuring support on the base and the positions of the measuring instruments, such as the high-speed camera and the laser displacement sensor, on the measuring support are appropriately adjusted, the position of the simulation sand box on the vibration table is appropriately adjusted, According to requirement of the test vibration casting mode can be alter OMMIN selected, and the parameters, such as vibration direction, frequency, and amplitude of the vibration table can be determined. After completion of the adjustment of each parameter, the gating system and the casting mold for the test arc fixedly mounted in the simulation sand box, and the reliable connection between the gating system and the sprue cup must be ensured; the appropriately adjusted medium such as water, slurry, or glycerine for simulating the liquid metal then can be poured into the test ladle and heated to a set temperature, and then drive the pouring apparatus to make the test ladle rotating, so as to perform a casting test task.

During the performing of vibration casting test task, the working table can generate vibrations of different directions and types by changing the mounted position of the vibration motors on the working table,the vibration direction of the vibration motors and the working manner(time sequence) of the vibration motors. Information obtained from the three-dimensional force sensor, the angle sensor, the temperature sensor, the flow rate meter, the laser displacement sensor, and the acceleration sensor, and the image shot information from the high-speed camera, and the like are all transmitted to the computer and the controller by means of the data acquisition card.

Compared with the prior art, the beneficial effects of the present invention are as follows: compact structure; , gravity casting, vibration casting, and a gravity casting mold filling process of the liquid metal can be simulated; the parameters can be conveniently adjusted, with great flexibility and practicability. There are many measurable parameters, which can provide reliable data for selection of a casting process solution, design of the gating system, research of a formation mechanism of a casting defect and a vibration casting mechanism, and research of a casting rule, and test data can be provided for research work such as solution design and optimization of a drive mechanism of a casting device and complete machine development, and principle sample machine verification can be performed. A test result can be obtained by moans of sensors mounted in the measuring apparatus, the vibration table, the simulated sand box, and the test ladle, and a test parameter can be automatically collected, analyzed, and converted by the computer. In the present invention, test solutions can be pertinently formulated according to different working conditions, gating systems, and casting molds, so as to obtain regular conclusions, and the present invention has many advantages such as research free from constraints of factors such as the environment and site, an easy operation, and a low cost, thus can overcoming the defects of the prior art.

Brief Description of the Drawings

FIG. 1 is an overall structural schematic diagram according to the present invention; FIG. 2 is a schematic diagram of the connection between a test ladle and a pouring apparatus according to the present invention; FIG. 3 is a structural schematic diagram of the test ladle according to the present invention; and FIG. 4 is a schematic diagram of the connection between a vibration table and a simulated sand box according to the present invention.

Detailed Description of the Preferred Embodiments

in order to make the technical means, inventive features, achieved objectives, and functions implemented by the present invention easier to be understood, the present invention will be described in further detail below with reference to specific embodiments and the drawings.

As shown in FIG. 1, FIG. 2, FIG. 3, and FIG. 4, providing a gravity casting simulation test bench, which comprises: a base 1, a ladle frame 2, a test ladle 3, a pouring apparatus 4, a vibration table 5, a simulation sand box 6, and a measuring apparatus 7. The ladle frame 2 is located at the center of the base 1 and is fixedly connected to the base 1 by means of screws; the test ladle 3 is mounted on the ladle frame 2, two sides of the test ladle 3 are connected to the ladle frame 2 by means of hinges; the pouring apparatus 4 is located at the rear of the base 1, the bottom of the pouring apparatus 4 is fixedly mounted on the base 1 by means of screw, the front end of the pouring apparatus 4 is connected to the test ladle 3 by means of hinges; the vibration table 5 is located at the front end of the base 1 and is fixedly connected to the base 1; the simulation sand box 6 is fixedly mounted on the top of the vibration table 5; the measuring apparatus 7 is located at the side of the frontend of the base 1, and the measuring apparatus 7 is fixedly mounted on the base 1 by means of sliding block(s) and the measuring apparatus 7 can move forwardly and backwardly along the base.

As shown in FIG. 1 and FIG. 2, the ladle frame 2 comprises center pillars 21, top beams 22, cross beams 23, and lifting means 24. The ladle frame 2 is used for supporting and mounting the test ladle 3. There are four center pillars 21 symmetrically and fixedly mounted on the base 1 by means of corner connectors and screws. There are two top beams 22, each of them is fixedly mounted on the top of corresponding left and right center pillars 21 respectively. There are two cross beams 23, each of them is mounted between the corresponding front and rear center pillars 21 respectively, and is connected to the corresponding front and rear center pillars 21 by means of a sliding pair which allows the cross beam sliding upwardly and downwardly along the center pillars 21.There is a rotation pin 231, which is used for connecting to the test ladle 3, is further disposed in the middle of each cross beam 23; Two lifting means 24,which are symmetrically arranged at the corresponding left and right sides of the base 1 respectively, are used for driving the cross beams 23 and the test ladle 3 to move upwardly and downwardly along the center pillars 21; the bottom of each lifting means 24 is fixedly connected to the base 1, the top of each lifting means 24 is connected to the cross beam 23 by means of a lunge; and a three-dimensional force sensor and an angle sensor are further disposed on the rotation pin 231 of the cross beam 23 and are used for measuring the force applied by the test ladle 3 and the pouring apparatus 4 to the cross beam 23. The lifting means 24 can be linear actuators, hydraulic cylinders, electrohydraulic cylinders, or air cylinders.

As shown in FIG. I, FIG. 2, and FIG. 3, a ladle mouth 31 is disposed on the front top of the test ladle 3, fixed pin sleeves 32 are disposed on both sides of middle part of the test ladle 3; an upper side T-shaped groove 33 and a lower side T-shaped groove 34 are respectively disposed at the upper side and lower side of each fixed pin sleeve 32, an upper movable pin sleeve 35 and a lower movable pin sleeve 36 are respectively fixedly mounted outside each upper side T-shaped groove 33 and each lower side T-shaped groove 34, both the upper movable pin sleeves 35 and the lower movable pin sleeves 36 are connected to the test ladle 3 by means of T-shaped screws; a rear upper T-shaped groove 37 and a rear lower T-shaped groove 38 are further disposed on the side of the rear of the test ladle 3; an upper lug 39 and a lower lug 310 are respectively fixedly mounted outside the rear upper T-shaped groove 37 and the rear lower T-shaped groove 38, and both the upper lug 39 and the lower lug 310 are connected to the test ladle 3 by means of T-shaped screws; the test ladle 3 is thus connected to the rotation pins 231 on the cross beams 23 by means of the fixed pin sleeves 32, the upper movable pin sleeves 35, or the lower movable pin sleeves 36; and a temperature sensor, an electrical heater, and an electrical heating temperature controller are disposed in the test ladle 3. The fixed pin sleeves 32, the upper movable pin sleeves 35, and the lower movable pin sleeves 36 can cooperate with the rotation pins 231 on the cross beams 23. The upper movable pin sleeves 35 and the lower movable pin sleeves 36 can respectively slide in the upper side T-shaped groove 33 and the lower side T-shaped groove 34 so as to adjust the position of the rotation axis of the test ladle 3 during pouring, from which the research of the impacts of different rotation axes of the test ladle 3 on a casting morphology and a mold filling effect of liquid metal, and the impacts of different rotation axes of the test ladle 3 on the structure of the pouring apparatus 4 and driving force can be carried out. The upper lug 39 and the lower lug 310 can also respectively slide for adjustment and be fixed in the rear upper T-shaped groove 37 and the rear lower T-shaped groove 38 to adjust the positions of the upper and lower connecting hinges between the pouring apparatus 4 and the test ladle 3, thereby further adjust the angle of the pouring force applied to the test ladle 3 by the pouring apparatus 4, so as to research the impacts of the parameters such as maimer, direction, and dimension of the force applied by the pouring apparatus 4 on pouring casting of the test ladle 3, and to perform comprehensive, analytic, and optimizing researches and tests for a mechanism type of the pouring apparatus.

As shown in FIG. 1 and FIG. 2, the pouring apparatus 4 comprises a rear pillar 41, an upper telescopic rod 42, and a lower telescopic rod 43. The pouring apparatus 4 is used for driving the test ladle 3 to rotate about the axis of the rotation pin 231, so as to implement the pouring casting. The rear pillar 41 is used for mounting and supporting the upper telescopic rod 42 and the lower telescopic rod 43, the bottom of the rear pillar 41 is fixedly mounted on the base 1 by means of corner connectors and screws, a scale ruler is disposed on the front surface of the rear pillar 41 and is used for calibrating and measuring the mounting positions of the rear ends of the upper telescopic rod 42 and the lower telescopic rod 43 on the rear pillar 41; the rear end of the upper telescopic rod 42 is connected to the rear pillar 41 by means of a hinge, the front end of the upper telescopic rod 42 is connected to the upper lug 39 by means of a hinge; and the rear end of the lower telescopic rod 43 is connected to the rear pillar 41 by means of a hinge, the front end of the lower telescopic rod 43 is connected to the lower lug 310 by means of a hinge. The upper telescopic rod 42 and the lower telescopic rod 43 can be linear actuators, hydraulic cylinders, electrohydraulic cylinders, or air cylinders.

As shown in FIG. 1 and FIG. 4, the simulation sand box 6 is used for substituting for a sand box and casting mold in a casting molding test, and different types of test-used gating systems and casting molds are mounted in the simulation sand box 6, so as to research the impacts of different types of gating systems and casting molds on a mold filling process of the liquid metal. A sprue cup 61 is disposed on the middle top of the simulation sand box 6, two symmetrically arranged open risers 62 are disposed on the front top of the simulation sand box 6, a test-used replaceable gating system and casting mold are disposed in the simulation sand box 6, and a flow rate meter is disposed in the sprue cup 61 and is used for measuring the flow rate and flow parameter during pouring of a medium such as water, slurry, or glycerine for simulating the liquid metal in the test process. The simulation sand box 6, the sprue cup 61, the open riser 62, and the gating system and the casting mold mounted in the simulation sand box 6 are made of transparent polymethyl methacrylate materials or completely transparent acrylic materials, for ease of a tester to perform visual observation or photography by using a high-speed camera 72 during the test.

As shown in FIG. 1, the measuring apparatus 7 comprises a measuring support 71, a high-speed camera 72, and a laser displacement sensor 73. The bottom of the measuring support 71 is fixedly mounted on the base 1 by means of sliding block(s) and is used for mounting the high-speed camera 72, the laser displacement sensor 73, or other measuring instruments which are temporarily required; the measuring support 71 can move forwardly and backwardly along the base 1, so as to adjust the measuring positions in front and rear directions; and locking screw(s) is(are) further disposed on the bottom of the measuring support 71 for fixing the measuring support 71. The high-speed camera 72 is mounted on the upper end of the measuring support 71 and is used for measuring the displacement and the tracking of the medium such as water, slurry, or glycerine for simulating the liquid metal and an inclusion during the casting process; the high-speed camera 72 is connected to the measuring support 71 by means of a supporting base 721 with an adjustable inclination angle, and the shooting angle of the high-speed camera 72 can be adjusted by means of the supporting base 721 with an adjustable inclination angle. The laser displacement sensor 73 is located below the high-speed camera 72 and is used for measuring the position and the thickness information of the medium such as water, slurry, or glycerine for simulating the liquid metal and an inclusion during the casting process; and the laser displacement sensor 73 is mounted on the measuring support 71 by means of T-shaped lockable screw(s) on the tail thereof, for case of adjusting the height thereof on the measuring support 71. A scale ruler is disposed on a side of the base 1 where the measuring support 71 is mounted and is used for measuring and marking the position of the measuring support 71 on the base 1.

As shown in FIG. 1 and FIG. 4, the vibration table 5 comprises telescopic supporting legs 51, a working table 52, and vibration motors 53. There are four telescopic supporting legs 51 symmetrically arranged on the base 1 and used for supporting and adjusting the height of the working table 52; and the bottom of each telescopic supporting leg 51 is fixedly connected to the base 1 by means of screw(s), the top of each telescopic supporting leg 51 is connected to the working table 52 by means of a spherical hinge. There are two vibration motors 53, both of which are fixedly mounted on the bottom of the working table 52 and provide excitation power for vibrating the working table 52; a weighing sensor is disposed on the top of the working table 52 and is used for measuring the weight change of the simulation sand box 6 mounted on the working table and the weight of the medium poured into the simulation sand box 6 for simulating the liquid metal; and an acceleration sensor is further disposed below the working table 52 and is used for real time measuring the displacement, the speed, and the acceleration of the working table 52. Axes of the two vibration motors 53 are parallel to each other, specifications and models of the two vibration motors 53 are completely identical, and the two vibration motors 53 synchronously rotate in opposite directions during working. The telescopic supporting legs 51 can be double-action hydraulic cylinders, double-action electrohydraulic cylinders, or double-action air cylinders, and such a design makes the telescopic supporting legs 51 to further have the function as shock absorbers.

An electric cabinet is further disposed outside the mechanical body of the present invention, wherein a data acquisition card, a controller, and a computer are disposed in the electric cabinet and used for collecting, analyzing, and processing sensing information obtained by each sensor.

During use, different types of medium for formulating the liquid metal and heating temperature of the test ladle 3 are firstly selected according to different test contents, the positions of the front and rear ends of the upper telescopic rod 42 and the lower telescopic rod 43 in the pouring apparatus 4 on the test ladle 3 and the rear pillar 41 need to be respectively adjusted according to specific test needs, the position of the upper movable pin sleeves 35 in the upper side T-shaped grooves 33 or the position of the lower movable pin sleeves 36 in the lower side T-shaped grooves 34 can be determined and locking fixed, the position of the measuring support 71 on the base 1 and the positions of the measuring instruments such as the high-speed camera 72 and the laser displacement sensor 73 on the measuring support 71 are appropriately adjusted, the position of the simulation sand box 6 on the vibration table 5 is appropriately adjusted, whether a vibration casting mode is to be selected is determined according to the test needs, and parameters such as a vibration direction, frequency, and amplitude of the vibration table 5 are determined. After completion of the adjustment of each parameter, the test-used gating system and casting mold are fixedly mounted in the simulation sand box 6, and the connection between the gating system and the spme cup 61 is ensured to be reliable; then, the appropriately adjusted medium such as water, slurry, or glycerine for simulating the liquid metal is poured into the test ladle 3 and is heated to set temperature, and then the pouring apparatus 4 is enabled to drive the test ladle 3 to rotate, so as to perform a casting test task.

During the performance of a vibration casting test task, the working table 52 can generate vibrations of different directions and different types by changing the mounting position and direction of the vibration motors 53 relative to the working 25 table 52 and a working time sequence of the vibration motors 53. Information obtained by the three-dimensional force sensor, the angle sensor, the temperature sensor, the flow rate meter, the laser displacement sensor 73, and the acceleration sensor, information of an image shot by the high-speed camera 72, and the like arc all transmitted to the computer and the controller by means of the data acquisition card. 30 In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms such as "upper", "lower", "left", "right" "horizontal", "top", "bottom", "inside", "outside", "front", and "rear" are based on the orientation or positional relationships shown in the drawings, and are merely for convenience in describing the present invention and simplification of the description, instead of indicating or suggesting that the indicated apparatus or element must have a specific orientation or be constructed and operated in a specific orientation, and thus are not to be construed as limitations on the present invention.

The basic principles, main features and advantages of the present invention have been shown and described above. It should be understood by those skilled in the art that the present invention is not limited by the above embodiments, and only the principles of the present invention are described in the above embodiments and description. Various changes and modifications can be made to the present invention without departing from the spirit and scope of the present invention, and all of these changes and modifications fall into the scope claimed by the present invention. The scope claimed by the present invention is defined by the attached claims and equivalents thereof

Claims

CLAIMS1. A gravity casting simulation test bench, comprising: a base, a ladle frame, a test ladle, a pouring apparatus, a vibration table, a simulation sand box, and a measuring apparatus, wherein: the ladle frame is located at the center of the base and is fixedly connected to the base by means of screws; the test ladle is mounted on the ladle frame, two sides of the test ladle are connected to the ladle frame by means of hinges; the pouring apparatus is located at the rear end of the base, the bottom end of the pouring apparatus is fixedly mounted on the base, the front end of the pouring apparatus is connected to the test ladle by means of hinges; the vibration table is located at the front end of the base and is fixedly connected to the base; the simulation sand box is fixedly mounted on the top of the vibration table; the measuring apparatus is located at the front side of the base, and the measuring apparatus is fixedly mounted on the base by means of sliding block(s) and can move forwardly and backwardly along the base; the ladle frame comprises center pillars, top beams, cross beams, and lifting means, wherein there are four center pillars symmetrically and fixedly mounted on the base, there are two top beams,each of which is fixedly mounted on the top of the corresponding left and right center pillars respectively; there are two cross beams, each of which is mounted between the corresponding front and rear center pillars, each cross beam is connected to the center pillars by means of sliding pair which allows the cross beam sliding upwardly and downwardly along the center pillars,; a rotation pin is further disposed in the middle of each cross beam; there are two lifting means symmetrically arranged at left and right sides of the base, the bottom of each lifting means is fixedly connected to the base, the top of each lifting means is connected to the cross beam by means of a hinge; and a three-dimensional force sensor and an angle sensor are further disposed on the rotation pin of the cross beam; a ladle mouth is disposed on the front top of the test ladle, fixed pin sleeves are disposed on both sides of middle part of the test ladle; an upper side T-shaped groove and a lower side T-shaped groove are respectively disposed at upper side and lower side of each fixed pin sleeve, an upper movable pin sleeve and a lower movable pin sleeve are respectively fixedly mounted outside each upper side T-shaped groove and each lower side T-shaped groove, both the upper movable pin sleeves and the lower movable pin sleeves arc connected to the test ladle by means of T-shaped screws; a rear upper T-shaped groove and a rear lower T-shaped groove are further disposed on the side of the rear end of the test ladle; an upper lug and a lower lug are respectively fixedly mounted outside the rear upper T-shaped groove and the rear lower T-shaped groove, and both the upper lug and the lower lug are connected to the test ladle by means of T-shaped screws; the test ladle is connected to the rotation pins on the cross beams by means of either the fixed pin sleeves, or the upper movable pin sleeves, or the lower movable pin sleeves; and a temperature sensor, an electrical heater, and an electrical heating temperature controller are disposed in the test ladle; the pouring apparatus comprises a rear pillar, an upper telescopic rod and a lower telescopic rod; the bottom of the rear pillar is fixedly mounted on the base, a scale ruler is disposed on the front surface of the rear pillar; the rear end of the upper telescopic rod is connected to the rear pillar by means of a hinge, the front end of the upper telescopic rod is connected to the upper lug by means of a hinge; the rear end of the lower telescopic rod is connected to the rear pillar by means of a hinge, the front end of the lower telescopic rod is connected to the lower lug by means of a hinge; a spate cup is disposed on the middle top of the simulation sand box, two symmetrically arranged open risers are disposed on the front top of the simulation sand box, a test-used replaceable gating system and casting mold are disposed in the simulation sand box, and a flow rate meter is disposed in the sprue cup; and the measuring apparatus comprises a measuring support, a high-speed camera and a laser displacement sensor; the bottom of the measuring support is fixedly mounted on the base by means of sliding block(s) which allows the measuring support moving forwardly and backwardly along the base, lock screw(s) is(are) further disposed on the bottom of the measuring support; the high-speed camera is mounted on the upper end of the measuring support and is connected to the measuring support by means of a supporting base with an adjustable inclination angle; the laser displacement sensor is located below the high-speed camera, and the laser displacement sensor is mounted on the measuring support by means of T-shaped lockable screw(s) on the tail thereof.
2. The gravity casting simulation test bench according to claim I, wherein: the vibration table comprises telescopic supporting legs, a working table, and vibration motors, there are four telescopic supporting legs symmetrically arranged on the base, the bottom of each telescopic supporting leg is fixedly connected to the base by means of screw(s), the top of each telescopic supporting leg is connected to the working table by means of a spherical hinge; there are two vibration motors, both of which are fixedly mounted on the bottom of the working table; and a weighing sensor is disposed on the top of the working table, and an acceleration sensor is further disposed below the working table.
3. The gravity casting simulation test bench according to claim I, wherein: the simulation sand box, the sprue cup, the open riser, the gating system, and the casting mold are made of transparent polymethyl methacrylate materials or completely transparent acrylic materials.
4. The gravity casting simulation test bench according to claim 2, wherein: axes of the two vibration motors are parallel to each other, and specifications and models of the two vibration motors are completely identical.
5. The gravity casting simulation test bench according to claim 1, wherein: the lifting gear, the upper telescopic rod, and the lower telescopic rod are linear actuators, hydraulic cylinders, clectrohydraulic cylinders, or air cylinders.
6. The gravity casting simulation test bench according to claim 2, wherein: the telescopic supporting legs are double-action hydraulic cylinders, double-action electrohydraulic cylinders, or double-action air cylinders.