WO2021147505A1 - 基于3d打印的适用于整体式多路阀的铸造方法和系统 - Google Patents

基于3d打印的适用于整体式多路阀的铸造方法和系统 Download PDF

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WO2021147505A1
WO2021147505A1 PCT/CN2020/131735 CN2020131735W WO2021147505A1 WO 2021147505 A1 WO2021147505 A1 WO 2021147505A1 CN 2020131735 W CN2020131735 W CN 2020131735W WO 2021147505 A1 WO2021147505 A1 WO 2021147505A1
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valve
sand
sand mold
cast
printing
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PCT/CN2020/131735
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English (en)
French (fr)
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薄夫祥
何冰
陈鹏飞
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江苏徐工工程机械研究院有限公司
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Priority to US17/428,546 priority Critical patent/US11858031B2/en
Priority to DE112020000378.7T priority patent/DE112020000378T5/de
Publication of WO2021147505A1 publication Critical patent/WO2021147505A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082—Sprues, pouring cups
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/088—Feeder heads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings
    • B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing

Definitions

  • the present disclosure relates to the technical field of construction machinery additive manufacturing, in particular to a 3D printing-based casting method and system suitable for integral multi-way valves.
  • the large integral hydraulic multi-way valve is the core control element of construction machinery. It is located between the pump and the actuator. It is used to control the flow size and direction of the hydraulic oil, so as to centrally control the movement direction and speed of the actuator. It is widely used in engineering. Machinery, mining machinery, port machinery and other fields. The performance of the large integrated multi-way valve directly affects the overall working performance of the product, and affects the reputation and sales of the complete product.
  • the manufacture of large-scale integral hydraulic multi-way valves usually adopts traditional sand casting method. According to the design model, the metal mold is first manufactured, then the sand mold is made by the metal mold, and finally the casting is completed to obtain the hydraulic valve blank.
  • the traditional manufacturing method is mold manufacturing. The long cycle and high mold cost are not conducive to multiple revisions of the model in the design stage, which limits the rapid replacement of large-scale integral hydraulic multi-way valves.
  • sand mold 3D printing has a high application success rate on aluminum alloy castings and thick and large parts, but the strength of sand molds quickly manufactured based on sand mold 3D printing technology is much lower than that of transmission mold manufacturing sand molds, especially when the internal structure is complex, small structure, Large-scale integral hydraulic multi-way valves with many features such as suspension structure generally have problems such as low rapid casting success rate and poor molding quality. Casting defects such as broken cores and overhangs are easy to occur during the casting process. The process is immature and difficult to satisfy the industry. Optimized application requirements.
  • the present disclosure provides a casting method suitable for an integral multi-way valve, including:
  • the structural parameters of the valve to be cast determine the position of each inner gate of each layer, so that all the inner gates are located on the same side of the valve body to be cast;
  • each gate model with the corresponding number of layers and positions;
  • a runner model connected with the inner gate is arranged separately;
  • valve to be cast As well as the inner gate model, runner model, sprue model, and riser model, create a sand core model to be 3D printed, and include inner gate, runner, straight Sand model of sprue and riser;
  • 3D printing is performed according to the sand mold model and the sand core model to obtain the sand mold and the sand core of the valve to be cast;
  • the sand mold and sand core obtained by 3D printing are used for pouring casting to obtain an integral valve body.
  • the present disclosure provides a multi-layer composite pouring and casting method adopting a side-casting method, which can disperse and balance the influence of gravity and scouring force during the liquid filling process, and the 3D-printed sand mold is an integral sand mold with no sticking inside the sand mold
  • the joint gap can ensure the surface quality of the finished valve body castings, and at the same time can realize the rapid casting of the integral hydraulic valve, which is suitable for batch and standardized manufacturing.
  • the body model of the integral multi-way valve to be cast can be generated to facilitate more intuitive setting of the positions of the gate, runner, sprue, riser, etc.
  • the integral multi-way valve casting method further includes:
  • a conformal vent is provided in the corresponding sand core that needs to be connected to the periphery of the sand mold. That is, the path of the exhaust hole is arranged along the center path of the valve hole. The arrangement of the exhaust channel and the exhaust hole can improve the exhaust efficiency of the integral sand core.
  • the integral multi-way valve casting method further includes: before pouring, the sand mold obtained by 3D printing is dip-coated with zircon powder paint, and then dried.
  • the zircon powder paint with a Baume degree between 40 and 60 is used for dip coating, the number of dip coatings is ⁇ 3 times, the drying temperature is 100 to 180°C, and the drying time is set to: 1 to 1.5h .
  • the integral multi-way valve casting method further includes selecting a 3D sand mold printing process for sand core printing according to the weight of the valve to be cast:
  • weight of the valve to be cast is ⁇ 50kg, use selective laser sintering technology or adhesive jet printing technology for sand core 3D printing;
  • the sand core 3D printing is carried out using the binder jet printing technology. It can further protect the sand core to reduce core breakage and other situations.
  • the valve to be cast is an integral hydraulic multi-way valve; when pouring, nodular cast iron is used for pouring casting, the pouring temperature is 1350-1400°C, and the holding time after pouring is ⁇ 8h.
  • the determination of the number of layers N of the inner gate according to the height L of the valve body is: dividing the height L of the valve body by a predetermined height interval L0, and approximately rounding the result obtained to obtain the number of layers N. Approximate rounding can be a rounding approximation, or the quotient of the integer part can be directly taken.
  • the preset height interval L0 can be adjusted as needed, for example, set to 100mm.
  • different ingates located on the same layer have at least one height position. That is, in the present disclosure, the inner gates of the same layer can be set at different heights to meet other structural requirements, such as avoiding structural positions that are not suitable for direct scouring.
  • the inner gate is located away from the internal oil passage of the sand mold. It can ensure that the oil channel sand core will not be directly washed away during the liquid filling process, and the casting defects such as broken core and drape due to the impact of molten iron during the casting process can be reduced.
  • the present disclosure also provides a casting system suitable for an integral multi-way valve, including a sand mold body, a sprue, a runner, an inner gate and a riser;
  • the sprue, the runner and the inner gate are arranged on one side of the sand mold body; a plurality of runners are arranged along the height direction of the sand mold body, and each runner is provided with a plurality of inner gates in the extending direction, Each runner is connected to the sand mold body through the plurality of internal gates; the plurality of runners are respectively connected to the sprue, and the riser is arranged on the top of the sand mold body.
  • the number of runners is set as the value obtained by dividing the height L of the valve body by a predetermined height interval L0, and the result obtained is approximately rounded to an integer;
  • All internal gates connected by a single runner have at least two height positions, and each internal gate is set away from the internal oil passage of the sand mold;
  • the peripheral wall thickness of the sand mold ⁇ 25mm
  • a through-type exhaust channel is provided in the sand core corresponding to the main valve hole;
  • the sand core connected to the periphery of the sand mold corresponding to the valve holes other than the main valve hole is provided with an accompanying vent hole.
  • the number of risers is multiple; all the ingates are arranged on the side of one side of the sand mold parallel to the axial direction of the main valve hole. That is, the side where the inner gate is located is not the top or bottom surface of the sand mold.
  • Fig. 1 is a schematic diagram showing the positions of an inner gate, a runner, a sprue, and a riser according to an embodiment of the present disclosure
  • Figure 2 shows a detailed schematic diagram of the parts of Figure 1;
  • Fig. 3 is a schematic diagram showing the structure of an integral multi-way valve sand core corresponding to the embodiment in Fig. 1;
  • Fig. 4 is a schematic diagram showing the distribution of gates in a certain integral multi-way valve corresponding to the embodiment in Fig. 1;
  • Fig. 5 is a schematic diagram of an overall multi-way valve exhaust system corresponding to the embodiment in Fig. 1;
  • Figure 1- Figure 5 1-Integral multi-way valve, 2- sprue, 3-cross runner, 4 (41 to 42, 42-1 to 42-5,) is the gate, 5-take Port, 61 (62)-main valve hole sand core, 63-67 is the internal oil passage sand core, 71-72 is the main valve hole position exhaust channel, 73 is the conformal exhaust hole.
  • the inventive concept of the present disclosure is: firstly, by determining the multiple layers and multiple internal gates, connecting multiple runners of the internal gates of each layer, and connecting multiple runners according to the structural parameters of the integral multi-way valve to be cast It uses 3D printing technology to print the integral sand mold, realizes the multi-layer composite casting method and the corresponding casting system, disperses the influence of gravity and scouring force in the liquid filling process, and reduces core fracture and internal defects Casting defects such as drape, main valve hole bending, etc., and realize rapid casting, while ensuring the quality stability of the formed valve.
  • the present disclosure provides a multi-layer composite pouring and casting method using a side pouring method, and a corresponding casting system.
  • the multi-layer composite pouring method can disperse and balance the influence of gravity and scouring force in the liquid filling process, and reduce sand Casting defects such as core fracture, internal defects overhanging seams, and bending of the main valve hole.
  • the 3D printed sand mold is a monolithic sand mold, there is no bonding gap inside the sand mold, and the consistency between the sand molds is good, which can guarantee the surface quality and quality stability of the finished valve body castings, and at the same time, it can realize the integration of the hydraulic valve. Rapid casting is suitable for batch and standardized manufacturing, which better supports the rapid upgrade of large-scale integral hydraulic multi-way valve products, greatly reduces trial production costs, shortens trial production cycles, and further realizes the industrial application of sand mold 3D printing technology.
  • This embodiment is a casting method suitable for an integral multi-way valve based on 3D printing, including:
  • the structural parameters of the valve to be cast determine the position of each inner gate of each layer, so that all the inner gates are located on the same side of the valve body to be cast;
  • each gate model with the corresponding number of layers and positions;
  • a runner model connected with the inner gate is arranged separately;
  • valve to be cast As well as the inner gate model, runner model, sprue model, and riser model, create a sand core model to be 3D printed, and include inner gate, runner, straight Sand model of sprue and riser;
  • 3D printing is performed according to the sand mold model and the sand core model to obtain the sand mold and the sand core of the valve to be cast;
  • the sand mold and sand core obtained by 3D printing are used for pouring casting to obtain an integral valve body.
  • the present disclosure provides a multi-layer composite pouring and casting method adopting a side-casting method, which can disperse and balance the influence of gravity and scouring force during the liquid filling process, and the 3D-printed sand mold is an integral sand mold with no sticking inside the sand mold
  • the joint gap can ensure the surface quality of the finished valve body castings, and at the same time can realize the rapid casting of the integral hydraulic valve, which is suitable for batch and standardized manufacturing.
  • the casting method of the integral multi-way valve is specifically introduced by taking the valve to be cast as an integral hydraulic multi-way valve as an example.
  • the body model 1 of the integral multi-way valve to be cast can be generated to facilitate more intuitive setting of the internal gate, runner, sprue, riser, etc. For the location, refer to Figure 1 and Figure 2.
  • the integral multi-way valve casting method also includes: setting a through-type exhaust channel in the sand core corresponding to the main valve hole; for valve holes other than the main valve hole, in the corresponding sand core that needs to be connected to the periphery of the sand mold Set up a conformal vent. That is, the path of the exhaust hole is arranged along the center path of the valve hole. The arrangement of the exhaust channel and the exhaust hole can improve the exhaust efficiency of the integral sand core, as shown in Figure 5;
  • select the 3D sand mold printing process for sand core printing if the weight of the valve to be cast is ⁇ 50kg, use selective laser sintering technology or adhesive jet printing technology for sand core 3D printing; if the weight of the valve to be cast is >50kg , Adopting binder jet printing technology for sand core 3D printing. It can further protect the sand core to reduce core breakage and other situations.
  • the sand mold obtained by 3D printing is dip coated with zircon powder paint, and then dried.
  • zircon powder paint with a Baume degree of 40-60 can be used for dip coating, the number of dip coatings is less than or equal to 3 times, the drying temperature is 100-180°C, and the drying time is set to: 1-1.5h.
  • nodular cast iron is used for casting during pouring, the pouring temperature is 1350-1400°C, and the holding time after pouring is ⁇ 8h.
  • different gates on the same layer can be set at different heights to meet other structural requirements, such as avoiding structural locations that are not suitable for direct scouring, including the internal oil passages of the sand mold, to ensure the liquid filling process In the casting process, the sand core of the oil passage will not be directly washed, and the casting defects such as broken core and overhanging due to the impact of molten iron during the casting process are reduced.
  • the embodiment of the present disclosure also provides a casting system suitable for an integral multi-way valve, including a sand mold body, a sprue 2, a runner 3, an inner gate 4, and a riser 5;
  • the sprue 2, the runner 3 and the inner gate 4 are arranged on one side of the sand mold body; there are multiple runners along the height direction of the sand mold body, and a plurality of inner runners are arranged in the extending direction of each runner.
  • each runner is connected to the sand mold body through the plurality of internal gates; the plurality of runners are respectively connected to the sprue, and the riser 5 is arranged on the top of the sand mold body.
  • the following embodiments specifically introduce the casting system of the integral multi-way valve shown in FIGS. 1 to 5.
  • the number of gate layers is two;
  • All internal gates connected by a single runner have at least two height positions, and each internal gate is set away from the internal oil passage of the sand mold;
  • a through-type exhaust channel is provided in the sand core corresponding to the main valve hole;
  • the sand core connected to the periphery of the sand mold corresponding to the valve holes other than the main valve hole is provided with a conformable vent hole;
  • the number of risers is multiple; all the internal gates are arranged on the side of one side of the sand mold parallel to the axial direction of the main valve hole. That is, the side where the inner gate is located is not the top or bottom surface of the sand mold.
  • the inner gate 4 is arranged on the side of the pouring sand mold, between the two layers of main valve holes 61 and 62, the number of single-layer inner gates is not less than 3, as shown in Figure 4, 42-1 to 42-5, the total number is 5.
  • the internal gates must avoid adjacent internal oil passages such as 63 to 67 to ensure that the metal liquid does not directly scour the sand core of the oil passage during the filling process and reduce the impact of molten iron during the casting process. Lead to casting defects such as broken core and overhanging seams.
  • the present disclosure adopts 3D printing process to manufacture integral sand molds. There are no bonding gaps in the sand molds. As shown in Figure 5, the outer wall thickness of the sand mold is ⁇ 25mm, and all main valve holes are provided with exhaust through the exhaust. The channels are shown as 71 and 72 in Fig. 5, and other valve holes connected with the periphery are provided with conformal vent holes as shown in 73 in Fig. 5 to improve the exhaust efficiency of the integrated sand core.
  • the casting system is matched with a special casting process: zircon powder coating is used, and the method of dip coating is adopted.
  • the Baume degree of the coating is set to be between 40 and 60.
  • the number of coating dips is less than or equal to 3 times.
  • the drying temperature of the sand core 100 to 180°C, drying The dry time is set to: 1 ⁇ 1.5h.
  • the internal oil passage of the valve body has complicated characteristics, traditional casting, sand mold split bonding and molding, and casting defects such as drape seams are prone to occur.
  • the present disclosure realizes the integrated manufacturing of sand molds based on the 3D printing process, avoids internal bonding of sand cores, and reduces The number of hidden defects in casting defects can ultimately improve casting quality;
  • the success rate of integral hydraulic multi-way valve casting with sand mold 3D printing technology in the market is generally low.
  • the present disclosure proposes a composite pouring system, which can reasonably set the number of internal runners and the number of layers according to the specific structural size of the valve body, effectively reducing the impact of heat flow during the sand core pouring process, and further improving the casting success rate;
  • the heat-resistant strength of the sand core is further improved. Choosing ceramsite sand as the raw sand for 3D printing of sand cores improves the heat resistance strength of the sand cores. With special zircon powder coatings, the heat resistance strength of the 3D printing sand cores is further improved, and the strength of the 3D printing sand cores is insufficient. The key problem leading to low casting success rate;

Abstract

一种基于3D打印的适用于整体式多路阀的铸造方法，其包括：根据待铸造整体式多路阀的结构参数，确定多层多个内浇口，连接各层内浇口的多个横浇道，以及连接多个横浇道的直浇道，并利用3D打印技术打印整体式砂型。以及一种基于3D打印的适用于整体式多路阀的铸造系统。该铸造方法和系统实现了多层复合式浇注。

Description

基于3D打印的适用于整体式多路阀的铸造方法和系统
相关申请的交叉引用
本公开是以申请号为202010305784.4，申请日为2020年4月17日，发明名称为“基于3D打印的适用于整体式多路阀的铸造方法和系统”的中国专利申请为基础，并主张其优先权，该中国专利申请的公开内容在此作为整体引入本公开中。
技术领域
本公开涉及工程机械增材制造技术领域，特别是一种基于3D打印的适用于整体式多路阀的铸造方法和系统。
背景技术
大型整体式液压多路阀是工程机械的核心控制元件，它位于泵和执行元件之间，用于控制液压油的流量大小和流向，从而集中控制执行元件的运动方向和速度，广泛应用于工程机械、矿山机械、港口机械等领域。大型整体式多路阀性能的好坏直接影响产品整体的工作性能，影响整机产品的口碑及销售。
由于整体式液压多路阀阀体的主阀孔细长，内部油道复杂，悬空结构多、油槽多、截面形状及尺寸各不相同，铸造难度大，整体式液压多路阀铸造成功率较低。目前，大型整体式液压多路阀的制造通常采用传统砂型铸造方式，根据设计模型，先制造金属模具，然后利用金属模具制造砂型，最后完成浇注，得到液压阀毛坯，传统的制造方式，模具制造周期长，模具成本较高，不利于设计阶段模型的多次修改，限制了大型整体式液压多路阀的快速更新换代。
目前砂型3D打印在铝合金铸件及厚大件上应用成功率较高，但基于砂型3D打印工艺快速制造的砂型强度远低于传动模具制造砂型，特别是在遇到内部结构复杂，细小结构、悬浮结构等特征较多的大型整体式液压多路阀，普遍存在快速铸造成功率低、成型质量差等问题，浇注过程中易出现断芯，披缝等铸造缺陷，工艺不成熟，难以满足产业化应用需求。
发明内容
本公开采取的技术方案如下：
第一方面，本公开提供一种适用于整体式多路阀的铸造方法，包括：
确定待铸造阀的结构参数；
以垂直于主阀孔轴向的方向作为高度方向，确定待铸造阀的阀体高度L；
根据阀体高度L确定内浇口的层数；
根据待铸造阀的结构参数，确定各层各内浇口的位置，使得所有内浇口均位于待铸造阀体的同一侧；
根据待铸造阀的结构参数，布置相应层数、位置的各内浇口模型；
对应每层内浇口分别布置与内浇口连通的横浇道模型；
设置冒口模型以及连通各横浇道的直浇道模型；
根据待铸造阀的结构参数，以及所述内浇口模型、横浇道模型、直浇道模型、冒口模型，创建待3D打印的砂芯模型，以及包括内浇口、横浇道、直浇道和冒口的砂型模型；
根据所述砂型模型和砂芯模型进行3D打印，得到待铸造阀的砂型和砂芯；
利用3D打印得到的砂型和砂芯进行浇注式铸造，得到整体式阀体。
本公开提供了一种采用侧浇方式的多层复合式浇注铸造方法，可分散均衡液体充型过程中的重力和冲刷力等影响，且通过3D打印的砂型为整体式砂型，砂型内部无粘接缝隙，可保障浇注完成的阀体铸件表面质量，同时能够实现整体式液压阀的快速铸造，适合批量、规格化制造。
在确定待铸造阀的结构参数后，可生成待铸造整体式多路阀的本体模型，便于更加直观的设置内浇口、横浇道、直浇道、冒口等的位置。
在一些实施例中，整体式多路阀铸造方法还包括：
在对应主阀孔的砂芯中设置贯穿式排气通道；
对于除主阀孔之外的其它阀孔，在对应的、需连接砂型外围的砂芯中设置随型排气孔。也即排气孔的路径沿阀孔的中心路径设置。排气通道和排气孔的设置可提高整体式砂芯的排气效率。
在一些实施例中，整体式多路阀铸造方法还包括：在浇注前，对3D打印得到的砂型采用锆英粉涂料浸涂，然后进行烘干处理。
在一些实施例中，采用波美度为40～60之间的锆英粉涂料浸涂，浸涂次数≤3次，烘干温度为100～180℃，烘干时间设置为：1～1.5h。
在一些实施例中，整体式多路阀铸造方法还包括，根据待铸造阀的重量选择3D 砂型打印工艺进行砂芯打印：
若待铸造阀重量≤50kg，采用选择性激光烧结技术或粘接剂喷射打印技术进行砂芯3D打印；
若待铸造阀重量>50kg，采用粘结剂喷射打印技术进行砂芯3D打印。可进一步保障砂芯减少断芯等情况。
在一些实施例中，所述待铸造阀为整体式液压多路阀；浇注时，采用球墨铸铁进行浇注式铸造，浇注温度为1350-1400℃，浇注后保温时间≥8h。
在一些实施例中，所述根据阀体高度L确定内浇口的层数N为：将阀体高度L除以一预设高度间隔L0，对所得到的结果近似取整，即得到层数N。近似取整可为四舍五入近似，也可直接取整数部分的商。预设高度间隔L0可根据需要调整，如设置为100mm等。在具体布置各层内浇口时，最好避开与各路主阀孔相平齐的位置，比如可设置于两层主阀孔平齐位置之间。
在一些实施例中，位于同一层的不同内浇口具有至少一个高度位置。也即本公开中同一层的内浇口可以高度不一地设置，以适应其它结构需求，如避开不宜直接冲刷的结构位置。
在一些实施例中，所述内浇口远离砂型内部油道设置。可保证液体充型过程中不会直接冲刷油道砂芯，降低铸造过程中由于铁水冲击导致断芯、披缝等铸造缺陷。
第二方面，本公开还提供一种适用于整体式多路阀的铸造系统，包括砂型本体、直浇道、横浇道、内浇口和冒口；
以垂直于主阀孔砂芯轴向的方向作为砂型本体的高度方向；
所述直浇道、横浇道和内浇口设置于砂型本体的一侧；横浇道沿砂型本体高度方向设置有多个，各横浇道的延伸方向上设有多个内浇口，各横浇道通过所述多个内浇口连接砂型本体；多个横浇道分别连通直浇道，冒口设置于砂型本体的顶部。
在一些实施例中，横浇道的数量设置为，将阀体高度L除以一预设高度间隔L0，对所得到的结果近似取整后的结果值；
单个横浇道所连的所有内浇口具有至少两个高度位置，各内浇口远离砂型内部油道设置；
砂型外围壁厚≥25mm；
对应主阀孔的砂芯中设置有贯穿式排气通道；
除主阀孔之外的其它阀孔所对应的、连接砂型外围的砂芯中设置有随型排气孔。
在一些实施例中，冒口数量为多个；所有内浇口均设置于砂型平行于主阀孔轴向的一个侧面的侧部。也即内浇口所在侧面非砂型顶面或底面。
附图说明
图1所示为本公开一种实施例的内浇口、横浇道、直浇道、冒口位置示意图；
图2所示为图1的部位详解示意图；
图3所示为图1实施例对应的某整体多路阀砂芯结构示意图；
图4所示为图1实施例对应的某整体多路阀内浇口分布示意图；
图5所示为图1实施例对应的某整体多路阀排气系统示意图；
图1-图5中：1-整体式多路阀，2-直浇道，3-横浇道，4(41至42，42-1至42-5、)为内浇口，5-冒口，61(62)-主阀孔砂芯，63-67为内部油道砂芯，71-72为主阀孔位置排气通道，73为随型排气孔。
具体实施方式
以下结合附图和具体实施例进一步描述。
本公开的发明构思为：首先通过根据待铸造整体式多路阀的结构参数，确定多层多个内浇口，连接各层内浇口的多个横浇道，以及连接多个横浇道的直浇道，并利用3D打印技术打印整体式砂型，实现多层复合式浇注铸造方法以及相应的铸造系统，分散液体充型过程中的重力和冲刷力等影响，减少砂芯断裂，内部缺陷披缝，主阀孔弯曲等铸造缺陷，并实现快速铸造，同时保障成型阀的质量稳定性。
本公开提供了一种采用侧浇方式的多层复合式浇注铸造方法，以及相应的铸造系统，多层复合式的浇注方法可分散均衡液体充型过程中的重力和冲刷力等影响，减少砂芯断裂，内部缺陷披缝，主阀孔弯曲等铸造缺陷。且通过3D打印的砂型为整体式砂型，砂型内部无粘接缝隙，砂型之间的一致性较好，可保障浇注完成的阀体铸件表面质量以及质量稳定性，同时能够实现整体式液压阀的快速铸造，适合批量、规格化制造，更好地支撑大型整体式液压多路阀产品快速升级，大幅降低试制成本，缩短试制周期，进一步实现砂型3D打印技术的产业化应用。
本实施例为基于3D打印的适用于整体式多路阀的铸造方法，包括：
确定待铸造阀的结构参数；
以垂直于主阀孔轴向的方向作为高度方向，确定待铸造阀的阀体高度L；
根据阀体高度L确定内浇口的层数；
根据待铸造阀的结构参数，确定各层各内浇口的位置，使得所有内浇口均位于待铸造阀体的同一侧；
根据待铸造阀的结构参数，布置相应层数、位置的各内浇口模型；
对应每层内浇口分别布置与内浇口连通的横浇道模型；
设置冒口模型以及连通各横浇道的直浇道模型；
根据待铸造阀的结构参数，以及所述内浇口模型、横浇道模型、直浇道模型、冒口模型，创建待3D打印的砂芯模型，以及包括内浇口、横浇道、直浇道和冒口的砂型模型；
根据所述砂型模型和砂芯模型进行3D打印，得到待铸造阀的砂型和砂芯；
利用3D打印得到的砂型和砂芯进行浇注式铸造，得到整体式阀体。
本公开提供了一种采用侧浇方式的多层复合式浇注铸造方法，可分散均衡液体充型过程中的重力和冲刷力等影响，且通过3D打印的砂型为整体式砂型，砂型内部无粘接缝隙，可保障浇注完成的阀体铸件表面质量，同时能够实现整体式液压阀的快速铸造，适合批量、规格化制造。
以下实施例以待铸造阀为整体式液压多路阀为例进行整体式多路阀的铸造方法的具体介绍。
在一些实施例中，在确定待铸造阀的结构参数后，可生成待铸造整体式多路阀的本体模型1，便于更加直观的设置内浇口、横浇道、直浇道、冒口等的位置，参考图1和图2所示。
整体式多路阀铸造方法还包括：在对应主阀孔的砂芯中设置贯穿式排气通道；对于除主阀孔之外的其它阀孔，在对应的、需连接砂型外围的砂芯中设置随型排气孔。也即排气孔的路径沿阀孔的中心路径设置。排气通道和排气孔的设置可提高整体式砂芯的排气效率，参考图5所示；
根据待铸造阀的重量选择3D砂型打印工艺进行砂芯打印：若待铸造阀重量≤50kg，采用选择性激光烧结技术或粘接剂喷射打印技术进行砂芯3D打印；若待铸造阀重量>50kg，采用粘结剂喷射打印技术进行砂芯3D打印。可进一步保障砂芯减少断芯等情况。
在浇注前，对3D打印得到的砂型采用锆英粉涂料浸涂，然后进行烘干处理。此处可采用波美度为40～60之间的锆英粉涂料浸涂，浸涂次数≤3次，烘干温度为 100～180℃，烘干时间设置为：1～1.5h。
对于整体式液压多路阀，在浇注时采用球墨铸铁进行浇注式铸造，浇注温度为1350-1400℃，浇注后保温时间≥8h。
在确定内浇口层数时，根据阀体高度L确定内浇口的层数N：将阀体高度L除以一预设高度间隔L0，此处L0取100mm，对所得到的结果近似取整，即得到层数N。近似取整可为四舍五入近似，也可直接取整数部分的商。
参考图4所示，位于同一层的不同内浇口可以高度不一地设置，以适应其它结构需求，如避开不宜直接冲刷的结构位置，包括砂型内部油道等，可保证液体充型过程中不会直接冲刷油道砂芯，降低铸造过程中由于铁水冲击导致断芯、披缝等铸造缺陷。
本公开实施例还提供一种适用于整体式多路阀的铸造系统，包括砂型本体、直浇道2、横浇道3、内浇口4和冒口5；
以垂直于主阀孔砂芯轴向的方向作为砂型本体的高度方向；
所述直浇道2、横浇道3和内浇口4设置于砂型本体的一侧；横浇道沿砂型本体高度方向设置有多个，各横浇道的延伸方向上设有多个内浇口，各横浇道通过所述多个内浇口连接砂型本体；多个横浇道分别连通直浇道，冒口5设置于砂型本体的顶部。
以下实施例具体介绍图1至图5所示的整体式多路阀的铸造系统。
横浇道的数量设置为，将阀体高度L除以一预设高度间隔L0＝100mm，对所得到的结果近似取整后的结果值，如图1至图5所示的实施例，内浇口的层数为两层；
单个横浇道所连的所有内浇口具有至少两个高度位置，各内浇口远离砂型内部油道设置；
对应主阀孔的砂芯中设置有贯穿式排气通道；
除主阀孔之外的其它阀孔所对应的、连接砂型外围的砂芯中设置有随型排气孔；
冒口数量为多个；所有内浇口均设置于砂型平行于主阀孔轴向的一个侧面的侧部。也即内浇口所在侧面非砂型顶面或底面。
也即，参考图1至图5，本实施例铸造系统为多层复合式浇注系统，采用了侧浇方式，主阀孔水平设置，以此确定重力浇注方向，在重力浇注方向上测量阀体高度L，以N＝L/100，四舍五入后取整数值，进行内浇口层数确定，如图2，两层内浇口分别为41与42。
内浇口4布置在浇注砂型侧面，在两层主阀孔61、62之间，单层内浇口数量不小于3个，如图4所示为42-1至42-5，总数为5个，不同内浇口之间可高度不一，内 浇口须避开63到67等邻近内部油道，保证金属液体充型过程中不直接冲刷油道砂芯，降低铸造过程中由于铁水冲击导致断芯、披缝等铸造缺陷。
随形设置冒口5，无需考虑拔模角度，可设置为方形、圆形，如图2所示设置为方形，可更好的进行零件内部的补缩不需要考虑冒口套制造的复杂度。
区别于传统射砂制芯工艺，本公开采用3D打印工艺制造整体式砂型，砂型内部无粘接缝隙，如图5所示，砂型外围壁厚≥25mm，所有主阀孔开设排气贯穿排气通道，如图5中71、72所示，其他与外围连接阀孔均开设随形排气孔如图5中73所示，提高整体式砂芯排气效率。
铸造系统配合专用铸造工艺：采用锆英粉涂料，采用浸涂方式，涂料波美度设置为40～60之间，涂料浸涂次数≤3次，砂芯烘干温度：100～180℃，烘干时间设置为：1～1.5h。采用球墨铸铁进行整体式液压多路阀快速铸造，浇注温度控制在1350-1400℃之间，浇注后保温时间≥8h。
利用本公开铸造方法和铸造系统铸造整体式多路阀具有以下优点至少之一：
1.内部质量好。阀体内部油道特征弯曲复杂，传统铸造，砂型分体粘接成型，易出现披缝等铸造缺陷，本公开基于3D打印工艺实现砂型模具的一体化制造，避免砂芯内部粘接，减小铸造缺陷位置隐患数量，最终能够提高铸造质量；
2.成功率高。市场上采用砂型3D打印技术进行整体式液压多路阀铸造成功率普遍较低。本公开提出了复合式浇注系统，可根据阀体具体结构尺寸大小合理的设置内流道数量及层数，有效的降低了砂芯浇注过程中热流冲击，进一步提高了铸造成功率；
3.砂芯耐热强度进一步提高。选择陶粒砂作为砂芯3D打印用原砂，提高了砂芯的耐热强度，配合专用的锆英粉涂料，进一步提高3D打印砂芯的耐热强度，解决了3D打印砂芯因强度不足导致铸造成功率低的关键难题；
4.灵活性高。基于3D打印工艺，可不考虑打印结构的复杂性，能够进行随形设计冒口形式，冒口位置，浇注系统结构形式，实现了针对性的设计，无需考虑砂型模具制造的难度，设计灵活性得到大幅提升。
以上所述仅是本公开的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本公开技术远离的前提下，还可以做出若干改进和变形，这些改进和变形也应视为本公开的保护范围。

Claims (13)

  1. 一种适用于整体式多路阀的铸造方法，包括：
    确定待铸造阀的结构参数；
    以垂直于主阀孔轴向的方向作为高度方向，确定待铸造阀的阀体高度L；
    根据阀体高度L确定内浇口的层数；
    根据待铸造阀的结构参数，确定各层各内浇口的位置；
    根据待铸造阀的结构参数，布置相应层数、位置的各内浇口模型；
    对应每层内浇口分别布置与内浇口连通的横浇道模型；
    设置冒口模型以及连通各横浇道的直浇道模型；
    根据待铸造阀的结构参数，以及所述内浇口模型、横浇道模型、直浇道模型、冒口模型，创建待3D打印的砂芯模型，以及包括内浇口、横浇道、直浇道和冒口的砂型模型；
    根据所述砂型模型和砂芯模型进行3D打印，得到待铸造阀的砂型和砂芯；
    利用3D打印得到的砂型和砂芯进行浇注式铸造，得到整体式阀体。
  2. 根据权利要求1所述的方法，其中，根据待铸造阀的结构参数，确定各层各内浇口的位置，使得所有内浇口均位于待铸造阀体的同一侧。
  3. 根据权利要求1或2所述的方法，还包括：
    在对应主阀孔的砂芯中设置贯穿式排气通道；
    对于除主阀孔之外的其它阀孔，在对应的、需连接砂型外围的砂芯中设置随型排气孔。
  4. 根据权利要求1至3中任一项所述的方法，还包括：
    在浇注前，对3D打印得到的砂型采用锆英粉涂料浸涂，然后进行烘干处理；
    采用波美度为40～60之间的锆英粉涂料浸涂，浸涂次数≤3次，烘干温度为100～180℃，烘干时间设置为：1～1.5h。
  5. 根据权利要求1至4中任一项所述的方法，还包括根据待铸造阀的重量选择 3D砂型打印工艺进行砂芯打印；
    若待铸造阀重量≤50kg，采用选择性激光烧结技术或粘接剂喷射打印技术进行砂芯3D打印；
    若待铸造阀重量>50kg，采用粘结剂喷射打印技术进行砂芯3D打印。
  6. 根据权利要求1至5中任一项所述的方法，其中，所述待铸造阀为整体式液压多路阀；浇注时，采用球墨铸铁进行浇注式铸造，浇注温度为1350-1400℃，浇注后保温时间≥8h。
  7. 根据权利要求1至6中任一项所述的方法，其中，所述根据阀体高度L确定内浇口的层数N为：
    将阀体高度L除以一预设高度间隔L0，对所得到的结果近似取整，即得到层数N；
    位于同一层的不同内浇口具有至少一个高度位置。
  8. 根据权利要求1至7中任一项所述的方法，其中，所述内浇口远离砂型内部油道设置。
  9. 一种适用于整体式多路阀的铸造系统，包括砂型本体、直浇道、横浇道、内浇口和冒口；
    以垂直于主阀孔砂芯轴向的方向作为砂型本体的高度方向；
    所述直浇道、横浇道和内浇口设置于砂型本体的一侧；横浇道沿砂型本体高度方向设置有多个，各横浇道的延伸方向上设有多个内浇口，各横浇道通过所述多个内浇口连接砂型本体；多个横浇道分别连通直浇道，冒口设置于砂型本体的顶部。
  10. 根据权利要求9所述的适用于整体式多路阀的铸造系统，其中，
    横浇道的数量设置为，将阀体高度L除以一预设高度间隔L0，对所得到的结果近似取整后的结果值；
    单个横浇道所连的所有内浇口具有至少两个高度位置，各内浇口远离砂型内部油道设置；
    砂型本体中，砂型外围壁厚≥25mm；
    对应主阀孔的砂芯中设置有贯穿式排气通道；
    除主阀孔之外的其它阀孔所对应的、连接砂型外围的砂芯中设置有随型排气孔。
  11. 根据权利要求9或10所述的适用于整体式多路阀的铸造系统，其中，冒口数量为多个。
  12. 根据权利要求9至11中任一项所述的适用于整体式多路阀的铸造系统，其中，所有内浇口均设置于砂型平行于主阀孔轴向的一个侧面的侧部。
  13. 根据权利要求9至12中任一项所述的适用于整体式多路阀的铸造系统，其中，冒口形状随形设置。
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