阅读说明：本技术 一种组合式进气歧管铝合金下歧管铸造毛坯及其专用模具 (Combined type intake manifold aluminum alloy lower manifold casting blank and special die thereof ) 是由 姜洁 郑为鼻 高平 刘春哲 罗大宇 刘禹辰 李岳 郑宝龙 于 2019-12-10 设计创作，主要内容包括：一种组合式进气歧管铝合金下歧管铸造毛坯及其专用模具,属于汽车发动机技术领域,克服了现有技术铝合金进气下歧管铸造毛坯铸造冒口端的重量大于产品端的重量,造成冒口端先脱离上模毛坯铸造冒口型腔,使产品端被卡滞在模具中,顶出不平衡,脱模困难,产品端被顶伤,生产效率低和废品率高的问题,特征是在毛坯铸造冒口上面设有第一冒口抱紧柱、第二冒口抱紧柱和第三冒口抱紧柱,在上模上设有第一冒口抱紧柱型腔、第二冒口抱紧柱型腔和第三冒口抱紧柱型腔,有益效果是,利用3个冒口抱紧柱深入上模冒口抱紧柱型腔内,增加了铸造毛坯冒口与模具型腔间的摩擦力,克服了冒口端先脱离铸造冒口型腔的现象,实现了铝合金下歧管铸造毛坯顶出平衡的目的。(A combined type air inlet manifold aluminum alloy lower manifold casting blank and a special die thereof belong to the technical field of automobile engines and overcome the problems that the weight of a casting head end of an aluminum alloy air inlet lower manifold casting blank in the prior art is larger than that of a product end, so that the head end is firstly separated from an upper die blank casting head cavity, the product end is blocked in the die, the ejection is unbalanced, the demoulding is difficult, the product end is damaged by the top, the production efficiency is low and the rejection rate is high, and the combined type air inlet manifold aluminum alloy lower manifold casting blank is characterized in that a first head enclasping column, a second head enclasping column and a third head enclasping column are arranged on a blank casting head, a first head enclasping column cavity, a second head enclasping column cavity and a third head enclasping column cavity are arranged on an upper die, and the combined type air inlet manifold aluminum alloy lower manifold casting blank has the advantages that 3 head enclasping columns are, the phenomenon that the riser end is separated from the riser casting cavity is overcome, and the purpose of ejecting balance of the cast blank of the aluminum alloy lower manifold is achieved.)

1. The utility model provides a modular air intake manifold aluminum alloy lower manifold casting blank, includes cylinder cap flange (11), be equipped with first air flue (1), second air flue (2), third air flue (3) and fourth air flue (4) be connected with cylinder cap flange (11) on cylinder cap flange (11), be equipped with above first air flue (1), second air flue (2), third air flue (3) and fourth air flue (4) with the flange joint (10) of resin upper manifold connection, its characterized in that be equipped with below cylinder cap flange (13) 3 blank casting runners (8), be equipped with 1 inverted chevron shape blank casting rising head (91) in front of 3 blank casting runners (8) below cylinder cap flange (11), be equipped with respectively on inverted chevron shape blank casting rising head (91) and be used for embracing tightly first rising head enclasping post (7-11) and the rising head enclasping post type chamber enclasping, The second riser enclasping column (7-21) and the third riser enclasping column (7-31), a left blank blind riser (61) is arranged on the left side of the first air passage (1) below the docking flange (10), and a right blank blind riser (51) is arranged on the right side of the fourth air passage (4) below the docking flange (10).

2. The casting blank for the combined aluminum alloy lower manifold of the intake manifold as claimed in claim 1, wherein the first riser hugging column (7-11), the second riser hugging column (7-21) and the third riser hugging column (7-31) have the same shape, the riser hugging column bodies (71) of the first riser hugging column (7-11), the second riser hugging column (7-21) and the third riser hugging column (7-31) are all truncated cones, an included angle α between the beveled edge (72) of the outer surface of the riser hugging column body (71) and a vertical central axis is 1-1.5 degrees, a riser hugging column arc surface (74) formed by a chamfered corner with a radius of 1mm is arranged between the upper bottom surface (73) of the riser hugging column and the outer surface (72) of the riser hugging column, and the ratio of the diameter of the lower bottom surface (75) of the riser hugging column to the height of the riser hugging column is 1: 1.5.

3. The combined intake manifold aluminum alloy lower manifold casting blank according to claim 2, wherein the diameter of the lower bottom surface (75) of the riser hugging column is 10mm, and the height of the riser hugging column is 15 mm.

4. The special die for the combined intake manifold aluminum alloy lower manifold casting blank as claimed in claim 1, 2 or 3, comprising an upper die fixing plate (12) and a lower die fixing plate (18), wherein an upper die ejection mechanism (13) is installed on the upper die fixing plate (12), the upper die ejection mechanism (13) comprises an upper ejector plate (13-1), a plurality of upper thimbles (13-2) are installed on the upper ejector plate (13-1), an upper die ejection mechanism connecting plate (13-3) is installed in the middle of the upper ejector plate (13-1), an upper die (14) is installed on the lower surface of the upper die fixing plate (12), an outer runner (15) is installed in front of the upper die fixing plate (12), an upper die blank right side blind riser cavity (52), an upper die left side blank blind riser cavity (62) and a lower die cavity are arranged on the upper die (14), An upper die blank casting riser cavity (92), a first riser enclasping column cavity (7-12), a second riser enclasping column cavity (7-22) and a third riser enclasping column cavity (7-32); the lower die ejection mechanism (19) is installed on the lower die fixing plate (18), the lower die ejection mechanism (19) comprises a lower ejector plate (19-1), a plurality of lower ejectors (19-2) are installed on the lower ejector plate (19-1), a lower die ejection mechanism connecting plate (19-3) is installed in the middle of the lower ejector plate (19-1), a lower die (17) is installed on the upper surface of the lower die fixing plate (18), and a lower die right side blank blind riser cavity (53), a lower die left side blank blind riser cavity (63) and a sprue cup (16) are arranged on the lower die (17).

5. The special die for casting the blank of the aluminum alloy lower manifold of the combined intake manifold as claimed in claim 4, it is characterized in that in the process of downwards ejecting an upper ejector pin (13-2) of the upper die ejection mechanism (13) out of an aluminum alloy lower manifold casting blank of the intake manifold, through the friction force among the first riser clamping column (7-11), the second riser clamping column (7-21) and the third riser clamping column (7-31) arranged on the inverted-chevron-shaped blank casting riser (9) in front of the blank casting runner (8), the first riser clamping column cavity (7-12), the second riser clamping column cavity (7-22) and the third riser clamping column cavity (7-32), the casting riser end and the product end of the aluminum alloy lower manifold casting blank of the intake manifold are simultaneously ejected downwards by the upper ejector pin (13-2).

Technical Field

The invention belongs to the technical field of automobile engines, and particularly relates to a combined intake manifold aluminum alloy lower manifold casting blank manufactured by using a resin material and an aluminum alloy material and a special die thereof.

Background

With the development of automobile technology and the enthusiasm of drivers for vehicle maneuverability and driving pleasure, the performance of engines and their peripheral components is increasingly enhanced. The engine intake manifold, which is a critical component of the engine intake system, functions primarily to uniformly provide the engine with a fresh intake charge. The prior intake manifold is made of aluminum alloy materials mostly, and the aluminum alloy intake manifold made of the aluminum alloy materials has the defects of heavy weight and serious influence on the oil consumption of an engine. With the gradual development of technology, resin materials become the dominant materials of an engine intake manifold. However, the strength of the resin intake manifold made of resin materials is lower than that of the aluminum alloy intake manifold, and when the resin intake manifold is longer in air passage, the volume of the pressure stabilizing box is larger, and the product is heavier, the root of the air passage at the connecting section of the resin intake manifold and the engine cylinder cover is easy to crack. In order to overcome the problems of a single aluminum alloy intake manifold or a single resin intake manifold, a combined intake manifold has appeared in the prior art in recent years, namely, the combined intake manifold is made of resin materials and aluminum alloy materials, for example, the invention with the application number of CN201811502633.7 discloses that a lower manifold and a throttle body are made of resin materials, and the condition that the two original manifolds are both metal is changed, namely the intake manifold is composed of an intake upper manifold and an intake manifold lower manifold, wherein the intake upper manifold or the intake manifold lower manifold is made of resin materials to reduce the whole weight of the intake manifold; and the lower intake manifold or the upper intake manifold is made of an aluminum alloy material so as to ensure the strength of the intake manifold. In the intake manifold made of aluminum alloy material, in order to reduce the weight of the intake manifold, the aluminum alloy intake lower manifold is usually small in volume, short in air passage and light in weight, when an aluminum alloy intake lower manifold casting blank is actually produced, the aluminum alloy intake lower manifold casting blank mainly comprises an aluminum alloy intake lower manifold product and a casting riser, and the weight of the casting riser is far greater than that of the aluminum alloy intake lower manifold product, so that in the casting process, the weight of the riser end and the product end of the aluminum alloy intake lower manifold blank is not uniform, the riser end of the aluminum alloy intake lower manifold blank is separated from the upper mold blank casting riser cavity firstly due to gravity, the product end of the aluminum alloy intake lower manifold is clamped in a mold, the ejection is unbalanced, the aluminum alloy intake lower manifold blank is difficult to demold, and the aluminum alloy intake lower manifold blank is often damaged by jacking, in order to avoid top damage to the aluminum alloy intake lower manifold blank, manual demoulding is needed, so that the production efficiency of the aluminum alloy intake lower manifold blank is seriously affected, the production takt of a single blank is increased, and the rejection rate is increased, therefore, research and development of a combined intake manifold aluminum alloy lower manifold casting blank and a special die thereof are needed to solve the problems.

Disclosure of Invention

The invention aims to solve the problems of the prior art and overcome the defects and defects of the prior art, and provides a combined intake manifold aluminum alloy lower manifold casting blank and a special die thereof, which can solve the problem that the ejection imbalance is caused by the fact that a product end is clamped in a die because a riser end is firstly demoulded due to gravity in the casting production process of an aluminum alloy lower manifold of a combined intake manifold made of a resin material and an aluminum alloy material, so that the production efficiency and the yield of the aluminum alloy lower manifold blank are improved.

The technical scheme adopted by the invention for casting the blank of the combined type intake manifold aluminum alloy lower manifold comprises a cylinder cover connecting flange, a first air passage, a second air passage, a third air passage and a fourth air passage which are connected with the cylinder cover connecting flange are arranged on the cylinder cover connecting flange, a butt flange connected with a butt flange of a resin upper manifold is arranged on the first air passage, the second air passage, the third air passage and the fourth air passage, 3 blank casting runners are arranged below the cylinder cover connecting flange, 1 inverted-Chinese-character-shaped blank casting riser is arranged in front of the 3 blank casting runners below the cylinder cover connecting flange, a first riser holding column, a second riser holding column and a third riser holding column which are used for holding a riser holding column cavity tightly are respectively arranged on the inverted-Chinese-character-shape blank casting, a left blank riser is arranged on, and a right blank blind riser is arranged on the right side of the fourth air passage below the butting flange.

The first riser enclasping column, the second riser enclasping column and the third riser enclasping column are the same in shape, the riser enclasping column bodies of the first riser enclasping column, the second riser enclasping column and the third riser enclasping column are truncated cones, an included angle α between the inclined edge of the outer surface of the riser enclasping column body and the vertical center shaft is 1-1.5 degrees, a fillet with the radius of 1mm is formed between the upper bottom surface of the riser enclasping column and the inclined edge of the outer surface of the riser enclasping column, and the ratio of the diameter of the lower bottom surface of the riser enclasping column to the height of the riser enclasping column is 1: 1.5.

The diameter of the lower bottom surface of the riser enclasping column is 10mm, and the height of the riser enclasping column is 15 mm.

The invention relates to a special die for casting a blank of an aluminum alloy lower manifold of a combined type intake manifold, which comprises an upper die fixing plate and a lower die fixing plate, wherein an upper die ejection mechanism is arranged on the upper die fixing plate, the upper die ejection mechanism comprises an upper ejector plate, a plurality of upper ejector pins are arranged on the upper ejector plate, an upper die ejection mechanism connecting plate is arranged in the middle of the upper ejector plate, an upper die is arranged on the lower surface of the upper die fixing plate, an outer pouring gate is arranged in front of the upper die fixing plate, and an upper die right side blank blind riser cavity, an upper die left side blank blind riser cavity, an upper die blank casting riser cavity, a first riser enclasping column cavity, a second riser enclasping column cavity and a third riser enclasping column; the upper surface of the lower die fixing plate is provided with a lower die ejection mechanism, the lower die ejection mechanism comprises a lower ejector plate, a plurality of lower ejectors are arranged on the lower ejector plate, a lower die ejection mechanism connecting plate is arranged at the middle position of the lower ejector plate, a lower die is arranged on the upper surface of the lower die fixing plate, and a lower die right blank blind riser cavity, a lower die left blank blind riser cavity and a sprue cup are arranged on the lower die.

In the process of downwards ejecting an upper ejector pin of the upper die ejection mechanism out of a casting blank of an aluminum alloy lower manifold of the intake manifold, through the friction force among a first riser head enclasping column, a second riser head enclasping column and a third riser head enclasping column arranged on an inverted-chevron-shaped blank casting riser in the front of a blank casting runner, a first riser head enclasping column cavity, a second riser head enclasping column cavity and a third riser head enclasping column cavity, the casting riser end and the product end of the casting blank of the aluminum alloy lower manifold of the intake manifold are simultaneously ejected downwards by the upper ejector pin.

Compared with the prior art, the invention has the beneficial effects that:

(1) the invention is characterized in that a blank casting riser is arranged in front of 3 blank casting runners below a cylinder cover connecting flange, a first riser enclasping column, a second riser enclasping column and a third riser enclasping column are staggered on the blank casting riser, the 3 staggered riser enclasping columns are truncated cones, 3 first riser enclasping column cavities matched with the first riser enclasping column, the second riser enclasping column cavities and the third riser enclasping column cavities are arranged on an upper die corresponding to the first riser enclasping column, the second riser enclasping column and the third riser enclasping column on the blank casting riser, the 3 staggered riser enclasping columns of the blank casting riser are deep into the 3 staggered riser enclasping column cavities of the upper die, the 3 staggered risers enclasping column cavities of the upper die are used for enclasping the 3 staggered riser enclasping columns, the friction force between the riser of the casting blank of the aluminum alloy lower manifold and the die cavity is increased, the phenomenon that the casting riser is separated from the die cavity of the casting riser of the upper die blank firstly due to gravity at the riser end is avoided, and the purpose of ejecting balance of the casting blank of the aluminum alloy lower manifold is realized.

(2) In order to increase the friction force between the first, second and third riser enclaves and the upper die cavity as much as possible, but not to cause the situation that the riser enclaves cannot be demolded or broken in the die cavity due to overlong or too thin, the ratio of the diameter to the height of the lower bottom surface of the riser enclave is 1:1.5, preferably, the diameter of the lower bottom surface of the riser enclave is 10mm, the height of the riser enclave is 15mm, and the demolding angle of the riser enclave is smaller than the conventional sidewall demolding angle of aluminum alloy casting by 3-5 degrees in the die opening direction, and the demolding angle is 1-1.5 degrees. Although the diameter of the lower bottom surface of the riser enclasping column is only 10mm, and the height of the riser enclasping column is only 15mm, the short and thin riser enclasping column has enough strength, so that the friction force between the riser enclasping column and the upper die cavity is increased, and the phenomenon that the riser enclasping column cannot be demolded or is broken in the die cavity due to overlong or thinness is avoided.

(3) The upper bottom surface of the riser enclasping column is provided with a fillet with the radius of 1mm to form an arc surface of the enclasping column, so that the riser enclasping column is in smooth transition without a sharp edge, aluminum liquid can be conveniently and smoothly filled into a mold riser enclasping column cavity, and a first riser enclasping column, a second riser enclasping column and a third riser enclasping column which are in perfect and smooth shapes are formed.

Drawings

Figure 1 is a front view of an aluminum alloy lower manifold casting blank of the present invention,

figure 2 is a right side view of figure 1,

the cross-sectional view a-a of figure 1 of figure 3,

figure 4 is a front view of the die dedicated to the casting of the aluminum alloy lower manifold blank of the present invention,

figure 5 is a top view of figure 4,

figure 6 is a cross-sectional view B-B of figure 5,

figure 7 is a bottom view of the upper die of the present invention,

figure 8 is a top view of the lower die of the present invention,

figure 9 is a front view of the inventive riser cinching post,

fig. 10 is a top view of fig. 9.

In the figure:

1. a first air passage, 2, a second air passage,

3 a third air passage, 4, a fourth air passage,

51. a right blank blind riser, 52, an upper die right blank blind riser cavity, 53, a lower die right blank blind riser cavity,

61. a left blank blind riser, 62, an upper die left blank blind riser cavity, 63, a lower die left blank blind riser cavity,

7-11, 7-21, 7-31,

7-12, a first riser enclasping column cavity, 7-22, a second riser enclasping column cavity,

7-32. the third riser tightly holds the column cavity,

71. a riser hugging column body, 72, the outer surface bevel edge of the riser hugging column,

73. the riser tightly holds the upper bottom surface of the column, 74, the riser tightly holds the circular arc surface of the column, 75, the riser tightly holds the lower bottom surface of the column,

8. a flow passage is cast by a blank,

91. blank casting riser, 92, upper die blank casting riser die cavity,

10. a butt flange, 11, a cylinder cover connecting flange,

12. an upper die fixing plate 13, an upper die ejection mechanism,

13-1, 13-2, 13-3, an upper ejector pin, and an upper die ejection mechanism connecting plate,

14. an upper die, 15, an outer pouring channel,

16. a pouring cup, 17, a lower die, 18, a lower die fixing plate,

19. a lower die ejection mechanism is arranged on the lower die,

19-1, a lower ejector pin plate, 19-2, a lower ejector pin and 19-3, and a lower die ejection mechanism connecting plate.

Detailed description of the preferred embodiments

The invention will be further explained with reference to the drawings.