CN101209486A - Method for preventing casting tooth surface from generating casting flaw in large-scale casting tooth casting parts - Google Patents
Method for preventing casting tooth surface from generating casting flaw in large-scale casting tooth casting parts Download PDFInfo
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- CN101209486A CN101209486A CNA2007101726858A CN200710172685A CN101209486A CN 101209486 A CN101209486 A CN 101209486A CN A2007101726858 A CNA2007101726858 A CN A2007101726858A CN 200710172685 A CN200710172685 A CN 200710172685A CN 101209486 A CN101209486 A CN 101209486A
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- slag collecting
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- 238000005266 casting Methods 0.000 title claims abstract description 133
- 238000000034 method Methods 0.000 title claims abstract description 34
- 239000002893 slag Substances 0.000 claims abstract description 62
- 230000007547 defect Effects 0.000 claims abstract description 15
- 239000004576 sand Substances 0.000 claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- 238000004140 cleaning Methods 0.000 claims abstract description 8
- 238000001816 cooling Methods 0.000 claims abstract description 6
- 238000010438 heat treatment Methods 0.000 claims abstract description 4
- 238000003754 machining Methods 0.000 claims description 12
- 238000000465 moulding Methods 0.000 claims description 8
- 238000003723 Smelting Methods 0.000 claims description 6
- 239000007849 furan resin Substances 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000011081 inoculation Methods 0.000 claims description 2
- 238000005498 polishing Methods 0.000 abstract description 6
- 239000000463 material Substances 0.000 abstract description 4
- 238000012545 processing Methods 0.000 abstract description 3
- 244000035744 Hura crepitans Species 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 229910052742 iron Inorganic materials 0.000 description 3
- 230000002093 peripheral effect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 210000003739 neck Anatomy 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229910000805 Pig iron Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
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Abstract
The invention relates to a method for preventing the cast tooth surface of a large cast tooth casting generating casting defects. The invention comprises mold fabrication, modeling, mould closing, casting, casting mold cooling, casting cleaning and heat treatment. The casting technique parting surface of the casting mold is arranged at the upper plane of the cast tooth, the cast tooth of the casting is positioned at a lower half casting box, a ring-shaped slag collecting groove connected with all cast teeth is arranged above the cast tooth addendum circle of a sand mould parting surface, and multi riser runners are arranged at the upper part of the slag collecting groove. By adopting the method of the invention, the cast tooth surface of the large casting such as a disk wheel can be prevented from generating a slag blowhole, the material compactness of the casting can be improved, and precision of the tooth profile of the cast tooth can be improved. The method of the invention has simple modeling operation, reduces workload of casting cleaning and polishing and processing, improves production efficiency and reduces production cost.
Description
Technical Field
The invention relates to material forming, in particular to a method for preventing casting defects of cast teeth of a large toothed part in a casting process, and application of the method in the casting process of a large diesel engine disc wheel casting.
Background
The turning gear is a large toothed circular thick part in a low-speed diesel engine for a ship, and has the main function of starting the turning gear by the diesel engine. The size phi of the casting is 3000-4000mm, the thickness is 200-400mm, and the weight is 15-25 tons. If the tooth shape is formed by machining, the machining cost is high, and the machining period is long. In order to reduce the processing cost and shorten the production period, the teeth of the large-scale disc wheel are changed into cast teeth, and only grinding and finishing are carried out without mechanical processing, so that the requirement on the tooth shape is extremely high, and the surface defects of slag holes, sand holes, air holes, impurities and the like with the depth of more than or equal to 5mm are not allowed to exist on the surface of the cast teeth except the requirement on high casting precision. According to the technical specification, the casting material is C4(HT300), and the performance of the split test bar is as follows: tensile strength of 300-400N/mm2Brinell hardness of 200-250 HB; the brinell hardness of the tooth side surface of the disc wheel body is more than or equal to 160 HB; nominal chemical composition value C: 3.1%, Si: 1.7%, Mn: 0.8 percent, less than or equal to 0.2 percent of P and less than or equal to 0.15 percent of S.
For the casting method of a disc wheel casting with casting teeth, generally, measures such as cleaning dross in molten iron as much as possible, designing a casting system with a good slag blocking effect, increasing the polishing amount of the surface of the casting teeth, increasing the machining allowance of the upper plane of the casting teeth, increasing the number of the air outlet risers of the upper plane of the casting teeth and the like are taken, but the casting process cannot be avoided, secondary oxidation slag inclusion generated in a cavity by scattered sand and molten iron flows to the surface of the casting teeth along with molten iron flow, gas in the cavity in the area of the casting teeth is difficult to discharge, the defects such as slag inclusion, sand inclusion, air holes and the like are easily generated on the surface of the casting teeth, the operation is troublesome, the polishing workload is large, and the quality of the surface of the casting.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a method for preventing cast teeth from having casting defects in the casting process of large cast tooth parts, so as to prevent the cast tooth surfaces from generating slag holes, sand holes, air holes and inclusions, improve the compactness of the cast teeth, facilitate operation, reduce polishing, improve efficiency and reduce cost.
In order to achieve the purpose, the technical scheme provided by the invention is as follows:
a method for preventing the large cast-tooth casting from generating casting defects on the surface of cast teeth includes such steps as making mould, moulding, closing mould, casting, cooling, cleaning and heat treating, and features that the parting surface of casting mould is arranged on the upper surface of cast-tooth casting to make all the cast teeth of casting be in lower half-mould box and molten liquid is poured by bottom pouring.
The casting method used in the casting of the large disc wheel to obtain the qualified cast tooth mainly comprises the following steps: the method comprises the following steps of manufacturing a mould, molding resin sand, horizontally parting, arranging casting teeth of a casting in a drag flask, arranging 6-8 teeth as a mud core, combining a plurality of mud cores to form peripheral casting teeth of a disc wheel, bottom pouring and an open type pouring system with a filter screen, arranging a feeding head at the thick part of the disc wheel, arranging a slag collecting groove at the round top of a tooth top, wherein the slag collecting groove is designed in an annular mode, arranging an exhaust head above the slag collecting groove, and mainly achieving the functions of exhausting and facilitating the concentration of scum to the slag collecting groove.
The casting steps are as follows;
1) taking the upper plane of the casting teeth as a horizontal parting surface, and weaving a casting process of the disc wheel, wherein the casting process comprises the design of a bottom pouring system with a filter screen slag collecting bag;
2) designing an annular slag collecting groove and an air outlet open riser according to the shape and the size of the cast tooth;
3) manufacturing an outer die and a core box according to the requirements of a casting process drawing;
4) adopting furan resin self-hardening sand for molding and core making;
5) matching boxes, closing the boxes, and preheating the casting molds;
6) smelting and pouring, smelting in an intermediate frequency furnace, wherein the maximum melting temperature is as follows: 1500-1520 ℃; inoculation temperature: 1420-1360 deg.C; pouring temperature: 1300-1330 ℃;
7) slowly cooling the cast in the casting mould after pouring;
8) cleaning a casting;
9) performing conventional heat treatment on the casting to eliminate stress;
10) and marking off the casting blank after the casting blank is qualified, and removing the slag collecting groove during rough machining.
Foretell plate wheel is at the casting in-process, and the collection slag chute that designs is the annular, and it sets up above casting the tooth plane, and the cross section of collection slag chute is isosceles trapezoid, and the bottom outer fringe and the outer fringe of casting tooth crest circle of trapezoidal collection slag chute coincide mutually, and the casting tooth is in the die joint below, and annular collection slag chute is in the die joint top, has a plurality of dead heads of giving vent to anger at collection slag chute top equipartition.
The process method is a method for obtaining cast teeth with few defects or no defects on a large disc wheel casting. The designed slag collecting groove connects all the cast teeth together, so that the exhaust and slag collection are realized, and the problem that the turnover tooth surface of a casting is easy to damage is solved. The method for casting the disc wheel has the advantages of simple operation, reduced labor intensity, improved production efficiency, effective elimination of slag pores on the tooth surface, improved compactness of the cast tooth material and improved tooth profile precision.
Drawings
FIG. 1 is a schematic diagram of the position of a slag trap on a casting in an embodiment of the invention.
FIG. 2 is an enlarged view of a casting slag collecting groove part.
Wherein,
1-parting surface 2-disc wheel 3-pouring system 4-mud core
5-casting tooth 6-slag collecting groove 7-air outlet open riser
Detailed Description
The method for preventing the cast tooth surface from generating casting defects of the cast tooth casting of the invention is further described in the following by combining the drawings and specific embodiments, and the application of the method in the casting of large diesel engine disc wheels is described in detail.
The production process of the casting is almost the same as the original process method, and only has some differences in the manufacturing, modeling and rough machining of the wood pattern. When the wooden mold is manufactured, an annular slag collecting groove and a plurality of air outlet open riser wooden molds are added, when the wooden mold is molded, the annular slag collecting groove and an air outlet riser cavity are manufactured in an upper sand box, the annular slag collecting groove is machined during rough machining of a casting, and other procedures are the same as those of the original process method.
The casting method used in the casting of the large disc wheel to obtain the qualified cast tooth mainly comprises the following steps: the casting method comprises the steps of manufacturing a mold, molding resin sand, horizontally parting, arranging casting teeth of a casting in a lower half sand box, arranging a mud core in every 6-8 teeth, forming peripheral casting teeth of a disc wheel by combining a plurality of mud cores, bottom pouring and an open type pouring system with a filter screen, arranging a feeding head at the thick part of the disc wheel, arranging a slag collecting groove at the tooth crest circle, wherein the slag collecting groove is in an annular design, the cross section of the slag collecting groove is isosceles trapezoid, the size of the bottom edge of the slag collecting groove is equal to 1/4-1/2 of the casting teeth, the height of the trapezoid is equal to the bottom edge of the slag collecting groove, and the diameter of the annular bottom of the slag collecting groove. An exhaust riser is arranged above the slag collecting groove, the main functions of the exhaust riser are exhaust and are beneficial to the concentration of scum to the slag collecting groove, a round open riser is adopted, the diameter of a riser neck is 0.8-0.9 of the length of the trapezoid upper side of the slag collecting groove, and the number of the riser necks is 8-12. The visual illustration of the design is shown in fig. 1, fig. 1 is a schematic position diagram of a slag collecting groove on a casting in the embodiment of the invention, the left side in the drawing is a plan view of the casting of the disc wheel, the right side is a sectional view in the direction of a-A in the left side in the drawing, as can be seen from the drawing, the circular disc wheel 2 is flatly placed in a lower half sand box after being subjected to wood molding, the upper surface of the disc wheel 2 is taken as a parting surface 1, the whole disc wheel 2 is positioned in the lower half sand box, a plurality of mud cores 4 are combined to form a peripheral casting tooth 5 of the disc wheel 2, the slag collecting groove 6 is arranged at the upper part of a tooth top circle formed by the outer edge of the casting tooth, the slag collecting groove 6 is positioned in the upper half sand box, the slag collecting groove 6 is annular, the cross section of the slag collecting groove is. After casting is finished, the air outlet open riser 7 is removed when the casting is cleaned, and the slag collecting groove 6 is machined during rough machining of the casting.
Examples
The application of the method of the present invention is further illustrated by taking the casting process of a disc wheel of a marine diesel engine model 6K80MC-C as an example, but the scope of the present invention is not limited thereby.
The parameters of the marine diesel engine 6K80MC-C disc wheel are as follows: the diameter of the cast tooth top circle is 3800mm, the tooth thickness is 210mm, and the total number of the cast tooth top circle is 60 teeth.
The method comprises the following specific steps:
1) compiling a disc wheel casting process according to a horizontal parting method, wherein disc wheel casting teeth are all arranged in a lower half sand box, and the upper plane of the disc wheel casting teeth is taken as a parting surface;
2) designing a slag collecting groove according to the size of the casting tooth, wherein the slag collecting groove is annular, the cross section of the slag collecting groove is trapezoidal, the slag collecting groove is arranged in an upper half sand box above the casting tooth, 12 air outlet risers are arranged above the slag collecting groove, and for the design of the slag collecting groove, a more detailed request is made in figure 2, and figure 2 is an enlarged view of the part of the casting slag collecting groove and is provided with a wheel;
3) manufacturing an outer die and a core box according to the requirements of a casting process drawing;
4) adopting furan resin self-hardening sand for molding and core making. The diameter of the outer circle of the annular slag collecting groove of the upper half sand box is the same as the diameter of the addendum circle of the disc wheel of the lower half sand box, and both diameters are 3800 mm. When the box is assembled, the tooth-casting mud cores are sequentially arranged, each tooth-casting mud core comprises 6 casting teeth, the total 10 mud cores form 60 teeth of the turning wheel, and each next mud core is inspected by using an inspection template to check whether the size of the casting tooth root meets the requirement. After mud cores in the center holes of the disc wheels are laid down, sucking loose sand and accumulated dust in the cavities, and closing the box; and (4) preheating the casting mold by using casting mold hot air, and preparing before casting.
6) And (4) smelting and pouring. The furnace burden proportion is as follows: 20% of fresh pig iron, 40% of scrap steel and 40% of foundry returns by adopting an intermediate frequency furnace for smelting, wherein the highest melting temperature is 1500-;
7) slowly cooling the cast in a casting mould for 6 days after pouring, and opening the box;
8) cleaning the casting, and removing a pouring gate, a dead head and a flash;
9) performing conventional heat treatment on the casting to eliminate stress;
10) and (4) after the casting blank is qualified, conveying the casting blank to a machining workshop for scribing, and removing a slag collecting groove on the casting during rough machining.
The disc wheel cast by the method can effectively prevent casting defects such as slag holes, sand holes, air holes, inclusions and the like on the casting tooth surface, has small polishing workload after casting is finished, has high dimensional precision, and only needs simple polishing without machining.
Claims (3)
1. A method for preventing the surface of cast teeth from generating casting defects on a large cast tooth casting includes such steps as making mould, moulding, closing box, casting, cooling, cleaning and heat treating, setting the parting surface of casting mould on the upper surface of cast tooth casting, putting all the cast teeth in the lower semi-sand box, and pouring in bottom pouring mode.
2. The use of the method of preventing casting defects in cast teeth of a large cast tooth casting according to claim 1 in the casting of large marine diesel disc wheels, comprising the steps of:
1) the casting process of the disc wheel is compiled by taking the upper plane of the disc wheel casting teeth as a horizontal parting surface, and a bottom pouring system with a filter screen slag collecting bag is designed;
2) designing a slag collecting groove and an air outlet riser according to the size of the cast tooth;
3) manufacturing an outer die and a core box according to the requirements of a casting process drawing;
4) adopting furan resin self-hardening sand for molding and core making;
5) matching boxes, closing the boxes, and preheating the casting molds;
6) smelting and pouring, namely smelting in an intermediate frequency furnace, wherein the highest melting temperature is 1500-1520 ℃, the inoculation temperature is 1420-1360 ℃, and the pouring temperature is 1300-1330 ℃;
7) slowly cooling the cast in the casting mould after pouring;
8) cleaning a casting;
9) performing conventional heat treatment on the casting to eliminate stress;
10) and marking off the casting blank after the casting blank is qualified, and removing the slag collecting groove during rough machining.
3. The method for preventing cast teeth from generating casting defects in the casting of large-scale disc wheels according to claim 2, wherein the slag collecting groove is annular and is arranged above the plane of the cast teeth, the cross section of the slag collecting groove is trapezoidal, the outer edge of the bottom of the trapezoidal slag collecting groove is coincided with the outer edge of the top circle of the cast teeth, the cast teeth are arranged below a parting surface, the annular slag collecting groove is arranged above the parting surface, and a plurality of air outlet risers are uniformly distributed at the top of the slag collecting groove.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNA2007101726858A CN101209486A (en) | 2007-12-21 | 2007-12-21 | Method for preventing casting tooth surface from generating casting flaw in large-scale casting tooth casting parts |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNA2007101726858A CN101209486A (en) | 2007-12-21 | 2007-12-21 | Method for preventing casting tooth surface from generating casting flaw in large-scale casting tooth casting parts |
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| CN101209486A true CN101209486A (en) | 2008-07-02 |
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| CNA2007101726858A Pending CN101209486A (en) | 2007-12-21 | 2007-12-21 | Method for preventing casting tooth surface from generating casting flaw in large-scale casting tooth casting parts |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101837432A (en) * | 2010-05-20 | 2010-09-22 | 衡阳中钢衡重铸锻有限公司 | Tyre casting method and casting die |
| CN101961768A (en) * | 2010-11-18 | 2011-02-02 | 沪东重机有限公司 | Method for casting cast steel cylinder cover |
| CN102784889A (en) * | 2012-07-27 | 2012-11-21 | 宁夏共享集团有限责任公司 | Casting method of complex-structure ductile iron thin-wall casting of ship turbocharger |
| CN102873311A (en) * | 2012-09-19 | 2013-01-16 | 四川凯能机电设备制造有限公司 | Cast steel node manufacturing process |
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2007
- 2007-12-21 CN CNA2007101726858A patent/CN101209486A/en active Pending
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101837432A (en) * | 2010-05-20 | 2010-09-22 | 衡阳中钢衡重铸锻有限公司 | Tyre casting method and casting die |
| CN101837432B (en) * | 2010-05-20 | 2012-05-09 | 衡阳中钢衡重铸锻有限公司 | Tyre casting method and casting die |
| CN101961768A (en) * | 2010-11-18 | 2011-02-02 | 沪东重机有限公司 | Method for casting cast steel cylinder cover |
| CN102784889A (en) * | 2012-07-27 | 2012-11-21 | 宁夏共享集团有限责任公司 | Casting method of complex-structure ductile iron thin-wall casting of ship turbocharger |
| CN102873311A (en) * | 2012-09-19 | 2013-01-16 | 四川凯能机电设备制造有限公司 | Cast steel node manufacturing process |
| CN102873311B (en) * | 2012-09-19 | 2015-01-14 | 四川凯能机电设备制造有限公司 | Cast steel node manufacturing process |
| CN103587577A (en) * | 2013-09-04 | 2014-02-19 | 安徽安簧机械股份有限公司 | Manufacturing process of high-strength low-alloy cast steel forklift steering axle |
| CN106424554A (en) * | 2015-08-06 | 2017-02-22 | 江苏鼎泰工程材料有限公司 | Shaft-mounted braking disc production method and shaft-mounted braking disc prepared by using shaft-mounted braking disc production method |
| CN109344565A (en) * | 2015-08-06 | 2019-02-15 | 江苏鼎泰工程材料有限公司 | The production method of passenger train and train of high-speed motor train unit axle-mounted brake disk |
| CN105149548A (en) * | 2015-10-22 | 2015-12-16 | 富乐压铸(太仓)有限公司 | Sprue used for exterior face of automobile emergency key bit |
| CN106812834A (en) * | 2015-11-30 | 2017-06-09 | 江苏鼎泰工程材料有限公司 | A kind of axle-mounted brake disk and its manufacture method |
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