CN101444838A - Method for casting large jigger wheel with counterbalance - Google Patents

Method for casting large jigger wheel with counterbalance Download PDF

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Publication number
CN101444838A
CN101444838A CNA200810207375XA CN200810207375A CN101444838A CN 101444838 A CN101444838 A CN 101444838A CN A200810207375X A CNA200810207375X A CN A200810207375XA CN 200810207375 A CN200810207375 A CN 200810207375A CN 101444838 A CN101444838 A CN 101444838A
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China
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casting
wheel
chill
disc wheel
balance
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CNA200810207375XA
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CN101444838B (en
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高永建
江敏
陶卫生
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China Shipbuilding Marine Power Components Co Ltd
Hudong Heavy Machinery Co Ltd
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SHANGHAI HULIN HEAVY INDUSTRY Co Ltd
Hudong Heavy Machinery Co Ltd
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Priority to CN200810207375XA priority Critical patent/CN101444838B/en
Publication of CN101444838A publication Critical patent/CN101444838A/en
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Abstract

The invention relates to a method for casting a large jigger wheel with a counterbalance. The method comprises the steps of manufacturing a mould, molding, assembling the mould, casting, cooling a mold, cleaning the mold and heat treatment, wherein, during the process of casting the mold, a parting surface is arranged on an upper plane of cast teeth; all cast teeth of the jigger wheel are arranged at a lower half sand mold; a self counterbalance of the jigger wheel is arranged at an upper half sand mold, and an inner chill is arranged in the counterbalance. The method can effectively prevent the occurrence of shrinkage cavity at the position of the counterbalance of a large cast teeth jigger wheel and improve the material compactness of a cast under the condition of ensuing the quality of the cast teeth. For a large thick jigger wheel of a large diesel engine, the method can reduce the workload for cleaning and polishing the cast, save a great deal of machining workload, improve the production efficiency and reduce the production cost.

Description

Casting method of large disc wheel with balance weight
Technical Field
The invention relates to material forming, in particular to a casting method of a large disc wheel used on a diesel engine, wherein the disc wheel is provided with a balance block, the balance block and the disc wheel are cast together by adopting a method, and the casting defect of the disc wheel with the balance block is prevented in the casting process.
Background
The turning wheel is a large toothed round thick part in a marine low-speed diesel engine, and has the main function of starting turning of the diesel engine. The size phi of the casting is 2500 minus 3500mm, the thickness is 200 minus 900mm, and the weight is 15-25 tons. The main structures of the disc wheel are shown in two figures a and b in fig. 1, wherein fig. 1a is a schematic structural top view of the disc wheel with the balance weight on the marine diesel engine, and fig. 1b is a schematic structural side view of the disc wheel with the balance weight on the marine diesel engine. As can be seen from the figure, the disk wheel on the marine diesel engine is in a disk shape and consists of an outer circle and an inner circle which are concentric. The cast tooth is positioned at the edge of an excircle, two circular through holes are arranged on the excircle, a connecting line between the centers of the two circular holes passes through the center of the disc wheel, the balance blocks are positioned between the excircle and the inner circle, and the two balance blocks are symmetrically arranged at two sides of the connecting line between the centers of the two circular holes and are similar to the lung structure distribution of a human body.
In the prior art, the production method of the disc wheel with the extra-thick large balance weight comprises the following steps: the thick massive weights are cast separately and machined and then assembled with the disc wheel. Because the quality requirement of the large-sized plate wheel on the cast tooth is extremely high, the casting defects of slag holes, sand holes, air holes, inclusions and the like on the surface of the processed cast tooth are not allowed. According to the technical specification, the casting material is EN-GJL-HB255(HT350), the disk wheel connected body is attached with a casting sample, the casting sample is directly placed on a tooth point on the disk wheel and is poured out together with the casting, when the casting is cleaned, the sample is taken down for testing, and the performance of the casting sample is as follows: tensile strength greater than 260N/mm2, Brinell hardness greater than 185 HB; the brinell hardness of the tooth flank of the disc wheel body is more than or equal to 185 HB; nominal chemical composition value C: 3.05%, Si: 1.5%, Mn: 0.9%, P is less than or equal to 0.15%, S is less than or equal to 0.10%, Cu: 1.3 percent.
The casting method of the disc wheel casting with the particularly thick and large balance blocks is to cast and process the thick and large balance blocks and the disc wheel respectively, and finally assemble the thick and large balance blocks and the disc wheel together. The method has the advantages of large machining allowance, high machining cost, long production period, multiple operation links and very complex operation. If the thick balance block and the disc wheel are cast together, because the wall thickness difference is very different, the position of the balance block often generates casting defects such as shrinkage cavity and the like, and the shrinkage cavity is larger and the casting difficulty is very large when a large riser is used for feeding the position of the balance block.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides a method for preventing a large-scale cast tooth part from generating casting defects due to a balance block in the casting process. The method of the invention can effectively prevent the position with the balance block from generating the shrinkage cavity defect, improve the compactness of the casting, and simultaneously has convenient operation, reduced working procedures, improved efficiency and reduced cost.
In order to achieve the above purpose, the technical solution proposed by the present invention is as follows:
a method for casting large-scale plate wheel with balance block, the appearance of the plate wheel is a disc, it is made up of excircle and inner circle, wherein cast the tooth and locate at the edge of the excircle, still have two round holes on the excircle, the centre of a circle of the plate wheel is crossed to the line between the centre of a circle of two round holes, the balance block is two parts, all locate between excircle and inner circle, and symmetrical both sides of the line between the centre of a circle of two round holes, the method for casting the above-mentioned plate wheel includes the weaving and casting technology, makes the mould, models, closes the case, pours, casting mould cooling, casting cleaning and heat treatment, its detailed step is:
firstly, a split molding surface is positioned on the upper plane of a disc wheel with a balance block in a casting process, a casting tooth is positioned in a lower half sand mold, the balance block is positioned in an upper half sand mold, internal chill is placed in the balance block, the pouring system is a bottom pouring type pouring system with a filter screen and a slag collecting bag, a sprue is positioned on the circular center axis of a casting, a cross runner is a concentric circular ring positioned at the lower part of the disc wheel, a plurality of sub cross runners which are radially arranged are arranged between the sprue and the cross runner, the slag collecting bag and the filter screen are arranged in the sub cross runners, a rain-drenching sprue is connected with the cross runner and a casting cavity, and an air outlet riser is arranged at the highest position of the disc wheel;
manufacturing an outer die and a core box, designing an inner chill and a core support according to the size of a balance block, wherein the inner chill is roughly lung-shaped and is arranged inside a cavity of the balance block, the core support is cylindrical, a groove along an axis is arranged in the middle of the core support, the core support is divided into two types according to the purpose, one type is used for supporting the inner chill and the inner chill, the other type is arranged between the inner chill and the outer die, the inner chills arranged in the balance block are two blocks which are arranged in parallel, and the core supports are arranged between the inner chill and between the inner chill and the outer die;
thirdly, modeling and core making;
fourthly, matching boxes, closing the boxes, and preheating the casting molds;
smelting and pouring, wherein after pouring is finished, the casting is slowly cooled in the casting mould;
sixthly, cleaning the casting, and performing heat treatment to eliminate stress.
In the pouring system of the step (i), the area ratio of the cross sections of the sprue, the cross gate and the ingate is 1: 4: 2.
secondly, the distance between the edge of the inner chill and the outline of the balance block is 100-120 mm, the thickness of the inner chill is 80-100 mm, two through up-and-down round holes with the diameter of 100-200 are designed on the inner chill, and the total weight of the inner chill is 1/4-1/3 of the total weight of the balance block.
And in the third step, the molding and the core making both adopt furan resin self-hardening sand.
In the fifth step, an intermediate frequency furnace is adopted for smelting, and the weight percentage of furnace materials is as follows: 20% of fresh pig iron, 40% of scrap steel and 40% of scrap returns, wherein the maximum melting temperature is 1500-1520 ℃, the inoculation temperature is 1360-1420 ℃, the addition amount of inoculant is 75FeSi, the total weight of the burden accounts for 0.4%, and the pouring temperature is 1300-1330 ℃.
In the fifth step, the cooling time of the casting mould is 6 days.
Due to the adoption of the technical scheme, compared with the prior art, the invention has the following technical advantages:
as a casting method for preventing the balance block part of the large disc wheel from generating shrinkage cavities, the invention places the inner chill at the thick balance block part, balances the wall thickness difference, reduces the requirement of casting feeding, and thus obtains a compact casting. The method of the invention has the advantages of simple operation, reduced labor intensity, improved production efficiency, effectively eliminated shrinkage cavity on the balance weight, and simultaneously, the method for manufacturing the disc wheel with the thick and big balance weight which is assembled together after being respectively cast and mechanically processed is changed into conjoined casting, thereby greatly reducing the machining workload, improving the production efficiency and reducing the production cost.
Drawings
Fig. 1a is a schematic top view of a disc wheel with weights for a marine diesel engine.
Fig. 1b is a schematic side view of a configuration of a balance weight-equipped disc wheel of a marine diesel engine.
FIG. 2a is a schematic side view of the design of the gating system in the casting method of the large-scale disc wheel with the balance weight of the invention.
Fig. 2b is a schematic plan view of the gating system in the casting method of the large disk wheel with the balance weight of the invention.
Fig. 3a is a schematic top view of the placement of the inner chill and the chaplet in the casting method of the large disc wheel with the balance weight of the invention.
Fig. 3b is a schematic side view of the placement of the inner chill and the chaplet in the casting method of the large disc wheel with the balance weight of the invention.
Wherein,
1-balance block 2-round hole 3-sprue 4-horizontal runner
5-branch cross gate 6-filter screen 7-slag collecting ladle 8-deluge ingate
9-core support A-balance block outer mold B-internal chill
Detailed Description
The following detailed description of the method for casting a large disc wheel with a weight according to the present invention will be made with reference to the accompanying drawings and specific embodiments, but the scope of the present invention is not limited thereto.
The appearance of the plate wheel used on the marine low-speed diesel engine is a disc shape, and the plate surface consists of an outer circle and an inner circle. Wherein the casting teeth of the disc wheel are distributed on the circumferential edge of the excircle and need to be cast together with the disc wheel. The balance weight 1 on the disc wheel is arranged on one side of the disc wheel, between the outer circle and the inner circle, and symmetrically arranged on two sides of a connecting line between the circle centers of the two round holes 2. Two circular through holes are formed in the disc wheel and are the circular holes 2, and the circle center connecting line of the two through holes passes through the circle center of the disc wheel. The two balance blocks 1 are fan-shaped and symmetrically distributed on two sides of the connecting line of the through holes. The main structure of the wheel is shown in fig. 1, fig. 1a is a schematic top view of a structure of a disc wheel with a balance weight on a marine diesel engine, and fig. 1b is a schematic side view of a structure of a disc wheel with a balance weight on a marine diesel engine. Wherein the left figure is a top view and the right figure is a side sectional view along the arrow of the left figure. The method of the invention is to change the traditional method that the balance weight and the disc wheel are separately cast and then fixed together, and the balance weight and the disc wheel are cast together, and the casting defects such as shrinkage cavity and the like which are possibly generated are eliminated.
The thicker the thickness of the cast product, the more likely casting defects such as shrinkage cavities are generated during the casting process. In order to prevent the balance blocks on the disc wheel from generating shrinkage cavity defects, the method of the invention arranges the internal chill at the position of the particularly thick balance block, the size of the internal chill can be designed according to the size of the balance block, and can also be designed in blocks and supported in a casting mould by a core support. The internal chill is cast by the same proportion of the melt as the wheel of the plate wheel, and is used after shot blasting, polishing and drying.
When the casting begins to be cast, the casting process needs to be firstly compiled according to the size and the shape of the disc wheel with the balance weight: establishing a parting surface, designing a mold and designing a pouring system.
For a marine diesel engine model RT-flex60C, the disc wheel parameters were as follows: the diameter of the tooth top circle of the cast tooth is 2630mm, the tooth thickness is 150mm, the main wall thickness is 476mm, and the total thickness of the balance block part is 920 mm.
1) And (3) compiling a disc wheel casting process according to a horizontal parting method, wherein the disc wheel casting teeth are all in the lower half sand mold, and the upper plane of the disc wheel casting teeth is taken as a parting surface.
Before the disc wheel of the above-mentioned type is cast, it is necessary to construct a casting process: the die joint is located the last plane that has the dish wheel of balancing piece, the casting tooth be located lower half sand mould, balancing piece 1 is located last half sand mould, places the interior chill in balancing piece 1, the gating system for having filter screen 6 and the end pouring formula gating system of collection cinder ladle 7, wherein sprue 3 is in on the circle center axis of foundry goods, cross gate 4 is the concentric circle ring that is located dish wheel lower part, be a plurality of branch cross gates 5 of radial setting between sprue 3 and cross gate 4, be provided with album cinder ladle 7 and filter screen 6 in dividing cross gate 5, connect cross gate 4 and foundry goods die cavity for rain water ingate 8, the rising head of giving vent to anger sets up in the highest position department of dish wheel. Fig. 2a is a schematic side view showing the design of a gating system in the casting method of the large-sized disc wheel with the balance weight according to the present invention, and fig. 2b is a schematic top view showing the design of the gating system in the casting method of the large-sized disc wheel with the balance weight according to the present invention.
2) And designing inner chill and a core support according to the size of the balance weight of the disc wheel.
The internal chill B and the core support are designed according to the size of the balance weight 1, the internal chill B is roughly lung-shaped, as shown in figure 3a, figure 3a is a schematic plan view of the placement of the internal chill and the core support in the casting method of the large-scale disc wheel with the balance weight. The inner chill B is arranged inside the balance block cavity, the core support 9 is cylindrical, a groove along the axis is arranged in the middle of the core support 9, the core support 9 is divided into two types according to the purpose, one type is used for supporting the inner chill and the inner chill, the other type is arranged between the inner chill B and the balance block outer mold A, the inner chills arranged in each balance block 1 are two blocks which are arranged in parallel, and the core supports 9 are arranged between the inner chills and between the inner chills and the outer mold.
When the internal chill is placed in the sand mold, the edge of the internal chill is 100-120 mm away from the outline of the balance block, the thickness of the internal chill is 80-100 mm, two through up-and-down round holes with the diameter of 100-200 mm are designed on the internal chill, and the total weight of the internal chill is 1/4-1/3 of the total weight of the balance block. The placement of the internal chill and the chaplet is shown in fig. 3b, and fig. 3b is a schematic side view of the placement of the internal chill and the chaplet in the casting method of the large-scale disc wheel with the balance weight.
3) And manufacturing the outer die and the core box according to the requirements of a casting process drawing.
4) Adopting furan resin self-hardening sand for molding and core making. Sequentially placing cast tooth mud cores, placing wheel center hole mud cores, placing internal chill and a core support at the position of a balance block, completely absorbing scattered sand and accumulated ash in a cavity, and closing a box;
5) 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;
the disc wheel cast by the method can effectively prevent the balance block from generating shrinkage cavity defects, and a compact part is obtained.

Claims (6)

1. A method for casting large-scale plate wheel with balance block, the appearance of the plate wheel is a disc, it is made up of excircle and inner circle, wherein cast the tooth and locate at the edge of the excircle, still there are two round holes on the excircle, the centre of a circle of the plate wheel is crossed to the line between the centre of a circle of two round holes, the balance block is two parts, all locate between excircle and inner circle, and symmetrical both sides listed in the line between the centre of a circle of two round holes, the method for casting the above-mentioned plate wheel includes the weaving and casting technology, makes the mould, models, closes the case, pours, casting mould cooling, casting cleaning and heat treatment, its characterized by, its detailed step is:
firstly, a parting surface is positioned on the upper plane of a disc wheel with a balance block in a casting process, a casting tooth is positioned in a lower half sand mold, the balance block is positioned in an upper half sand mold, internal chill is placed in the balance block, the pouring system is a bottom pouring type pouring system, a sprue is positioned on a circular central axis of a casting, a cross runner is a concentric circular ring positioned at the lower part of the disc wheel, a plurality of sub cross runners which are radially arranged are arranged between the sprue and the cross runner, a slag collecting bag and a filter screen are arranged in the sub cross runners, a rain inner runner is connected with the cross runner and a casting cavity, and an air outlet riser is arranged at the highest position of the disc wheel;
manufacturing an outer die and a core box, designing an inner chill and a core support according to the size of the balance block, wherein the inner chill is lung-shaped and is arranged inside a cavity of the balance block, the core support is cylindrical, a groove along an axis is arranged in the middle of the core support, the core support is divided into two types according to the purpose, one type is supported between the inner chill and the inner chill, the other type is supported between the inner chill and the outer die, the inner chills arranged in each balance block are two blocks arranged in parallel, and the core supports are arranged between the inner chill and between the inner chill and the outer die;
thirdly, modeling and core making;
preparing a box, assembling the box and preheating the casting mold;
smelting and pouring, wherein after pouring is finished, the casting is slowly cooled in the casting mould;
sixthly, cleaning the casting, and performing heat treatment to eliminate stress.
2. The method for casting a large-sized disc wheel with a balance weight according to claim 1, wherein in the gating system in the step (r), the area ratio of the cross sections of the sprue, the cross runner and the ingate is 1: 4: 2.
3. the method for casting the large-sized disc wheel with the balance weight according to claim 1, wherein the distance between the edge of the inner chill and the contour of the balance weight is 100-120 mm, the thickness of the inner chill is 80-100 mm, two circular holes with the diameter of 100-200 mm are designed on the inner chill, the circular holes penetrate through the upper part and the lower part, and the total weight of the inner chill is 1/4-1/3 of the total weight of the balance weight.
4. The method for casting the large-sized disc wheel with the balance weight according to claim 1, wherein the molding and the core making in the third step are both made of furan resin self-hardening sand.
5. The casting method of the large-sized disc wheel with the balance weight according to claim 1, wherein the smelting in the fifth step adopts an intermediate frequency furnace, and the weight percentage of furnace materials is as follows: 20% of fresh pig iron, 40% of scrap steel and 40% of scrap returns, wherein the maximum melting temperature is 1500-1520 ℃, the inoculation temperature is 1360-1420 ℃, the addition amount of inoculant is 75FeSi, the total weight of the burden accounts for 0.4%, and the pouring temperature is 1300-1330 ℃.
6. The method for casting a large disc wheel with a balance weight according to claim 1 or 5, wherein the cooling time of the mold in the fifth step is 6 days.
CN200810207375XA 2008-12-19 2008-12-19 Method for casting large jigger wheel with counterbalance Active CN101444838B (en)

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Cited By (13)

* Cited by examiner, † Cited by third party
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
CN101912949A (en) * 2010-05-24 2010-12-15 河南省汤阴县华兴机械制造有限公司 Heavy wheel cast bottom mold making core supporting disc, device and process
CN101618428B (en) * 2009-07-25 2011-04-27 日月重工股份有限公司 Method for casting hub casts of aerogenerators
CN102672112A (en) * 2012-04-28 2012-09-19 浙江坤博机械制造有限公司 Casting method of motor casing
CN102115838B (en) * 2009-12-30 2012-10-10 西安航空动力控制有限责任公司 Aluminium alloy, core support prepared by same for forming of aluminum alloy casting and preparation of core support
CN103157767A (en) * 2013-01-31 2013-06-19 洛阳新火种节能技术推广有限公司 Method for improving finished product rate of saloon car power-assisted steering pump cases
CN102049494B (en) * 2009-11-03 2014-02-19 上海航天精密机械研究所 Casting method of aluminum-magnesium alloy movable coil for vibrating table
CN104722708A (en) * 2015-03-30 2015-06-24 共享铸钢有限公司 Modeling method and sand mold structure of sector-shaped end cover type casting for large-size mill
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
CN107309401A (en) * 2017-08-01 2017-11-03 安徽安庆市沙氏汽车配件有限公司 A kind of shaped device for automobile counterbalance
CN109317634A (en) * 2018-03-23 2019-02-12 上海宏钢电站设备铸锻有限公司 A kind of method of the recycling of ironcasting chill
CN109465399A (en) * 2018-12-26 2019-03-15 广东富华铸锻有限公司 A kind of reducing gearbox sand core structure and running gate system
CN111974946A (en) * 2020-08-19 2020-11-24 李恪 Composite casting method

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101618428B (en) * 2009-07-25 2011-04-27 日月重工股份有限公司 Method for casting hub casts of aerogenerators
CN102049494B (en) * 2009-11-03 2014-02-19 上海航天精密机械研究所 Casting method of aluminum-magnesium alloy movable coil for vibrating table
CN102115838B (en) * 2009-12-30 2012-10-10 西安航空动力控制有限责任公司 Aluminium alloy, core support prepared by same for forming of aluminum alloy casting and preparation of core support
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
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
CN101912949A (en) * 2010-05-24 2010-12-15 河南省汤阴县华兴机械制造有限公司 Heavy wheel cast bottom mold making core supporting disc, device and process
CN102672112A (en) * 2012-04-28 2012-09-19 浙江坤博机械制造有限公司 Casting method of motor casing
CN103157767A (en) * 2013-01-31 2013-06-19 洛阳新火种节能技术推广有限公司 Method for improving finished product rate of saloon car power-assisted steering pump cases
CN104722708A (en) * 2015-03-30 2015-06-24 共享铸钢有限公司 Modeling method and sand mold structure of sector-shaped end cover type casting for large-size mill
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
CN107309401A (en) * 2017-08-01 2017-11-03 安徽安庆市沙氏汽车配件有限公司 A kind of shaped device for automobile counterbalance
CN109317634A (en) * 2018-03-23 2019-02-12 上海宏钢电站设备铸锻有限公司 A kind of method of the recycling of ironcasting chill
CN109465399A (en) * 2018-12-26 2019-03-15 广东富华铸锻有限公司 A kind of reducing gearbox sand core structure and running gate system
CN109465399B (en) * 2018-12-26 2023-11-21 广东富华铸锻有限公司 Gating system with speed reducer shell sand core structure
CN111974946A (en) * 2020-08-19 2020-11-24 李恪 Composite casting method

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Patentee after: HUDONG HEAVY MACHINERY Co.,Ltd.

Patentee after: China Shipbuilding marine power components Co., Ltd

Address before: 200129 346, 2851 Pudong Avenue, Shanghai, Pudong New Area

Patentee before: HUDONG HEAVY MACHINERY Co.,Ltd.

Patentee before: Shanghai Hulin Heavy Industry Co., Ltd

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