CN1016853B - Bent axle integral one-step molding electroslag casting - Google Patents

Bent axle integral one-step molding electroslag casting

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Publication number
CN1016853B
CN1016853B CN 85109612 CN85109612A CN1016853B CN 1016853 B CN1016853 B CN 1016853B CN 85109612 CN85109612 CN 85109612 CN 85109612 A CN85109612 A CN 85109612A CN 1016853 B CN1016853 B CN 1016853B
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China
Prior art keywords
mould
loose piece
bent axle
crystallizer
offsetting
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CN 85109612
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CN85109612A (en
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苏学嵩
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JIANGXI LICHUAN SPECIAL STEEL PLANT
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JIANGXI LICHUAN SPECIAL STEEL PLANT
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Priority to CN 85109612 priority Critical patent/CN1016853B/en
Publication of CN85109612A publication Critical patent/CN85109612A/en
Publication of CN1016853B publication Critical patent/CN1016853B/en
Expired legal-status Critical Current

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Abstract

A kind of electroslag smelting casting method of bent axle integral one-step molding, this method are before the metal freezing forming step, also comprise the step that moves the distortion moulding of being carried out by mould.By clamp-oning or the offsetting of mould of loose piece mould, can finish the distortion moulding at the interface place in slag bath and molten bath, thereby enlarge the scope of application of electroslag casting, be particularly suitable for the very complicated single piece of founding shape.Product quality height and steady quality can be boosted productivity again exponentially, also can save the raw material and the energy, and cost can reduce by 20%~50%.

Description

Bent axle integral one-step molding electroslag casting
The present invention relates to a kind of extraordinary method of smelting, particularly a kind of bent axle integral one-step molding electroslag casting, it not only has the feature of refining purification and coagulation forming, but also has the feature of distortion moulding.
As everyone knows, electroslag casting is a kind of metal electrode that common method of smelting is made, place the water-cooled special-shaped crystallizer, pass to electric current, resistance heat by means of slag melts metal electrode, the metal that has melted pools molten drop, passes slag bath and enters the molten bath, is frozen into the method for irregularly-shaped castings in special-shaped water mold.Because electroslag casting can directly produce performance and the high-quality irregularly-shaped castings that compares favourably with the metal forging spare of common method of smelting production, and its equipment is simple, easy to operate, campaign is short, blank refinement, with low cost, so cause extensive attention both domestic and external, range of application enlarges gradually.So far, can produce the various irregularly-shaped castings of steel pipe, roll, valve body or the like.
But, the very complicated and thin-walled smallclothes for shape, for example, the electroslag smelting casting global formation of complicated parts such as mulit-turning crankshaft, connecting rod, rocking arm still is not reported.This is because in the electroslag smelting casting process, consutrode is difficult to insert in the die cavity of crystallizer, and can't carry out the event of normal melting, and this also is the limitation place of this method.Therefore, the production of the complicated part of this class, casting is changeed in general at present employing or electroslag smelting casting adds the electroslag burning-on method.Adopt segmentation electroslag smelting casting method to produce integral shaft, all there is report in the domestic and Soviet Union.The method is at first to make the crank armshaft that has garden shape lug with electroslag casting, take out rotate to an angle (according to the calibration decision of each rod journal of bent axle) then, lug is put into the corresponding lug of former crystallizer hole, begin second crank blank of melting again, simultaneously it is welded together with first crank arm blank.Repeat above-mentioned steps, just can produce integral body and turn number and all unrestricted bent axle of calibration.Another kind is the above-mentioned crank arm of having refined of contunuous wedling (the crank web position is melt into the hole earlier on the crank arm), until forming an integral shaft.Said method is owing to need repeatedly welding, and the heat affected area tissue of welding is had adverse effect, the visible melt run of low power, also can exist sometimes be mingled with, defectives such as pore, slag inclusion, lack of penetration, crackle, so this part performance is lower than the performance of other parts.And this part peak stress district in bent axle when work exactly.The fatigue fracture of bent axle all occurs in this zone basically.In addition, " agricultural machinery " 11-12 phase in 1978, a kind of electroslag smelting casting abnormal shape of having reported the 55-57 page or leaf turns the method for axle (guide wheel shaft), this method is in order to melt out of line upper and lower shaft part, when founding, consutrode and crystallizer also relatively move, and shift by certain route to guarantee electrode tip and high-temperature region, but do not have deformation process.If do not make improvements, this method is difficult to founding and goes out the very complicated mulit-turning crankshaft of shape or other complicated part.Because the crank thickness of bent axle is very little with the ratio of length and width, generally 1/8-1/4 only turns axle and is 1-1.5, can't carry out above-mentioned " transfer ".
Purpose of the present invention is intended to the electroslag smelting casting method is improved, and makes molten bath or slag bath generation local deformation in fusion-casting process, to overcome the above-mentioned limitation in the electroslag smelting casting method, reaches the purpose that whole founding goes out the very complicated product of shape.
In order to realize purpose of the present invention, the present invention is in electroslag casting before the metal freezing forming step, also being included in crank throw concave side electrode can't directly insert the part of carrying out normal founding and moulding and clamp-on the loose piece mould, by the step that moves the distortion moulding of being carried out of this mould, the indent position of the rod journal of moulding bent axle.The present invention adopts two kinds of modes to reach the distortion moulding.
First kind of mode is, can't directly insert at crank throw concave side electrode on the sidewall of the main body crystallizer that carries out normal founding and moulding some loose piece shape moulds are set, the loose piece mould can move back and forth the indent position of the rod journal of moulding bent axle with the direction perpendicular to main body crystallizer axis substantially in the main body crystallizer.The main body crystallizer is generally opposite opened, can be whole opposite opened, or one turn one section opposite opened, or turns one section opposite opened more, the shape of visual fusion casting product and deciding.In the electroslag smelting casting process, the loose piece mould is clamp-oned corresponding to the slag bath at crank throw indent position and the interface place in molten bath, can form one and turn.Along with the carrying out of melting, also can clamp-on second loose piece mould, the 3rd loose piece mould by the above ..., become whole mulit-turning crankshaft until founding.
The best time that the loose piece mould begins to clamp-on is that slag bath and molten bath interface and loose piece mould lower plane rigidly connect the moment of touching, and the best time of clamp-oning termination is that slag bath and molten bath interface rise to the moment that is higher than the loose piece mold thickness of clamp-oning on the loose piece mould lower plane 0.03~0.06 times.When weld pool surface rise to last one turn the lower crank arm time begin to extract the loose piece mould, extracting too early to influence formed precision, even molten steel crank arm on the burn through again, extracted evening increase is turned the neck residual stress and extracted difficulty.
Clamp-oning the loose piece mould will be designed to and the corresponding shape of deformation place.The width B and the thickness H that clamp-on the loose piece mould should meet following relational expression:
B=(0.8~1.2)d,H≤0.9L
In the formula: d is the rod journal diameter, and L is a rod journal length.
If B>1.2d, then the loose piece mould is clamp-oned difficulty.If B<0.8d then can shorten the service life of main body crystallizer widely.If H>0.9L then can't satisfy the required precision of crank arm moulding.
For the safety that guarantees to clamp-on and service life of clamp-oning the loose piece mould, will use water cooling in the loose piece mould, and water inlet to use jet pipe, centering high temperature dead angle area, intake pressure is than the high 1-2 of intake pressure times of main body crystallizer.
The type of belt drive that the loose piece mould is clamp-oned and extracted can be diversified prior art, still must guarantee the line of action of force and the rod journal centering of clamp-oning.
For mulit-turning crankshaft, rod journal (turning neck) calibration be 180 the degree, the main body crystallizer can be designed as and whenever turns one section, also can be designed to turn one section more, in addition integral body one section.Calibration is not 180 degree, and the main body crystallizer is designed to whenever turn one section.Respectively turn or section between crystallizer the outer mould of calibration and location the location, clamp and to guarantee.
The second way is segmentation displacement (offsetting).Mould by the bent axle of requirement founding be divided into plurality of sections (to call layer in the following text).Every layer of mould comprises internal crystallization device and necessary external mold, substantially can be by the crystallizer design of disclosed segmentation founding bent axle in the prior art.But requirement can overlappedly be fixed between every layer, and doing relatively again, level offsets.Respectively turn trunnion, rod journal, crank arm by this interlayer offsetting moulding bent axle, and in each layer mould of the present invention, its high-temperature region and dead angle area to adopt the type of cooling and the desired cooling water inflow described in first kind of mode.Before the founding, earlier which floor above-mentioned mould is overlaped.Interface when slag bath or molten bath or slag bath and molten bath rises to the position of turning accordingly, and this layer mould centering rod journal is made level and offsetted, and begins to offset to clamp-on constantly with described in first kind of mode.Simultaneously, each layer mould on the offsetting face also done translation relatively synchronously together with electrode.After this, minimum one deck mould down can deviate to keep supplying the use of face respective layer.Turn 8 layers of mould with 2, even only turn 4 layers of mould, just can founding go out several bent axles that turn more with 1.Offsetting and stopping the moment is that slag bath and molten bath interface rise to offsetting face top (0.03-0.06) Hp, and wherein Hp is the average thickness of each layer mould.
The balance position of crank arm tends to cause moulding not full, except the repair method of available forging and foundry goods permission is repaired.The present invention adopts the method that can put into prefabricated inserting (same steel grade) before the founding in the crystallizer die cavity, and it is welding in fusion-casting process on the bent axle body.
First kind of mode is applicable to that usually rod journal length is less than 100 millimeters, bent axle weight is less than 1 ton various middle-size and small-size bent axle, the distortion casting quality is controlled easily, distortion executing agency is simpler, the location of whole bent axle and assembling are all fairly simple, but it is shorter to clamp-on the loose piece life-span, and safety condition is had relatively high expectations, and the formed precision of rod journal is relatively poor.When rod journal length during greater than 100 millimeters, clamp-on loose piece and can make successively clamp-oning from bottom to top of multilayer, to reduce owing to clamp-on the excessive difficulty of bringing of loose piece H.
During the second way is applicable to usually, large-scale bent axle, handling safety condition broad, formed precision is higher, mould is economized, but auxiliary executing agency complexity.
Therefore the present invention makes some limitation of electroslag casting obtain remedying to a certain degree owing to increased the distortion forming step, even also the scope of application of electroslag casting has had expansion, is particularly suitable for the very complicated integral product of founding shape.And, the product quality height, the fatigue ratio segmentation founding bent axle of integral shaft and crankshaft forging improve more than 10%, especially improve the performance in part time job peak stress district.In addition, the wearability of product, seizure resistance also increases.The existing quality problems of segmentation fusing process of intermediate can not appear in constant product quality, can boost productivity exponentially.Also can save the material and the energy, cost can reduce 20-50%.
Below in conjunction with drawings and Examples the present invention is done narration in more detail.
Description of drawings:
Fig. 1 is crystallizer cross sectional representation that turns in the bent axle;
Fig. 2-1 2 turns bent axle and squeezes and to turn whole primary crystallization device and loose piece mould assembling schematic diagram (clamp-oning preceding);
Fig. 2-2 clamp-ons the back schematic diagram for loose piece mould among Fig. 2-1;
Fig. 3-1 and Fig. 3-2 turns a crowded schematic diagram that turns before deformation process begins that turns in the whole founding bent axle of distortion fusion casting for the loose piece mould squeezes; Fig. 3-3 turns the final state schematic diagram for squeezing; Fig. 3-4 is for beginning to extract loose piece mould schematic diagram;
Fig. 4-1-1 is the schematic diagram before the 3rd layer of mould offsetting deformation process begins in the layering offsetting distortion founding integral shaft; Fig. 4-1-2 is the distortion termination schematic diagram that offsets among Fig. 4-1-1;
Fig. 4-2-1 is after the described situation of Fig. 4-1-2, the schematic diagram before the 4th layer of mould offsetting deformation process begins; Fig. 4-2-2 is the distortion termination schematic diagram that offsets among Fig. 4-2-1;
Fig. 4-3-1 is after the described situation of Fig. 4-2-2, the schematic diagram before layer 5 mould offsetting deformation process begins; Fig. 4-3-2 is the distortion termination schematic diagram that offsets among Fig. 4-3-1.
Embodiment 1
Jiangxi Lichuan Special Steel Plant's founding BJ-212 Beijing jeep kart 492 engine crankshafts, 64 millimeters of trunnion diameters, connecting rod neck diameter is 58 millimeters, crankshaft length is 623 millimeters, 15 millimeters of crank thickness, width 80-100 millimeter, material is No. 45 steel.
With reference to Fig. 1, external mold 1 is used to make primary crystallization device 3 location to clamp, the main body crystallizer has a water inlet 6, a delivery port 2 is settled on the sidewall of main body crystallizer 3 and is clamp-oned loose piece mould 4, and loose piece mould 4 is by 5 coolings of water inlet jet pipe, the loose piece mould is under the effect of special guider (not marking among the figure), inwardly clamp-on and outwards extract with the direction of line of action of force and rod journal centering, left hollow arrow represents to clamp-on direction among the figure, and hollow arrow to the right represents to extract direction.
By the number that turns of bent axle, select a plurality of crystallizers as shown in Figure 1 for use, integral body of overlapping successively then fixedly formation.Also available whole opposite opened crystallizer 3 shown in Fig. 2-1 and Fig. 2-2, the sidewall of solid block mold 3 are provided with 4 the same loose piece moulds 4 among Fig. 1, and wherein Fig. 2-1 is the assembling situation of loose piece mould before clamp-oning, and Fig. 2-2 is for clamp-oning situation afterwards.
Electroslag casting process:
1. slag system:
Slag system: CaF70%, Al 2O 330%
The quantity of slag: add 3 kilograms for the first time, fusion-casting process divides 6 batches to add granulated slag, 0.5 kilogram every batch.
2. electric system:
Transformer: import 380 volts, single-phase 150 kilovolt-amperes, 450 kilovolt-amperes of three-phases, but on-load voltage regulation.
Melting voltage: 35 volts-55 volts.
Melting electric current: 1800 amp-2400 peaces.
3. cooling system:
Inflow temperature: 20 ℃-30 ℃, hydraulic pressure: 1-2kg/cm 2
Leaving water temperature: 40 ℃-50 ℃.
4. technology point:
The melt cinder starting improves electric current 20% in 5 minutes.Form the top of the slag monitoring of slag bath, can on the crystallizer die joint, perforate directly observe and measure, also available ammeter indication.With reference to Fig. 3-1, Fig. 3-2, Fig. 3-3 and Fig. 3-4, when founding proceeded to state shown in Fig. 3-1, slag bath 10 had entered in first main body crystallizer 3 that turns, was molten bath 9 below the slag bath, was the bent axle 8 that has solidified below again.Along with the continuous fusing of electrode 7, slag bath face and molten bath face rise gradually, and computing method is generally adopted in the monitoring of molten bath face, promptly calculate molten bath face height according to the fusing amount of consutrode 7.When founding proceeds to state shown in Fig. 3-2, that is slag bath 10 is when just contacting (promptly concordant) with loose piece mould 4 lower planes with the interface in molten bath 9, reduces electric current 20% and begins to squeeze and turn.When reaching state shown in Fig. 3-3, squeeze and turn termination, this moment, interface was higher than about 2 millimeters of loose piece mould lower surface.When interface rise to last one turn the lower crank arm time, when being state shown in Fig. 3-4, begin to extract the loose piece mould.Repeat above-mentioned step, can produce the integral one-step molding mulit-turning crankshaft, calibration is 180 degree.
Embodiment 2
With reference to Fig. 4-1-1, Fig. 4-1-2, Fig. 4-2-1, Fig. 4-2-2, Fig. 4-3-1, Fig. 4-3-2, fusible cast out calibration be not 180 the degree the integral one-step molding mulit-turning crankshafts.120 ° of calibration bent axles producing of Jiangxi Lichuan Special Steel Plant for example, the trunnion diameter is 65 millimeters or 75 millimeters, the rod journal diameter is 62 millimeters, crankshaft length is 910 millimeters or 960 millimeters, 20 millimeters of crank thickness, 102 millimeters or 110 millimeters of width, material is No. 45 steel.Technological specification is described with embodiment 1 substantially.Difference: the mould branch turns design, and calibration guarantees by special-purpose external mold and casting machine, when slag bath and molten bath interface 11 through mould M 1, M 2, just rise to and M 3Lower plane contact-promptly offsets, and concordant (begin when seeing Fig. 4-1-1) to offset by direction shown in the hollow arrow, simultaneously, layer mould of each on the offsetting face be together with electrode also translation relatively synchronously, rises to until slag bath and molten bath interface 11 to be higher than M for face 3Lower plane (0.03-0.06) Hp, wherein Hp is each layer mould average thickness, dislocation distortion stops (seeing Fig. 4-1-2).When interface 11 rises to apart from M 3(see Fig. 4-2-1), M during the Hp of last plane (0.03-0.06) 4Offset by direction shown in the hollow arrow, simultaneously, each layer mould on the offsetting face also do translation relatively synchronously together with electrode, until interface 11 and M 3Last plane is concordant, and the distortion that offsets stops (seeing Fig. 4-2-2).When interface 11 just rises to and M 3In lower plane when contact, (seen Fig. 4-3-1), M 3Offset by the hollow arrow direction, simultaneously, each layer mould on the offsetting face also do translation relatively synchronously together with electrode, rise to apart from M until interface 3During lower plane (0.03-0.06) Hp, the distortion that offsets stops (seeing Fig. 4-3-2).So far, first turn that founding finishes.Below, can progressively slough M 1, M 2Use for continuing.For the balance position filling that guarantees crank arm full, can be at M 6In put in advance prefabricated with the steel grade A that inserts.Repeat above-mentioned steps, can produce that integral one-step molding turns, calibration is not the bent axles of 180 degree more.
The type bent axles such as 481,485,492,692,6135 that adopt that embodiment 1 or the whole foundings of embodiment 2 distortion electroslags become contrast with the same model crankshaft forging, and mechanical performance is shown in table 1; Non-metallic inclusion is shown in table 2; The composition variation is shown in table 3; Using rate of metal is shown in table 4.
Figure 85109612_IMG2
Figure 85109612_IMG3
Figure 85109612_IMG4

Claims (9)

1, a kind of bent axle integral one-step molding electroslag casting, it comprises refining purification and coagulation forming step, also be included on the main body crystallizer sidewall loose piece mould that can move perpendicular to main body crystallizer axis direction is set, it is in fusion-casting process before the metal freezing moulding, can't directly insert the part of carrying out normal founding and moulding at crank throw concave side electrode and clamp-on the loose piece mould, the indent position of the rod journal of moulding bent axle, the beginning of loose piece mould clamp-oned and is slag bath and the moment that molten bath interface and described loose piece mould lower plane have just contacted constantly, and it is characterized in that: described loose piece mould width B and thickness H are of a size of:
B=(0.8~1.2)d,H≤0.9L
Wherein: d is the rod journal diameter
L is a rod journal length
Clamp-on and stop constantly clamp-oning (0.03~0.06) H place on the loose piece mould lower plane for slag bath and molten bath interface rise to.
2, method according to claim 1 is characterized in that: the rod journal calibration be 180 the degree, the main body crystallizer can be designed as and whenever turns one section, or is designed to turn one section more, or integral body one section.
3, method according to claim 1 is characterized in that: the rod journal calibration is not 180 degree, and the main body crystallizer is designed to whenever turn one section.
4, according to claim 2 or 3 described methods, it is characterized in that: for whenever turning one section or turn one section more, respectively turn or section between the location of the outer mould of calibration and location of crystallizer, clamp and guarantee.
5, method according to claim 1, it is characterized in that: melting voltage: 35 volts~55 volts, melting electric current: 1800 peaces~2400 peaces, melt cinder starts, improves in 5 minutes electric current 20%, when slag bath just contacts with loose piece mould lower plane with the molten bath interface in the melting, reduce electric current 20% and begin crowded turning.
6, a kind of bent axle integral one-step molding electroslag casting, it is that mould is divided into several layers by the bent axle of institute's founding, can be overlapped fixing between every layer, level offsets relatively again, the trunnion that in fusion-casting process, respectively turns by interlayer offsetting moulding bent axle, rod journal, crank arm, the moment that begins to offset be slag bath with the interface in molten bath just with the offsetting mould between concordant moment of offsetting face, it is characterized in that: turn 8 layers of mould with 2, even only turn 4 layers of mould with 1, the termination that offsets is that slag bath and molten bath interface rise to (0.03~0.06) Hp place, offsetting face top constantly, wherein Hp is the average thickness of each layer mould, when offsetting, layer mould of each on the offsetting face done translation relatively synchronously together with electrode.
7, method according to claim 6 is characterized in that: can put into prefabricated inserting (same steel grade) before the founding in the crystallizer die cavity, it is welding in fusion-casting process on the bent axle body.
8, method according to claim 6, it is characterized in that: melting voltage: 35 volts~55 volts, melting electric current: 1800 peaces~2400 peaces, melt cinder starts, improves in 5 minutes electric current 20%, slag bath and molten bath interface in the melting, just with mould between offsetting face when concordant, reduce electric current 20% and begin to offset.
9, according to claim 1 or 2 or 3 or 6 described methods, it is characterized in that: use water cooling in the loose piece mould, jet pipe is used in water inlet, centering high temperature dead angle area, and intake pressure is than the high 1-2 of intake pressure times of main body crystallizer.
CN 85109612 1985-12-23 1985-12-23 Bent axle integral one-step molding electroslag casting Expired CN1016853B (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
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CN1016853B true CN1016853B (en) 1992-06-03

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Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1095408C (en) * 2000-09-29 2002-12-04 徐登红 Successive electroslay smelting casting process of crank shaft blank
CN1309509C (en) * 2002-08-21 2007-04-11 蒋雪耕 Step electroslag melting technology and apparatus for crankshaft blank
CN107790685B (en) * 2016-08-31 2019-09-24 沈阳铸造研究所 Electroslag casting method without public chamber casting is prepared using the molten group equipment of intelligence
CN107790684B (en) * 2016-08-31 2019-11-15 沈阳铸造研究所 A kind of fixation and traveling electrode manufacture the electroslag casting method without public chamber casting
CN107774962B (en) * 2016-08-31 2019-09-17 沈阳铸造研究所 A kind of electroslag fusion manufacturing method of large-scale curved blade slab
CN109604566B (en) * 2019-01-18 2024-06-21 潍坊亚东冶金设备有限公司 Multilayer sectional combined split special-shaped crystallizer for electroslag casting blade
CN110014136B (en) * 2019-04-23 2021-05-04 沈阳铸造研究所有限公司 Method for removing subsidies in electroslag casting by nesting independent water-cooled crystallizers
CN110076326A (en) * 2019-05-20 2019-08-02 沈阳铸造研究所有限公司 A kind of electroslag smelting casting shaped piece crystallizer water route control method
CN111570747A (en) * 2020-07-03 2020-08-25 沈阳航空航天大学 Continuous casting device with replaceable combined dies and using method thereof

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