CN101716668A - Method for casting thin-shell nodular-cast-iron turbocharger - Google Patents
Method for casting thin-shell nodular-cast-iron turbocharger Download PDFInfo
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- CN101716668A CN101716668A CN200910117721A CN200910117721A CN101716668A CN 101716668 A CN101716668 A CN 101716668A CN 200910117721 A CN200910117721 A CN 200910117721A CN 200910117721 A CN200910117721 A CN 200910117721A CN 101716668 A CN101716668 A CN 101716668A
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Abstract
The invention relates to a method for casting a thin-shell nodular-cast-iron turbocharger, in particular to a method for casting the thin-shell nodular-cast-iron turbocharger and the like products, which is characterized by comprising the following steps of: process method design, three-dimensional model design of the casting process, mold-filling/solidifying simulation, analysis treatment for a simulated result, selection of mold materials, mold assembling simulation, molding, core making, mold assembling, molten iron melting, spheroidizing inoculation, and pouring. The process method provided by the invention is unique, which can solve the problem of shrinkage porosity because the partially overlarge part of an inner cavity cannot be fed by a riser, and can ensure the dimensional accuracy of air cavity, water cavity and oil cavity which are intersected one another in the inner cavity of the casting shell.
Description
Technical field
The present invention relates to a kind of casting method of shell spheroidal graphite cast-iron turbocharger, especially the casting method of shell spheroidal graphite cast-iron turbocharger class.
Background technology
Shell spheroidal graphite cast-iron turbocharger is because with high content of technology, and the production difficulty is big, is monopolized by the several families of American-European countries foundry enterprise always.This series shell spheroidal graphite cast-iron turbocharger ironcasting, the inner chamber arranged crosswise has air cavity, water cavity, oil pocket, complex structure.The wall thickness of minimum only is 5～6mm in each cavity.Simultaneously, air cavity, water cavity, oil pocket require during use to bear the pressure of demarcation, do not allow to leak.There is following difficult point in the Foundry Production of this series products:
(1) gauge, cavity space size, the control of cavity overall size between Nei Bu air cavity, water cavity, oil pocket position, chamber is very difficult;
(2) structure of material and foundry goods, it is too poor to adapt to the casting solidification shrinkage.The casting structure complexity, thick less than normal, the thick skewness of meat of inner chamber meat is easy to produce the interior tissue shrinkage porosite, casting process slag inclusion, the needs that bear pressure that can't fine adaptation use;
(3) foundry goods part intracavity space size is less than normal--and-core thickness only has 11～12mm, can't place arbor, and fuse very easily deforms.Adopt ordinary resin sand, arbor to make core, can't guarantee the bearing capacity of casting dimension and foundry goods;
(4) foundry goods key position allowance only is 3～4mm, and wherein some position is because the restriction of casting structure cannot be subsidized increase allowance;
(5) foundry goods inside needs the castingin steel tubes, requires the position accurate, and no scab in the steel pipe, inner surface are smooth, the iron liquid thickness of outer wrap steel pipe only 6～8mm, and require fusion well;
(6) 4～5 of each is thick on the foundry goods entity, thin exemplary position is on average drawn materials performance coupons must satisfy mechanical property of materials requirement.
Present general casting technique and melting, pouring procedure can't stably overcome above-mentioned defective.
Summary of the invention
The objective of the invention is to overcome the deficiencies in the prior art, a kind of process uniqueness is provided, can solves that the local thick large part of inner chamber can't adopt riser feeding and the casting method of a kind of shell spheroidal graphite cast-iron turbocharger of the dimensional accuracy of the shrinkage porosite problem that easily produces, the air cavity that guarantees foundry goods housing inner chamber arranged crosswise, water cavity, each cavity of oil pocket.
The present invention realizes by the following method:
A kind of casting method of shell spheroidal graphite cast-iron turbocharger, it is characterized in that: it comprises the steps:
A. process design: adopt the center somatotype, for saturating the situation that in one plane is not difficult for somatotype in foundry goods side, when technological design, adopt curved surface cope down method, take important flange face on the classifying method down, positive-pressure gating system, the mode of casting mold bottom multiple spot cast;
B. casting technique threedimensional model design: utilize computer software, set up the threedimensional model consistent with the casting technique design;
C. fill type/solidification simulation: by casting analogue simulation software, the parameter of selecting simulation to need is filled type, process of setting simulation;
D. Mold Making: according to casting structure characteristics, dimensional accuracy standard, the metal die that the manufactured size precision is high;
E. simulate mould assembling:, utilize three-dimensional software progressive type, core match case according to the threedimensional model of having optimized casting process scheme;
F. moulding: adopt conventional furan resin casting sand, carry out three casees or four casees branch mailbox method of pounding is made casting mold;
G. coremaking: utilize the approaching special-purpose arbor of threedimensional model design, making, use and sand core structure, simultaneously to air cavity, water cavity, oil pocket core, use the mound roughing sand, send general resin/curing agent making fuse, layer of sand intensity around the arbor reaches more than the 1.2Mp, and places special-purpose exhaust passage according to the position that has identified in the core box;
H. mould assembling: according to the order of casting Technology Design, with casting mold and core combination, place pouring basin and prepare cast, before the mould assembling, outside casting mold,, carry out surface treatment in advance, the pre-configured coating of brushing to the core seam of needs butt joint, the prevention dislocation, during mould assembling, adopt the special detection clamp of making, the casting dimension of control key position;
I. molten iron is melting: castings material is QT400-15, adopts furnace melting;
J. spheroidization and inoculation: adopt and pour the method spheroidization and inoculation;
K. cast: 1360～1390 ℃ of pouring temperatures, 2～3 minutes durations of pouring;
Described cast is that high temperature waters slowly, the mode of watering slowly by high temperature, and during cast, molten iron is full of to be chosen behind the pouring basin stifledly, keeps pouring basin to be full of in the casting process, notes the igniting bleed simultaneously, in time discharges gases at high pressure;
Adopt 75SiFe condiment during described spheroidization and inoculation, adopt then and pour the method spheroidization and inoculation, nodulizer adopts rare earth magnesium nodularizer, adding weight content is 0.8～1.4%, inovulant adopts silicon titanate innoculant, adding weight content is 0.4～0.6%, and spheroidization and inoculation was accomplished to the duration of pouring in 14 minutes.
The present invention has following effect:
1) in conjunction with relevant thin-walled spheroidal graphite cast-iron product technological design experience in company's early stage,, designed the casting process scheme of serial foundry goods at the design feature of shell spheroidal graphite cast-iron turbocharger foundry goods.The running gate system of this patent series shell spheroidal graphite cast-iron turbocharger foundry goods makes molten iron can fill the use of type and special-purpose chill reposefully, avoids shrinkage defect effectively, reaches client's quality requirement.This patent series shell spheroidal graphite cast-iron turbocharger cast casting technological design scheme, successful solution run into the mould material difficulty of living in moulding, coremaking and the mould assembling process and get, coremaking and mould assembling that air cavity core, water cavity core, oil pocket core intersection cause are interfered, and have well guaranteed the dimensional accuracy of foundry goods.
2) use of this patent series shell spheroidal graphite cast-iron turbocharger foundry goods metal die has guaranteed the complexity of foundry goods outward appearance and inner chamber and the requirement of dimensional accuracy.
3) critical process is simulated in earlier stage, has guaranteed the reliability of practical operation;
4) the process for making uniqueness of this patent regulation (under the conventional furan resin-sand formative method condition, is taken measures before mould comes into operation, has been guaranteed the location of special-purpose chill, reached the foundry goods profile target consistent with drawing.Special-purpose arbor has guaranteed the indeformable and core cavity size of core.General resin, mound roughing sand are sent in the use of this patent regulation, guarantee that the layer of sand intensity around the arbor reaches more than the 1.2Mp, have improved the intensity and the surface quality of core, avoid core to deform and the scab defective.The placement nylon airway method of this patent regulation guarantees that core gives vent to anger fully, and is smooth and easy.The outer treatment combination core method of type has guaranteed core cavity, casting section thickness dimensional accuracy before the mould assembling of this patent regulation.The method of clamp check that this patent adopts and control key position size has guaranteed that the high-grade dimensional tolerance of this series products is controlled quality.
5) to relate to castings material be QT400-15 to this patent, adopts the electro-smelting method, according to the melting operation guiding book control procedure parameter of making according to this invented technology, prevented the problem that general molten steel solidification crystallization nucleation core reduces effectively.
6) this patent adopts unique nodularizing inoculant and parameter, effectively prevents that spheroidization and inoculation from failing, and guarantees the effect of spheroidization and inoculation:
7) the method spheroidization and inoculation was poured in employing after this patent adopted 75SiFe condiment to make the interior hot metal composition of stove reach requirement, and nodulizer adopts rare earth magnesium nodularizer, and addition is 0.8～1.4%, and inovulant adopts silicon titanate innoculant, and addition is 0.4～0.6%.In order to prevent to breed and decaying spheroidisation, the control spheroidization and inoculation was accomplished to the duration of pouring in 14 minutes, effectively to prevent the spheroidization and inoculation decline, guaranteed the effect of spheroidization and inoculation.
8) the cast principle is that high temperature waters slowly, 1360～1390 ℃ of pouring temperatures, and be 2～3 minutes the duration of pouring, the mode of watering slowly by high temperature makes the liquid state contraction of molten iron can obtain feeding in casting process.Molten iron is full of and chooses behind the basin of the mouth of a river stifledly during cast, is beneficial to bits come-up in the molten iron, keeps the mouth of a river to be full of in the casting process, notes bleed simultaneously.
9) the present invention is by unique casting process scheme, special core production's method and running gate system, successfully solve the shrinkage porosite problem of the modal local position of shell spheroidal graphite cast-iron turbocharger series part and the dimensional accuracy problem of shell casting, reached steady production.
The specific embodiment
A kind of casting method of shell spheroidal graphite cast-iron turbocharger, it is characterized in that: it comprises the steps:
A. process design: adopt the center somatotype, the situation that in one plane is not difficult for somatotype for the saturating door in foundry goods side, when technological design, adopt curved surface cope down method to solve, consider that simultaneously foundry goods flange faying face has relatively high expectations, factors such as punch position is many in order to guarantee the faying face quality, are avoided the flange dreg defect, take important flange face down from classifying method, guarantee the clean level of important flange face.Positive-pressure gating system, the mode of casting mold bottom multiple spot cast makes molten iron steadily fill type;
B. casting technique threedimensional model design: utilize computer software, set up the threedimensional model consistent with the casting technique design;
C. fill type/solidification simulation: by casting analogue simulation software, the parameter of selecting simulation to need is filled type, process of setting simulation;
D. Mold Making: according to casting structure characteristics, dimensional accuracy standard, the metal die that the manufactured size precision is high;
E. simulate mould assembling:, utilize three-dimensional software progressive type, core match case according to the threedimensional model of having optimized casting process scheme;
F. moulding: adopt conventional furan resin casting sand, carry out three casees or four casees branch mailbox method of pounding is made casting mold;
G. coremaking: utilize the approaching special-purpose arbor of threedimensional model design, making, use and sand core structure.To air cavity, water cavity, oil pocket core, use special " mound " roughing sand, " sending general " resin/curing agent to make fuse simultaneously.Guaranteed that the layer of sand intensity around the arbor reaches more than the 1.2Mp, and placed special-purpose exhaust passage according to the position that has identified in the core box;
H. mould assembling:,, place pouring basin and prepare cast with casting mold and core combination according to the order of casting Technology Design.Before the mould assembling, to the core seam of needs butt joint, carry out surface treatment in advance, the pre-configured coating of brushing outside casting mold, the prevention dislocation during mould assembling, is adopted the special detection clamp of making, the casting dimension of control key position;
I. molten iron is melting: castings material is QT400-15, adopts furnace melting;
J. spheroidization and inoculation: adopt and pour the method spheroidization and inoculation;
K. cast: 1360～1390 ℃ of pouring temperatures, 2～3 minutes durations of pouring.
Above-mentioned cast is that high temperature waters slowly, the mode of watering slowly by high temperature, make the liquid state contraction of molten iron can in casting process, obtain feeding, during cast, molten iron is full of to be chosen behind the pouring basin stifledly, is beneficial to bits come-up in the molten iron, keeps pouring basin to be full of in the casting process, note the igniting bleed simultaneously, in time discharge gases at high pressure.
The method spheroidization and inoculation is poured in employing after adopting 75SiFe condiment to make the interior hot metal composition of stove reach requirement during spheroidization and inoculation, nodulizer adopts rare earth magnesium nodularizer, adding weight content is 0.8～1.4%, and inovulant adopts silicon titanate innoculant, and adding weight content is 0.4～0.6%.In order to prevent to breed and decaying spheroidisation, the control spheroidization and inoculation was accomplished to the duration of pouring in 14 minutes, effectively to prevent the spheroidization and inoculation decline, guaranteed the effect of spheroidization and inoculation.
Claims (3)
1. the casting method of a shell spheroidal graphite cast-iron turbocharger, it is characterized in that: it comprises the steps:
A. process design: adopt the center somatotype, for saturating the situation that in one plane is not difficult for somatotype in foundry goods side, when technological design, adopt curved surface cope down method, take important flange face on the classifying method down, positive-pressure gating system, the mode of casting mold bottom multiple spot cast;
B. casting technique threedimensional model design: utilize computer software, set up the threedimensional model consistent with the casting technique design;
C. fill type/solidification simulation: by casting analogue simulation software, the parameter of selecting simulation to need is filled type, process of setting simulation;
D. Mold Making: according to casting structure characteristics, dimensional accuracy standard, the metal die that the manufactured size precision is high;
E. simulate mould assembling:, utilize three-dimensional software progressive type, core match case according to the threedimensional model of having optimized casting process scheme;
F. moulding: adopt conventional furan resin casting sand, carry out three casees or four casees branch mailbox method of pounding is made casting mold;
G. coremaking: utilize the approaching special-purpose arbor of threedimensional model design, making, use and sand core structure, simultaneously to air cavity, water cavity, oil pocket core, use the mound roughing sand, send general resin/curing agent making fuse, layer of sand intensity around the arbor reaches more than the 1.2Mp, and places special-purpose exhaust passage according to the position that has identified in the core box;
H. mould assembling: according to the order of casting Technology Design, with casting mold and core combination, place pouring basin and prepare cast, before the mould assembling, outside casting mold,, carry out surface treatment in advance, the pre-configured coating of brushing to the core seam of needs butt joint, the prevention dislocation, during mould assembling, adopt the special detection clamp of making, the casting dimension of control key position;
I. molten iron is melting: castings material is QT400-15, adopts furnace melting;
J. spheroidization and inoculation: adopt and pour the method spheroidization and inoculation;
K. cast: 1360～1390 ℃ of pouring temperatures, 2～3 minutes durations of pouring.
2. the casting method of a kind of shell spheroidal graphite cast-iron turbocharger as claimed in claim 1, it is characterized in that: described cast is that high temperature waters slowly, the mode of watering slowly by high temperature, during cast, molten iron be full of choose behind the pouring basin stifled, keep pouring basin to be full of in the casting process, note the igniting bleed simultaneously, in time discharge gases at high pressure.
3. the casting method of a kind of shell spheroidal graphite cast-iron turbocharger as claimed in claim 1, it is characterized in that: adopt 75SiFe condiment during described spheroidization and inoculation, adopt then and pour the method spheroidization and inoculation, nodulizer adopts rare earth magnesium nodularizer, adding weight content is 0.8～1.4%, inovulant adopts silicon titanate innoculant, and adding weight content is 0.4～0.6%, and spheroidization and inoculation was accomplished to the duration of pouring in 14 minutes.
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| CN200910117721A CN101716668A (en) | 2009-12-15 | 2009-12-15 | Method for casting thin-shell nodular-cast-iron turbocharger |
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| CN200910117721A CN101716668A (en) | 2009-12-15 | 2009-12-15 | Method for casting thin-shell nodular-cast-iron turbocharger |
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| CN102049473A (en) * | 2011-01-25 | 2011-05-11 | 西峡县众德汽车部件有限公司 | Novel sand core and preparation method thereof |
| CN102069148A (en) * | 2010-12-21 | 2011-05-25 | 宁夏共享集团有限责任公司 | Method for casting brake disc for high-speed locomotive |
| CN102371345A (en) * | 2010-08-23 | 2012-03-14 | 上海华新合金有限公司 | Method for casting ductile iron casting of air-conditioning compressor |
| CN102717032A (en) * | 2012-07-09 | 2012-10-10 | 江苏多为泵业股份有限公司 | Precision casting method for automobile turbocharger casing part |
| 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 |
| CN103331421A (en) * | 2013-06-17 | 2013-10-02 | 龙岩市升伍旗车桥有限公司 | Overturning casting method for axle housing of 30F loader |
| CN103537629A (en) * | 2013-11-14 | 2014-01-29 | 宁夏共享集团有限责任公司 | Exhausting method for sand core for core shooting process of cold core box |
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| CN103934413A (en) * | 2014-03-25 | 2014-07-23 | 宁夏共享集团有限责任公司 | Strength enhancing method for sand core manufactured through cold core box core shooting technology |
| CN104040143A (en) * | 2012-01-25 | 2014-09-10 | 博格华纳公司 | Integrated Turbocharger Casting |
| CN104209471A (en) * | 2014-07-10 | 2014-12-17 | 陕西国德电气制造有限公司 | Preparation method of triplet shell casting |
| CN105834369A (en) * | 2016-04-28 | 2016-08-10 | 安徽霍山县象山机械制造有限公司 | Sand core with exhaust device |
| CN106955970A (en) * | 2016-01-11 | 2017-07-18 | 科华控股股份有限公司 | Supercharger volute angle master reference is extended to the sand mould structure of outer wall by inner chamber |
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| CN109402427A (en) * | 2017-12-29 | 2019-03-01 | 湖北航特装备制造股份有限公司 | A kind of aluminum alloy chassis hollow thin-wall fore sub frame metal mold gravity casting technique |
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| CN102371345A (en) * | 2010-08-23 | 2012-03-14 | 上海华新合金有限公司 | Method for casting ductile iron casting of air-conditioning compressor |
| CN102371345B (en) * | 2010-08-23 | 2012-12-19 | 上海华新合金有限公司 | Method for casting ductile iron casting of air-conditioning compressor |
| CN102069148A (en) * | 2010-12-21 | 2011-05-25 | 宁夏共享集团有限责任公司 | Method for casting brake disc for high-speed locomotive |
| CN102049473A (en) * | 2011-01-25 | 2011-05-11 | 西峡县众德汽车部件有限公司 | Novel sand core and preparation method thereof |
| CN104040143A (en) * | 2012-01-25 | 2014-09-10 | 博格华纳公司 | Integrated Turbocharger Casting |
| CN102717032A (en) * | 2012-07-09 | 2012-10-10 | 江苏多为泵业股份有限公司 | Precision casting method for automobile turbocharger casing part |
| CN102717032B (en) * | 2012-07-09 | 2014-01-15 | 江苏多为泵业股份有限公司 | Precision casting method for automobile turbocharger casing part |
| 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 |
| CN103331421A (en) * | 2013-06-17 | 2013-10-02 | 龙岩市升伍旗车桥有限公司 | Overturning casting method for axle housing of 30F loader |
| CN103557086B (en) * | 2013-10-30 | 2016-03-02 | 宁波裕隆汽车制泵有限公司 | The manufacture method of the gear chamber mould on automobile pump |
| CN103557086A (en) * | 2013-10-30 | 2014-02-05 | 宁波裕隆汽车制泵有限公司 | Gear chamber on pump for car as well as die design and manufacturing thereof |
| CN103537629A (en) * | 2013-11-14 | 2014-01-29 | 宁夏共享集团有限责任公司 | Exhausting method for sand core for core shooting process of cold core box |
| CN103934413A (en) * | 2014-03-25 | 2014-07-23 | 宁夏共享集团有限责任公司 | Strength enhancing method for sand core manufactured through cold core box core shooting technology |
| CN104209471A (en) * | 2014-07-10 | 2014-12-17 | 陕西国德电气制造有限公司 | Preparation method of triplet shell casting |
| CN106955970A (en) * | 2016-01-11 | 2017-07-18 | 科华控股股份有限公司 | Supercharger volute angle master reference is extended to the sand mould structure of outer wall by inner chamber |
| CN105834369A (en) * | 2016-04-28 | 2016-08-10 | 安徽霍山县象山机械制造有限公司 | Sand core with exhaust device |
| CN109402427A (en) * | 2017-12-29 | 2019-03-01 | 湖北航特装备制造股份有限公司 | A kind of aluminum alloy chassis hollow thin-wall fore sub frame metal mold gravity casting technique |
| CN109209624A (en) * | 2018-10-22 | 2019-01-15 | 天津宝信铸造股份有限公司 | A kind of casting and its preparation process of thick big high silicon molybdenum spheroidal graphite cast-iron |
| CN110421121A (en) * | 2019-08-29 | 2019-11-08 | 贵州安吉航空精密铸造有限责任公司 | A kind of vent control valve tube core manufacturing method in casting technique |
| CN114393178A (en) * | 2022-01-26 | 2022-04-26 | 安徽合力股份有限公司合肥铸锻厂 | Static pressure casting process of brake wheel shell casting |
| CN115351227A (en) * | 2022-07-25 | 2022-11-18 | 日月重工股份有限公司 | Casting mold for manufacturing wet exhaust pipe for high-silicon-molybdenum ship and forming method |
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Application publication date: 20100602 |