CN102078956A - Method for casting mechanical arm casting of robot - Google Patents
Method for casting mechanical arm casting of robot Download PDFInfo
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- CN102078956A CN102078956A CN 200910199800 CN200910199800A CN102078956A CN 102078956 A CN102078956 A CN 102078956A CN 200910199800 CN200910199800 CN 200910199800 CN 200910199800 A CN200910199800 A CN 200910199800A CN 102078956 A CN102078956 A CN 102078956A
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- 238000005266 casting Methods 0.000 title claims abstract description 80
- 238000000034 method Methods 0.000 title claims abstract description 48
- 238000011081 inoculation Methods 0.000 claims abstract description 17
- 238000010079 rubber tapping Methods 0.000 claims abstract description 15
- 238000003723 Smelting Methods 0.000 claims abstract description 13
- 239000004576 sand Substances 0.000 claims abstract description 12
- 238000011282 treatment Methods 0.000 claims abstract description 9
- 238000000465 moulding Methods 0.000 claims abstract description 7
- 238000007689 inspection Methods 0.000 claims abstract description 5
- 238000004140 cleaning Methods 0.000 claims abstract description 4
- 238000001816 cooling Methods 0.000 claims abstract description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 112
- 229910052742 iron Inorganic materials 0.000 claims description 49
- 239000002054 inoculum Substances 0.000 claims description 30
- 229910000519 Ferrosilicon Inorganic materials 0.000 claims description 16
- 239000000126 substance Substances 0.000 claims description 13
- XOCUXOWLYLLJLV-UHFFFAOYSA-N [O].[S] Chemical compound [O].[S] XOCUXOWLYLLJLV-UHFFFAOYSA-N 0.000 claims description 10
- 239000000919 ceramic Substances 0.000 claims description 10
- 239000003795 chemical substances by application Substances 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 7
- 238000002360 preparation method Methods 0.000 claims description 4
- 229910000859 α-Fe Inorganic materials 0.000 claims description 4
- 229910000805 Pig iron Inorganic materials 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 3
- 239000006260 foam Substances 0.000 claims description 3
- 230000006698 induction Effects 0.000 claims description 3
- 238000002156 mixing Methods 0.000 claims description 3
- 239000010959 steel Substances 0.000 claims description 3
- 230000007547 defect Effects 0.000 description 14
- 238000000576 coating method Methods 0.000 description 9
- 238000011049 filling Methods 0.000 description 8
- 239000007788 liquid Substances 0.000 description 7
- 239000011248 coating agent Substances 0.000 description 6
- 239000002893 slag Substances 0.000 description 6
- 230000001680 brushing effect Effects 0.000 description 5
- 239000011572 manganese Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000012535 impurity Substances 0.000 description 4
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- 238000004519 manufacturing process Methods 0.000 description 3
- 238000007493 shaping process Methods 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 229910001141 Ductile iron Inorganic materials 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
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- 238000007667 floating Methods 0.000 description 1
- 239000007849 furan resin Substances 0.000 description 1
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- 229910052748 manganese Inorganic materials 0.000 description 1
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- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
Abstract
The invention discloses a method for casting a mechanical arm casting of a robot, which comprises the steps of: sand mulling, modeling, core molding, mold assembly, furnace charge smelting, tapping spheroidizing and inoculation treatment, casting, cooling, unpacking, casting cleaning and product quality inspection. In the method, a two-side distributed casting process is adopted in terms of process designing, and external chill is arranged on the thicker part of the casting. The casting has mechanical properties such as tensile strength of more than or equal to 450MPa, yield strength of more than or equal to 310MPa, elongation rate of more than or equal to 10 percent and body hardness of 160 to 210HBS, and does not have any casting shortcoming.
Description
Technical Field
The invention relates to a casting method, in particular to a casting method of an industrial robot mechanical arm casting.
Background
The mechanical arm is a key part of a robot for production in the automobile industry, and the part needs to meet the requirement of high-precision displacement on the premise of bearing certain gravity and bending moment loads so as to meet the high-standard operation stability in the automobile industry, so that the part needs to have higher strength and deformation resistance at the same time. Aiming at the requirements, the part adopts a thin-wall (the main wall thickness is 7mm) square tube type design in structure, and a grade of nodular cast iron QT450-10 is selected, so that the dead weight is reduced as much as possible, and the part is ensured to have higher strength and toughness. The mechanical properties of the casting need to meet the requirements that the tensile strength is larger than or equal to 450MPa, the yield strength is larger than or equal to 310MPa, the elongation is larger than or equal to 10%, and the bulk hardness is 160-210 HBS. And does not allow any casting defects to exist in various parts of the casting. The technical index of the product is characterized in that:
the designed wall thickness of the mechanical arm is 7mm, the thinnest part is only 6mm, and the individual boss is thicker, so that the wall thickness is required to be accurate. The chemical composition has higher requirement on the manganese content, and the Mn content is less than or equal to 0.4 percent. The part belongs to a robot appearance part, so that the casting is required to have good surface quality; the inner cavity of the arm needs to be provided with a certain electric control device, so that the surface of the inner cavity has very high requirements, and the defects of burrs, wrinkles and the like are not allowed. Therefore, how to satisfy the above technical requirements becomes a key for successfully casting the mechanical arm.
Disclosure of Invention
The invention aims to provide a casting method of a robot mechanical arm casting, so that the produced robot mechanical arm casting can meet the technical requirements.
In order to achieve the purpose, the invention adopts the technical scheme that:
a casting method of a robot mechanical arm casting comprises the steps of sand mixing, molding, core making, mold assembling, furnace burden smelting, tapping spheroidization and inoculation treatment, pouring, cooling, unpacking and casting cleaning product quality inspection; the method comprises the following steps of charging smelting, wherein the charging smelting step comprises charging preparation and smelting, and the charging preparation comprises the following components in percentage by weight: 20-40% of pig iron, 20-50% of foundry returns and 10-60% of scrap steel; smelting in a medium-frequency induction furnace at 1440-1580 ℃; the tapping spheroidization inoculation step comprises two procedures of tapping spheroidization and ferrosilicon inoculant twice inoculation; in the pouring step, the pouring temperature is controlled to be 1380-1460 ℃, a two-side distributed pouring process is adopted, molten iron flows into the cross runners on two sides simultaneously after entering from the sprue, and then enters the cavity from the cross runners on two sides through a plurality of ingates, so that the mold filling temperature of the molten iron is balanced and improved, the mold filling time is shortened, and the product quality is ensured.
The tapping spheroidization inoculation process comprises two links of tapping spheroidization and ferrosilicon inoculant inoculation twice. And inoculating the inoculant twice, namely adding a ferrosilicon inoculant accounting for 0.2-0.5% of the total weight of the molten iron after primary tapping and spheroidizing, then stirring and slagging off, supplementing the molten iron, inoculating for the second time, adding the ferrosilicon inoculant accounting for 0.2-0.5% of the total weight of the molten iron to the ladle surface, stirring and slagging off. The particle size of the ferrosilicon inoculant is 3-25 mm, and the ferrosilicon inoculant comprises 72-75% of Si, 0.4-1.5% of Al, 0.4-1.0% of Ca and the balance of Fe.
In the pouring step, after the liquid iron is inoculated by a nodulizer, the pouring temperature of the liquid iron is ensured to be 1380-1460 ℃.
Furthermore, in the pouring step, a two-side distributed pouring process is adopted, molten iron flows into 3 cross runners simultaneously after entering from a sprue, and then enters the cavity from the cross runners on two sides through 7 ingates.
In the pouring step, a ceramic tube is adopted to guide molten iron to a third cross gate on the other side of the casting mold.
The added nodulizing agent accounts for 1.0-2.5% of the amount of smelted iron, and the nodulizing agent comprises the following chemical components in percentage by weight: 5.0-7.5% of Mg, 1.0-4.0% of RE, 35-48% of Si, 1.0-3.0% of Ca and the balance of Fe, wherein the grain size of the nodulizer is 3-25 mm.
The inoculant added in the two-time inoculation of the inoculant accounts for 0.2-0.5% of the total weight of the iron liquid. The ferrosilicon inoculant comprises the following chemical components in percentage by weight: 72-75% of Si, 0.4-1.0% of Ca, 0.4-1.5% of Al and the balance of Fe, wherein the particle size of the ferrosilicon inoculant is 3-25 mm.
In the pouring process, a sulfur-oxygen inoculant is adopted for stream inoculation, the particle size of the sulfur-oxygen inoculant is 0.1-1.0 mm, the weight percentage of chemical components of the sulfur-oxygen inoculant is 70-76% of Si, 0.75-1.25% of Al, 0.75-1.25% of Ca, 1.5-2.0% of Ce, 0.5-0.8% of S, 0.3-0.5% of O and the balance of Fe, and the adding amount accounts for 0.05-0.2% of the total amount of the iron liquid.
The final casting product comprises the following chemical components in percentage by weight: 3.0-3.8% of C, 2.0-3.2% of Si, less than or equal to 0.4% of Mn, less than or equal to 0.07% of P, less than or equal to 0.03% of S, 0.02-0.08% of Mg and the balance of Fe, wherein the metallographic structure of the casting product has a spheroidization rate of more than 80%, ferrite 60-85% and carbide of less than 0.3%.
In addition, in the process, open risers are arranged at the thicker positions of the two ends of the casting for feeding.
A ceramic foam filter is placed in the filter under the pouring cup.
And chill chilling is placed at the thick large part of the casting.
Further, the present invention employs a flow coating process in which the coating material is applied in a form that the coating material flows over the cavity surface in the coating process in the molding step.
The cast product has a metallographic structure with the nodularity of more than 80 percent, ferrite of 60-85 percent and carbide of less than 0.3 percent by the smelting, spheroidizing and inoculation treatment, so that the mechanical property requirement of the product is ensured.
In order to obtain a cast product without defects, the invention is characterized in that:
(1) adopting a two-side distributed pouring process: the method comprises the following steps that molten iron flows into three cross runners, namely a first cross runner, a second cross runner and a third cross runner, through a filter with a ceramic filter screen below after entering from a sprue, the molten iron flowing into the third cross runner is introduced through a ceramic pipe, and then the molten iron enters a cavity from the three cross runners through seven sheet-shaped inner runners so as to achieve the pouring effect of dispersing heat and quickly filling the cavity, and then the pouring temperature is controlled to be 1380-1460 ℃, so that the process can ensure that a casting product does not have cold insulation and air hole defects. Because the wall thickness of the casting product is only 6-7 mm, if the casting is carried out from one side by using the traditional casting process, the temperature drop is large when molten iron flows from the casting side to the other side in the cavity, and therefore cold insulation and air hole defects are generated at the mold back filling position in the molten iron. After the process is adopted, the mold filling temperature of the molten iron is balanced and improved, and the mold filling time is shortened, so that the problems generated by the traditional process can be avoided.
(2) 2 open risers are arranged at the thicker positions of the two ends of the casting for feeding so as to ensure that the two places do not generate shrinkage porosity defects.
(3) And a foamed ceramic filter plate is placed at the bottom of the sprue to filter the molten iron and remove impurities in the molten iron, so that the slag inclusion defect of the product is prevented.
(4) In the casting process, the thick and large part of the casting is chilled by adopting external chill to ensure that the thick and large part of the casting is accelerated to be cooled and solidified, and the defects of shrinkage porosity, shrinkage cavity and the like of the part are avoided.
(5) In the coating procedure of the molding step, in order to obtain a clear and attractive casting surface, a traditional brushing way is not adopted, but a more advanced flow coating process is adopted, namely, the coating is coated in a mode that the coating flows over the surface of the cavity, and the process does not generate the problems of brushing marks of the brushing process and accumulation of the coating on sharp corners of the cavity.
The invention adopts the ceramic tube to guide the molten iron in the process design, so that the molten iron realizes the rapid dispersion mold filling effect in the pouring process, and effectively overcomes the defects of cold shut and air holes which are easily generated by thin-wall castings.
After the casting method is adopted, the tensile strength of the produced robot manipulator casting is more than or equal to 450MPa, the yield strength is more than or equal to 310MPa, the elongation is more than or equal to 10%, and the body hardness is 160-210 HBS. All parts of the casting have no casting defects, and completely meet the technical requirements of customers.
Drawings
FIG. 1 is a schematic view of a method of casting a cast robotic arm of the present invention;
fig. 2 is a side sectional view of fig. 1.
Detailed Description
Example 1
Referring to fig. 1 and 2, the casting method of the robot mechanical arm casting for the automobile industry of the invention comprises the following steps:
1. sand mixing, molding and core making
The robot manipulator casting is subjected to molding and manufacturing of No. 1, No. 2 and No. 3 sand cores 1-3 after furan resin self-hardening sand is mixed by an automatic sand mixer. Before modeling, two strip chills 4 and 5 and an annular chiller 6 are placed on a lower shaping plate and are prevented from moving during modeling, and two open risers 10, four exhaust fins 9 and a strip chiller 7 are placed at specified positions of an upper shaping plate. Then filling sand, compacting, drawing, shaping, brushing paint and baking the surface. And then manufacturing three sand cores 1-3 of No. 1, 2 and 3 (a strip-shaped chilling block 8 is placed in the core 1 of No. 1), brushing paint, drying the surface and then placing for later use.
2. Combination type
Sequentially putting 3 sand cores 1, 2 and 3 into a lower sand mold, detecting by using a clamping plate and ensuring the wall thickness of a product to be uniform, and placing a ceramic filter screen 12 in a filter 11; after floating sand in the upper sand mold and the lower sand mold is blown off, the upper mold is hung and turned to be closed, and the boxes are fastened by bolts to wait for pouring.
3. Melting of charge
Firstly, preparing furnace burden, wherein the furnace burden comprises the following components in percentage by weight: 30% of pig iron, 30% of return materials and 40% of scrap steel, then sequentially putting the prepared furnace materials into a medium-frequency induction furnace to carry out molten iron smelting at the smelting temperature of 1550 ℃, standing and preserving heat for 5-10 minutes to enable impurities in the molten iron to fully float, covering the furnace slag with a deslagging agent, and then raking the furnace slag out of the furnace to prevent the impurities from remaining in the molten iron.
4. Tapping spheroidization inoculation treatment
Comprises two parts of nodulizing treatment of tapping and two-time inoculation treatment of ferrosilicon inoculant. The spheroidizing treatment adopts a punching spheroidizing treatment process, the grain size of a spheroidizing agent is 3-25 mm, the adding amount of the spheroidizing agent is 1.5%, the tapping temperature of molten iron is 1550 ℃, the first tapping amount is 2/3 of the total amount, the reaction time of the spheroidizing agent and the molten iron is 40-90 seconds, a ferrosilicon inoculant accounting for 0.3% of the total tapping amount is added after the reaction is finished, the rest 1/3 molten iron is supplemented, then, scum on the surface of the molten iron is stirred and completely removed, a ferrosilicon inoculant accounting for 0.3% of the total weight of the molten iron is added, stirring and slag removal are carried out, and finally, a heat-preservation covering agent is covered for pouring. Wherein the nodulizer comprises the following chemical components in percentage by weight: 6.5% of Mg, 2.15% of RE, 45% of Si, 2.3% of Ca and the balance of Fe; the ferrosilicon inoculant comprises the following chemical components in percentage by weight: 75% of Si, 0.7% of Ca, 0.5% of Al and the balance of Fe, and the particle size of the ferrosilicon inoculant is 3-25 mm.
5. Pouring
The casting temperature of the molten iron is 1430 ℃. After the molten iron is poured into the pouring cup and the sprue 13, the molten iron passes through the filter 11 of the foam filter screen 12, so that impurities in the molten iron are blocked, and the possibility of slag inclusion defects of castings is reduced. In addition, after the molten iron passes through the filter disc, the flow velocity of the molten iron is slowed down, and the impact force of the molten iron on the casting mold is lightened, so that the possibility of sand washing is reduced; the iron liquid is stably filled, and the secondary oxidation of the iron liquid in the casting mold is favorably reduced, so that the slag inclusion defect is reduced. The molten iron then flows into the three cross runners 14, 15 and 16 simultaneously, wherein the molten iron in the third cross runner 16 is introduced by a ceramic tube 17, and the molten iron simultaneously enters the cavity from seven sheet-shaped ingates 18 of the three cross runners at two sides of the cavity, so that the purposes of rapid dispersion and stable pouring are achieved; in the pouring process, a sulfur-oxygen inoculant is adopted for stream inoculation, the particle size of the sulfur-oxygen inoculant is 0.1-1.0 mm, the chemical components of the sulfur-oxygen inoculant are Si 71.2%, Al 0.96%, Ca 0.90%, Ce 1.67%, S0.75%, O0.76% and the balance of Fe, and the adding amount accounts for 0.05-0.2% of the total amount of the iron liquid; the total chemical composition percentage of the final casting product is as follows: 3.57% of C, 2.66% of Si, 0.38% of Mn, 0.042% of P, 0.009% of S, 0.018% of RE, 0.045% of Mg and the balance of Fe.
6. Cooling box opening
7. Cleaning of castings
8. Quality inspection
And (4) detecting unqualified products, eliminating and scrapping the unqualified products, and temporarily storing the qualified products in a casting qualified product warehouse.
After the casting method is adopted, the gross weight of the casting is 121kg, the dead head weight is 65kg, the process yield is 65%, and for the thin-wall casting with the main wall thickness of only 7mm, the result basically achieves the process effect of creating economic benefit.
The material brand of the product is nodular cast iron QT450, and the mechanical property inspection result of the product is as follows: tensile strength 490MPa, yield strength 340MPa, elongation 16%, and hardness 178 HBS; the metallographic structure detection result of the casting product is as follows: the spheroidization rate is 85 percent, the ferrite is 85 percent, and the carbide is less than 0.3 percent; and (3) detecting the chemical components of the product: 3.57% of C, 2.66% of Si, 0.38% of Mn, 0.042% of P, 0.009% of S, 0.018% of RE, 0.045% of Mg and the balance of Fe; the casting product has no casting defects after ultrasonic defect detection. The casting product completely meets the technical condition requirements of customers.
TABLE 1 Main Process parameters of the examples of the invention
The processes of examples 2, 3, 4 and 5 are the same as example 1 and will not be further described.
Claims (10)
1. A casting method of a robot mechanical arm casting comprises the steps of sand mixing, molding, core making, mold assembling, furnace burden smelting, tapping spheroidization and inoculation treatment, pouring, cooling, unpacking and casting cleaning product quality inspection; wherein,
the furnace burden smelting step comprises furnace burden preparation and smelting, wherein the furnace burden preparation comprises the following components in percentage by weight: 20-40% of pig iron, 20-50% of foundry returns and 10-60% of scrap steel; smelting in a medium-frequency induction furnace at 1440-1580 ℃;
the tapping spheroidization inoculation step comprises two procedures of tapping spheroidization and ferrosilicon inoculant twice inoculation;
in the pouring step, the pouring temperature is controlled to be 1380-1460 ℃, a two-side distributed pouring process is adopted, and molten iron flows into the cross runners on two sides simultaneously after entering from the sprue and then enters the cavity from the cross runners on two sides through a plurality of ingates.
2. The method for casting a cast on a robot arm according to claim 1, wherein the casting step comprises a two-side distributed casting process in which molten iron flows into 3 gates from a sprue and then flows into the cavity from the two gates through 7 gates.
3. A method of casting a cast robot arm as claimed in claim 1, wherein the pouring step is performed by introducing molten iron to a third runner on the other side of the mold using a ceramic pipe.
4. The method for casting a cast robot arm according to claim 1, wherein the added spheroidizing agent is 1.0 to 2.5% of the amount of the smelted iron, and the spheroidizing agent comprises the following chemical components in percentage by weight: 5.0-7.5% of Mg, 1.0-4.0% of RE, 35-48% of Si, 1.0-3.0% of Ca and the balance of Fe, wherein the grain size of the nodulizer is 3-25 mm.
5. The method of casting a cast robot arm as claimed in claim 1, wherein the inoculant added in the two inoculations is 0.2-0.5% of the total weight of the molten iron. The ferrosilicon inoculant comprises the following chemical components in percentage by weight: 72-75% of Si, 0.4-1.0% of Ca, 0.4-1.5% of Al and the balance of Fe, wherein the particle size of the ferrosilicon inoculant is 3-25 mm.
6. The method of casting a cast robot arm according to claim 1, wherein a sulfur-oxygen inoculant is used for stream inoculation during the casting process, the particle size of the sulfur-oxygen inoculant is 0.1-1.0 mm, the sulfur-oxygen inoculant comprises, by weight, 70-76% of Si, 0.75-1.25% of Al, 0.75-1.25% of Ca, 1.5-2.0% of Ce, 0.5-0.8% of S, 0.3-0.5% of O, and the balance Fe, and the amount of the sulfur-oxygen inoculant added is 0.05-0.2% of the total amount of the molten iron.
7. The method for casting a cast for a robotic manipulator of claim 1, wherein the final cast product comprises the following chemical components in weight percent: 3.0-3.8% of C, 2.0-3.2% of Si, less than or equal to 0.4% of Mn, less than or equal to 0.07% of P, less than or equal to 0.03% of S, 0.02-0.08% of Mg and the balance of Fe, wherein the metallographic structure of the casting product has a spheroidization rate of more than 80%, ferrite 60-85% and carbide of less than 0.3%.
8. The method of casting a cast robot arm as claimed in claim 1, wherein open risers are provided at thick positions at both ends of the cast for feeding.
9. The method of casting a cast robot arm as claimed in claim 1, wherein a ceramic foam filter is placed in the filter under the pouring cup.
10. A method of casting a cast robotic arm as claimed in claim 1, wherein a chill is placed in the bulk of the cast.
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| CN102310187B (en) * | 2011-09-13 | 2013-06-05 | 上海华新合金有限公司 | Elevator traction sheave casting method |
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| CN103949597A (en) * | 2014-04-29 | 2014-07-30 | 太湖县爱杰机械铸造有限公司 | Method for producing swing arm casting of hybrid electric vehicle |
| CN103949597B (en) * | 2014-04-29 | 2016-02-03 | 太湖县爱杰机械铸造有限公司 | The production method of hybrid vehicle swing arm foundry goods |
| CN109822049A (en) * | 2019-04-11 | 2019-05-31 | 浙江欧冶达机械制造股份有限公司 | A kind of casting technique of robot arm pedestal |
| CN111876658A (en) * | 2020-09-04 | 2020-11-03 | 浙江坤博精工科技股份有限公司 | Casting method of mechanical arm of industrial robot |
| CN111876658B (en) * | 2020-09-04 | 2021-11-12 | 浙江坤博精工科技股份有限公司 | Casting method of mechanical arm of industrial robot |
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| CN102078956B (en) | 2013-02-27 |
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