CN102554120A - Process for preparing plastic foam pattern for lost foam casting - Google Patents
Process for preparing plastic foam pattern for lost foam casting Download PDFInfo
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Abstract
The invention relates to a process for preparing plastic particles of a plastic foam pattern for lost foam casting. The process comprises the following steps of: 1) selecting the minimum and maximum particle models from plastic particle models; 2) obtaining the actual main particle sizes of the particles and finding out more than four kinds of main particles in a ratio; 3) drawing a gradation curve coordinate graph to determine qualified indexes; 4) drawing particle distribution curves of two kinds of main plastic particles, and determining the most proper volume ratio of the two kinds of particles according to the overlap, connection and separation of the two adjacent curves; 5) drawing a gradation curve in which the particles are matched in a ratio; 6) after the gradation curve is detected to be qualified, determining a mass ratio of various particles; and 7) weighing the two kinds of plastic particles to obtain the gradation foam pattern. The foam pattern meets the requirements on surface roughness Ra and the dimensional accuracy CT, and the density of the foam pattern is reduced as much as possible.
Description
Technical field
The present invention relates to a kind of plastic grain particle preparing process that is used for the plastic foam apperance of lost foam casting.
Background technology
At present, lost foam casting is because the superiority of itself develops rapidly, and its technology is tending towards perfect gradually in recent years.The basic manufacture craft of its Foam Pattern is: plastic pellet prefoam → slaking → second time of foaming → apperance.
The Eps bead that lost foam casting is commonly used has several kinds (according to shown in Figure 2), the apperance of wherein using A-105 model foam particle to make, and the surface size precision is minimum, and surface roughness is the highest, and intensity is minimum, and density is minimum; The apperance that A-108 model foam particle makes, the surface size precision is the highest, and surface roughness is minimum, and intensity is the highest, and density is maximum.(A-107, A-106, A-105 each item index are arranged in order) can find out that wherein the prepared cast(ing) surface dimensional accuracy of apperance of A-108 model foam is the highest; Surface roughness is minimum; But because its apperance density is maximum; Mean that apperance will cause many defectives of foundry goods in casting process, gas forming amount is excessive during like the apperance cracking, causes defectives such as cold shut, foundry goods deformation; The unit volume carbon content is high, causes defectives such as carbon distribution.Higher by about 25% through calculating the unit volume carbon content and the cast gas forming amount that compare A-108 than A-106.Experiment showed, that the density with Foam Pattern is controlled at 26 kg/m as far as possible
3Could effectively control above all kinds of defective with interior, satisfy the quality requirement of cast iron class foundry goods.A-107, A-108 particle apperance density are too high, all at 26kg/m
3More than; But the particle apperance that the following model foaming of A-106 makes is because after the post forming foaming; More than 1.6mm, its intergranular space causes apperance surface roughness Ra (usually at Ra>=25 μ m) not reach requirement more greatly to the foam particle diameter mostly, and dimensional accuracy is in CT6 ~ 8.Especially A-105 model, its surperficial particle voids can reach 2mm deeply, and area is at 3mm
2More than.The final cast product surface quality that forms usually can't satisfy the cast product requirement, has limited the application of lost foam casting on the high accuracy cast product.
The method is used in the manufacturing process of lost foam casting apperance, and the foundry goods that requires for high dimensional accuracy, low roughness can reduce all kinds of defectives that apperance produces significantly in casting process, improve casting yield.
Summary of the invention
In order to address the above problem, the present invention is a kind of preparing process that is used for the plastic pellet apperance of lost foam casting, and it satisfies under the prerequisite of apperance surface roughness Ra, dimensional accuracy CT, and the foam that descends is as much as possible touched a kind density.
To achieve these goals, the present invention mainly is able to solve by the following technical programs:
Be used for the preparing process of the plastic pellet apperance of lost foam casting, comprise following processing step:
1) selects the smallest particles model in the plastic pellet model according to the requirement of surface roughness Ra, dimensional accuracy CT, select the largest particles model according to the minimum wall thickness (MINI W.) that can make Foam Pattern;
2) according to the particle diameter that reaches behind the second time of foaming, the empirical parameter n after pushing mutually when multiply by grain forming, n gets 0.75 ~ 0.90, draws the actual main particle diameter diameter of particle; Find out the wherein main particle more than four kinds in proportion;
3) require to draw the grading curve coordinate diagram according to maximum density, confirm qualified index;
4) draw two curves based on the distribution of main plastic pellet gained particle of two kinds of different models of actual measurement, by two adjacent curves be overlapping, join, mutually from confirming two kinds of only volume ratios of particle;
5) draw out the grading curve that proportions, whether detect qualified defective can the adjustment the bead foaming process;
6) qualified back confirms that according to volume ratio various granular mass ratio mass ratioes are easy to weighing;
7) according to two kinds of plastic pellets of mass ratio weighing, prefoam, slaking mixes in the mixing drum of special use, at last compound is injected disappearance mould mould second time of foaming, makes the grating Foam Pattern.
As preferably, above-mentioned step 2) according to the maximal density curve, the relation curve that passes through percentage and particle diameter that gathers materials is more near parabola in, and this packing of gathering materials is big more, and the space is more little, and this result can be expressed as:
P
2=kd ……………………………………………………（1）
P---the particle that the middle screen size of gathering materials is d is through percentage (%)
D---the screen size of certain kind particle in gathering materials;
K---statistical parameter
The percentage that passes through of maximum particle diameter is 100 in gathering materials; Promptly when screen size d equals D; The percentage P that passes through of this particle is 100; This is concerned substitution formula (1):
the k value again behind the substitution formula 1, can be calculated the percentage that passes through of the main particle diameter d of any one-level particle according to formula (2):
Maximum particle diameter during certain of D in the formula---desire calculating gathers materials
D, P---the same formula of meaning (1)
Confirm the formate gradation composition of multiple particle; Reference axis is set, desired grating intermediate value is depicted as straight line, ordinate and abscissa are represented respectively through percentage and particle size, and when ordinate still is the arithmetic coordinate time, the position of abscissa will be confirmed by design grating intermediate value.
As preferably, in specification, paint a rectangle picture frame in the above-mentioned step 3) by certain size, connect diagonal; On ordinate, mark accumulative total through the percentage position by the arithmetic coordinatometer.Each particle diameter that design grating intermediate value is required is marked on the ordinate, and from ordinate diversion horizontal line diagonal is intersected through percentage, and it is crossing with abscissa to make vertical line from intersection point again, and its intersection point is the position of each corresponding grain size; This diagonal is for being the maximum closely knit level distribution of design, and each particle diameter approaches this line more in the apperance, explains that grating is good more.
As preferably, particle commonly used is combined with following: A-108 and A-106; A-107 and A-105; A-108 and A-105.
The present invention compares with prior art, and it satisfies under the prerequisite of apperance surface roughness Ra, dimensional accuracy CT through the Foam Pattern that makes after this technological process, and the foam that descends is as much as possible touched a kind density.And indexs such as the surface roughness of Foam Pattern, dimensional accuracy, density have directly determined the quality of foundry goods.
Description of drawings
Fig. 1: the structural representation (surface roughness can reach Ra6.3 ~ 12.5, dimensional accuracy can reach CT6 ~ 8) of the Foam Pattern that makes for the independent A-108 plastic grain second time of foaming of the embodiment of the invention.
Fig. 2: the structural representation (surface roughness Ra 12.5 ~ 25, dimensional accuracy can reach CT8 ~ 10) of the Foam Pattern that makes for the independent A-106 plastic grain second time of foaming of the embodiment of the invention.
Fig. 3: for the embodiment of the invention with A-106 and two kinds of particles of A-108 by grading composition after the structural representation (surface roughness can reach Ra6.3 ~ 12.5, dimensional accuracy can reach CT6 ~ 8) of the Foam Pattern that makes of second time of foaming.
Fig. 4: for the embodiment of the invention is that greatest limit particle, 0.6mm are the grading curve coordinate diagram of least limit particle with 3.0mm.
Fig. 5: be the well-graded district of grading curve of the 0.6mm ~ 3.0mm particle of the embodiment of the invention.
Fig. 6: be the qualified district of grading curve grating of the 0.6mm ~ 3.0mm particle of the embodiment of the invention.
Fig. 7: for the A-106 of the embodiment of the invention, A-108 accumulative total through percentage curves (two particle curves join).
Fig. 8: for A-106, the A-108 accumulative total of the embodiment of the invention are passed through percentage curves (two particle curves overlapped).
Fig. 9: for A-106, the A-108 accumulative total of the embodiment of the invention are passed through percentage curves (two particle curves leave mutually).
Figure 10: pass through percentage curves for A-106, the A-108 of the embodiment of the invention mixes back grain diameter accumulative total in proportion.
Figure 11: be the structural representation of the plastic pellet mixing drum of the embodiment of the invention.
The specific embodiment
Do further bright specifically below in conjunction with accompanying drawing to the specific embodiment of technical scheme of the present invention.
A kind of preparing process that is used for the plastic pellet apperance of lost foam casting, the preparing process step of plastic pellet apperance (making up the Foam Pattern that the back second time of foaming makes on request) according to A106 and two kinds of particles of A108.
Table 1: each specification of common plastics particle, use separately, foundry goods can reach roughness and dimensional accuracy
Table 2: according to each specification particle data, each foam data is surveyed in foaming separately
(1) this method is selected the smallest particles model in each plastic pellet model according to the requirement of surface roughness Ra, dimensional accuracy CT, selects the largest particles model in each plastic pellet model according to the minimum wall thickness (MINI W.) of Foam Pattern.Two kinds of particles mix back second time of foaming molding in the prefoam of calculating ratio.Obtained Foam Pattern reaches surface size precision and the surface roughness that is made apperance by the independent foaming of smallest particles basically, and the density of Foam Pattern is slightly larger than the density that is made apperance by the independent foaming of bulky grain.Promptly reach under the prerequisite that foundry goods requires in the surface size precision of apperance and surface roughness, apperance density is as far as possible little, thereby reduces casting flaw.
After A-106 model and A-108 model were according to said method made apperance, its dimensional accuracy and surface roughness were suitable basically with the Foam Pattern that is made by the A-108 particle separately, and the actual density of apperance has only 26 ~ 27kg/m
3Between, less than 28 ~ 32kg/m of A-108
3The method is used in the manufacturing process of lost foam casting apperance, and the foundry goods that requires for high accuracy, low roughness can reduce all kinds of defectives that apperance produces significantly in casting process, improve casting yield.
(2) according to the particle diameter behind the second time of foaming, the empirical parameter n after pushing mutually when multiply by grain forming gets between (0.75 ~ 0.90), draws the actual main particle diameter diameter of particle; According to the maximal density curve, the relation curve that passes through percentage and particle diameter that gathers materials is more near parabola, and this packing of gathering materials is big more, and the space is more little, and this result can be expressed as:
P
2=kd ……………………………………………………（1）
P---the particle that the middle screen size of gathering materials is d is through percentage (%)
D---the screen size of certain kind particle in gathering materials;
K---statistical parameter.
The percentage that passes through of maximum particle diameter is 100 in gathering materials; Promptly when screen size d equals D; The percentage P that passes through of this particle is 100; This is concerned substitution formula (1):
the k value again behind the substitution formula 1, can be calculated the percentage that passes through of the main particle diameter d of any one-level particle according to formula (2):
Maximum particle diameter during certain of D in the formula---desire calculating gathers materials
D, P---the same formula of meaning (1).
Confirm the formate gradation composition of multiple particle.Reference axis is set, desired grating intermediate value is depicted as straight line, ordinate and abscissa are represented respectively through percentage and particle size, and when ordinate still is the arithmetic coordinate time, the position of abscissa will be confirmed by design grating intermediate value.
With A-106, A-108 is that grain composition is an example: according to the particle diameter behind the second time of foaming, and the empirical parameter n after pushing mutually when multiply by grain forming, about (0.75 ~ 0.90), this calculating gets 0.85 according to our company's actual measurement experience to n through actual measurement.
The A-106 second time of foaming can reach particle diameter 1.7 ~ 3.1; The foam actual particle size of second time of foaming (extruding back) 1.4 ~ 2.6.
The A-108 second time of foaming can reach particle diameter 0.95 ~ 1.65; The foam actual particle size of second time of foaming (extruding back) 0.8 ~ 1.4.
Find out the wherein main particle more than four kinds in proportion.
The main particle diameter of A-106: 1.4; 1.8; 2.2; (2.6 increasing progressively) with 0.4mm
The main particle diameter of A-108: 0.8; 1.0; 1.2; (1.4 increasing progressively) with 0.2mm
With next ratio particle 0.6mm of minimum main particle diameter 0.8mm in two kinds of particles as the minimum limit value particle that possibly occur in the batching; With next ratio particle 3.0mm of maximum main particle diameter 2.6mm in two kinds of particles as the maximum limit particle that possibly occur in the batching.Wherein particle diameter minimum limit value particle is 0.6mm, and particle diameter maximum limit particle is 3.0mm.0.6mm following particle is disregarded.Accumulative total to obtain each main particle diameter is passed through percentage.
P
1=
(being that the 0.8mm particle needs 28.87% volume ratio).
P
2=
(being that 1.0mm and following particle need 40.82% volume ratio).
P
3=
(being that 1.2mm and following particle need 50.00% volume ratio).
P
4=
(being that 1.4mm and following particle need 57.74% volume ratio).
P
5=
(being that 1.8mm and following particle need 70.71% volume ratio).
P
6=
(being that 2.2mm and following particle need 81.65% volume ratio).
P
7=
(being that 2.6mm and following particle need 91.29% volume ratio).
(3) require to draw the grading curve coordinate diagram according to maximum density; In specification, paint a rectangle picture frame, connect diagonal by certain size.On ordinate, mark accumulative total through the percentage position by the arithmetic coordinatometer.Each particle diameter that design grating intermediate value is required is marked on the ordinate, and from ordinate diversion horizontal line diagonal is intersected through percentage, and it is crossing with abscissa to make vertical line from intersection point again, and its intersection point is the position of each corresponding grain size.This diagonal is for being the maximum closely knit level distribution of design, and each particle diameter approaches this line more in the apperance, explains that grating is good more.Fig. 4 is to be that greatest limit particle, 0.6mm are the grading curve coordinate diagram of least limit particle with 3.0mm.
Can get by this, reach like the foam particle ratio:
| Main particle diameter: | 0.8 | 1.0 | 1.2 | 1.4 | 1.8 | 2.2 | 2.6 |
| The accumulative total passing ratio: | 28.87% | 40.82% | 50.0% | 57.74% | 70.71% | 81.65% | 91.29% |
Then the grating of this Foam Pattern is the most reasonable, and corresponding packing is the highest, and each item index is the most desirable.
Confirm good, qualified index: connect and the adjacent horizontal ordinate integral point of the maximum closely knit level distribution of design, the grid dash area is well-graded scope, and promptly the plastic pellet distribution of particles drops in this interval basically, and is then well-graded.Fig. 5 is the well-graded district of grading curve of 0.6mm ~ 3.0mm particle.
Connect and adjacent two horizontal stroke, the ordinate integral point of the maximum closely knit level distribution of design; The bottom starting point is taken to the centre position of 0.6mm and 0.8mm; Diagonal line hatches partly is the grating acceptability limit, and promptly the plastic pellet distribution of particles drops in this interval basically, and then grating is qualified.Fig. 6 is the qualified district of grading curve grating of 0.6mm ~ 3.0mm particle.
(4) draw two curves based on the distribution of main plastic pellet gained particle of two kinds of different models of actual measurement, in two adjacent curves be overlapping, join, mutually from confirming various particle volume ratios.
Because each foam particle manufacturer, the disappear difference of mould apperance manufacturing process respectively, the distribution of particles ratio of foam particle has very big difference in the reality.How according to the actual distribution of particles situation of A-108, A-106, find out proper proportion, obtaining maximum density as much as possible will be the following key that will solve.
Method: the distribution situation of the main plastic pellet gained particle of two kinds of different models of actual measurement; On maximum density grading curve coordinate diagram, draw two particle distribution curve A, B; Relation between the particle curve has three kinds of situation, can confirm its optimal proportion according to the relation between each particle.
A. two grain diameter curves join
As the ratio of surveying is curve plotting:
Table 3:A-106, A-108 actual measurement particle percent of pass, and calculate the accumulative total percent of pass
| A-106 | Each particle percent of pass | The accumulative total percent of pass | A-108 | Each particle percent of pass | The accumulative total percent of pass |
| 1.4? mm | a 1=0% | β 1=a 1=0% | 0.6? mm | a 1=0% | β 1=a 1=0% |
| 1.8? mm | a 2=20% | β 2=a 1+a 2=20% | 0.8? mm | a 2=20% | β 2=a 1+a 2=20% |
| 2.2? mm | a 3=50% | β 3=a 1+a 2+a 3=70% | 1.0? mm | a 3=30% | β 3=a 1+a 2+a 3=50% |
| 2.6? mm | a 4=20% | β 4=a 1+a 2+a 3+a 4=90% | 1.2? mm | a 4=30% | β 4=a 1+a 2+a 3+a 4=80% |
| 3.0? mm | a 5=10% | β 5=a 1+...+a 5=100% | 1.4? mm | a 5=20% | β 5=a 1+...+a 5=100% |
Fig. 7 is that A-106, A-108 accumulative total are through percentage curves (two particle curves join).Show as A particle grain size distribution curve end and B particle grain size distribution curve head end just in time on vertical line.Need A curve end is directly linked with B curve head end for this situation, get vertical line.Meet at a M with diagonal, mistake M makes a horizontal line and ordinate meets at the P point, even the P point is cut apart the cut-point of two kinds of foam particle volume ratios.Measure two segment length A particle consumption=42.26%; B particle consumption=57.74% (as shown in Figure 7).
Table 4:A-106, A-108 two particle calculate ratio after mixing separately
B. two grain diameter curves overlapped
As based on actual measurement foam beads scale curve, get: (the actual measurement percent of pass slightly).Fig. 8 is that A-106, A-108 accumulative total are through percentage curves (two particle curves overlapped).
Curve plotting shows as the bottom and the B particle curve top overlap joint of A particle curve.At this moment, between two curves, draw a vertical line, make it to equate, i.e. a=a ' with the curve intercept of A particle and B particle.Vertical line and diagonal meet at a M, make a horizontal line and ordinate meets at the P point through M, even the P point is cut apart the cut-point of two kinds of foam particle volume ratios.Measure two segment length A particle consumption=46.13%; B particle consumption=53.87%.
Later step and two grain diameter curves join identical (summary).
C. two grain diameter curves leave mutually
As based on actual measurement foam beads scale curve, must pass through percentage curves (two particle curves leave mutually) like Fig. 9: A-106, A-108 accumulative total.
Show as A particle curve terminal with a B particle curve head end segment distance away from each other in the horizontal direction.At this moment, make a vertical line and divide the distance of leaving mutually equally, make a=a '.Vertical line and diagonal meet at a M, make a horizontal line and ordinate meets at the P point through M, even the P point is cut apart the cut-point of two kinds of foam particle volume ratios.Measure two segment length A particle consumption=39.65%; B particle consumption=60.35%.
Later step and two grain diameter curves join identical (summary).
(5) draw out the grading curve that proportions, whether detect qualified (defective can the adjustment) the bead foaming process.Fig. 9 is that grain diameter accumulative total was passed through percentage curves after A-106, A-108 mixed in proportion.
The particle grating distributes and drops on basically in the good interval, and grating is qualified.As defective, then a kind of foam process of particle is wherein adjusted, obtain the percent of pass of different-grain diameter ratio, row configuration again.
(6) confirm various granular mass ratios according to volume ratio;
According to the particle volume ratio of gained, concrete formula is: by known A:B=a%:b% of second step; By A, B actual density intermediate value ρ
A, ρ
B, like A-106=20 ~ 24 kg/m
3, ρ
A=22 kg/m
3Draw: M
A: M
B=ρ
AA%: ρ
BThe density intermediate value A-106 that b% gets the two is 22 kg/m
3, A-108 is 30 kg/m
3Being converted into mass ratio is: M
A: M
B=ρ
AA%: ρ
BB%.Draw: A-106 particle volume ratio is 42.26%, and A-108 particle volume ratio is 57.74%.Estimate that mixed foaming apperance density is p=42.26% * 22+57.74% * 30=26.62 kg/m
3M
A: M
B=ρ
AA%: ρ
BB%=22 * 42.26%:30 * 57.74%=1:1.86, promptly the granular mass of A-106, A-108 is than being 1:1.86.
(7) according to two kinds of plastic pellets of mass ratio weighing, prefoam, slaking.Together put into special-purpose mixing drum (like Figure 11) and mix, the mixing drum bottom feeds compressed air, and pre-expanded beads is mixed, and prevents segregation, at last compound is injected disappearance mould mould second time of foaming, makes the foam particle apperance that meets grating.
Claims (4)
1. preparing process that is used for the plastic pellet apperance of lost foam casting comprises following processing step:
1) selects the smallest particles model in the plastic pellet model according to the requirement of surface roughness Ra, dimensional accuracy CT, select the largest particles model according to the minimum wall thickness (MINI W.) that can make Foam Pattern;
2) according to the particle diameter that reaches behind the second time of foaming, the empirical parameter n after pushing mutually when multiply by grain forming, n gets 0.75 ~ 0.90, draws the actual main particle diameter diameter of particle; Find out the wherein main particle more than four kinds in proportion;
3) require to draw the grading curve coordinate diagram according to maximum density, confirm qualified index;
4) draw two curves based on the distribution of main plastic pellet gained particle of two kinds of different models of actual measurement, by two adjacent curves be overlapping, join, mutually from confirming two kinds of only volume ratios of particle;
5) draw out the grading curve that proportions, whether detect qualified defective can the adjustment the bead foaming process;
6) qualified back confirms that according to volume ratio various granular mass ratio mass ratioes are easy to weighing;
7) according to two kinds of plastic pellets of mass ratio weighing, prefoam, slaking mixes in the mixing drum of special use, at last compound is injected disappearance mould mould second time of foaming, makes the grating Foam Pattern.
2. a kind of preparing process that is used for the plastic pellet apperance of lost foam casting according to claim 1; It is characterized in that step 2) in according to the maximal density curve; The relation curve that passes through percentage and particle diameter that gathers materials is more near parabola; This packing of gathering materials is big more, and the space is more little, and this result can be expressed as:
P
2=kd ……………………………………………………（1）
P---the particle that the middle screen size of gathering materials is d is through percentage (%)
D---the screen size of certain kind particle in gathering materials;
K---statistical parameter
The percentage that passes through of maximum particle diameter is 100 in gathering materials; Promptly when screen size d equals D; The percentage P that passes through of this particle is 100; This is concerned substitution formula (1):
the k value again behind the substitution formula 1, can be calculated the percentage that passes through of the main particle diameter d of any one-level particle according to formula (2):
Maximum particle diameter during certain of D in the formula---desire calculating gathers materials
D, P---the same formula of meaning (1)
Confirm the formate gradation composition of multiple particle; Reference axis is set, desired grating intermediate value is depicted as straight line, ordinate and abscissa are represented respectively through percentage and particle size, and when ordinate still is the arithmetic coordinate time, the position of abscissa will be confirmed by design grating intermediate value.
3. a kind of preparing process that is used for the plastic pellet apperance of lost foam casting according to claim 1 is characterized in that in specification, painting a rectangle picture frame by certain size in the step 3), connects diagonal; On ordinate, mark accumulative total through the percentage position by the arithmetic coordinatometer; Each particle diameter that design grating intermediate value is required is marked on the ordinate, and from ordinate diversion horizontal line diagonal is intersected through percentage, and it is crossing with abscissa to make vertical line from intersection point again, and its intersection point is the position of each corresponding grain size; This diagonal is for being the maximum closely knit level distribution of design, and each particle diameter approaches this line more in the apperance, explains that grating is good more.
4. a kind of preparing process that is used for the plastic pellet apperance of lost foam casting according to claim 1, it is following to it is characterized in that the particle of using always is combined with: A-108 and A-106; A-107 and A-105; A-108 and A-105.
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| CN106238673A (en) * | 2016-09-20 | 2016-12-21 | 桃江新兴管件有限责任公司 | A kind of forming method of the low-density EPS apperance for lost foam casting |
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| CN102554120B (en) | 2013-12-11 |
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