CN103223463A - Environment-friendly and energy-saving sand mold casting process - Google Patents

Environment-friendly and energy-saving sand mold casting process Download PDF

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CN103223463A
CN103223463A CN2013101366491A CN201310136649A CN103223463A CN 103223463 A CN103223463 A CN 103223463A CN 2013101366491 A CN2013101366491 A CN 2013101366491A CN 201310136649 A CN201310136649 A CN 201310136649A CN 103223463 A CN103223463 A CN 103223463A
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sand
electromagnet
metal
weight portions
mold
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CN103223463B (en
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卜基山
卜诗宇
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Anhui Datian Casting Co., Ltd.
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TIANCHANG TIANZENG MACHINERY FITTINGS FACTORY
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Abstract

The invention relates to an environment-friendly and energy-saving sand mold casting process. The process comprises a first step of mixing metal sand and a binder uniformly to prepare metal molding sand; a second step of assembling a sand box and a mold and filling the metal molding sand until the sand box is full; a third step of firstly starting a vibrator to vibrate the sand box, then closing the vibrator and supplying power to an electromagnet so as to generate an electromagnetic force, wherein the electromagnet and the vibrator are arranged out of the sand box, at the same time hardening the metal molding sand to prepare the sand mold, removing the electromagnet or turning off electricity of the electromagnet when the hardening process is finished, pulling out the sand mold and coating high temperature-resistant coating on the surface of the sand mold to obtain the casting mold; and a fourth step of placing the casting mold between two magnetic poles of the electromagnet, turning on electricity for the electromagnet, pouring a metal liquid in the casting mold, forming a casting member when the metal liquid is cured, and performing sand shakeout and shot blasting treatment on the casting member when the casting mold is cooled down. With the process provided by the invention, pollutions to the production environment can be prevented, consumption of mineral resource is prevented, and at the same time, mechanical performance and size precision of the casting member can be increased significantly.

Description

The environmental protection and energy saving sand casting process
Technical field
The present invention relates to a kind of environmental protection and energy saving sand casting process, belong to the machine casting technical field.
Background technology
In the modern mechanical industry, various fields such as automobile, mine, metallurgy, space flight and aviation, agricultural machinery still are all to be unable to do without casting in the daily life.Wherein, sand casting is to use at present casting technique very widely, has characteristics such as wide adaptability, cost are low, technical maturity.At present, sand casting process can be divided into: clay wet sand casting, the casting of clay dry sand mold, water-glass sand mold casting, self-setting silicate process mold casting, resin bonded sand mould casting etc.
But, mainly there is following problem in sand casting: (1) needs use mineral sand such as a large amount of quartz sand, limestone sand, zircon sand, chromite sand, when obtaining these mineral resources, can damage natural environment inevitably, casting process can produce a large amount of antiquated sands and dust simultaneously, can cause environmental pollution.(2) owing to use a lot of complicated Casting Equipments of Machine, not only consume a large amount of electric energy, also can produce the high-decibel noise, worsen production on-site environment.(3) the sand mold thermal conductivity factor is little, and radiating condition is poor, causes easily that casting crystalline grain is thick, the numerous defectives of tissue looseness, sand hole, pore or the like, makes the mechanical performance of foundry goods lower.In addition, in technical process, be easy to generate mould shift when greensand mold molding, mould assembling, because wet type intensity is lower, molten metal causes the case that rises, scab after entering casting mold easily, makes the casting dimension error bigger, rough surface simultaneously; Dry sand mold casting, water-glass sand mold casting etc. are then because the sand mold retained strength is higher, and labour intensity is big during casting cleaning, and the dust concentration height can the grievous injury health of operators.
In addition, understand according to the applicant, in the evolution of lost foam casting process, a kind of magnetic molding process technology that adopts shot or shot once occurred, yet the very strong electromagnetic field of this arts demand is shot or shot fixedly, can produce bigger electromagnetic pollution undoubtedly; Because magnetic molding process is harsh to the foundry goods shape need, thereby makes the adaptability of this technology be very limited; Simultaneously, this technology only is fit to lost foam casting process, can't directly overlap to be used for other casting technique.In addition, misrun, elephant skin, carburizing, surface carbon hole and the inner stain black line that causes owing to the existence of foam plastics mould, also happen occasionally because of casting flaws such as magnetic field intensity the control improper collapsing that causes, puncture and expansions.Simultaneously, the foam plastics mould of lost foam casting can only use once, and foamed plastics density is little, intensity is low, and apperance is yielding, influences casting dimension accuracy, and the gas that the apperance vaporization produces during casting pollutes the environment.
At present, each producer that grasps lost foam casting process often gets up the key point of lost foam casting process as commercial privacy protection, cooperate less each other.For other producers, it is too high to obtain ripe lost foam casting process cost to existing producer, and independent research and development are consuming time longer, if can make improvement to the sand casting process of using extensively, maturity is high, make it to overcome existing defective, then help promoting the market competitiveness of this producer greatly, booster action is played in producer's development.
Summary of the invention
Main purpose of the present invention is: overcome the problem that prior art exists, a kind of environmental protection and energy saving sand casting process is provided, need not to consume mineral sand, can not produce mineral sand dust in the production process, avoid environment is produced pollution.
Technical conceive of the present invention is as follows: the applicant is through repeatedly practising research, on the basis of existing sand casting, use for reference magnetic molding process technology, develop the sand casting process that adopts the metal molding sand, thereby avoid occurring adopting the problem of next mineral resources consumption in mineral abrasive band and generation harmful dust.
The present invention realizes that the technical scheme of above-mentioned main purpose is as follows:
A kind of environmental protection and energy saving sand casting process is characterized in that, may further comprise the steps:
The first step, metal sand, the 0.26-1.5 parts by weight of adhesive mixing of 100 weight portions made the metal molding sand; Described metal sand is made by the magnetic metal material; Described metal sand sieves before use, and sieve number is the 20-140 order;
Second step, elder generation install sandbox and model group, charge into the metal molding sand again to trunkful; Described sandbox, model are made by nonmagnetic substance respectively;
The 3rd step, described sandbox outside are provided with electromagnet and vibrator, and sandbox is between two magnetic poles of electromagnet; Vibrator vibration sandbox was opened at least 5 seconds by elder generation, closed vibrator then and produced electromagnetic force to the electromagnet energising, and while metal molding sand carries out cure process and makes sand mold; Treat to remove electromagnet after sclerosis finishes or make the electromagnet outage; Trip out sand mold, and, promptly make casting mold at sand mold surface-coated high-temperature resistant coating;
The 4th goes on foot, casting mold is placed between electromagnet two magnetic poles, after the electromagnet energising, injects molten metal in casting mold, treats to remove electromagnet or make the electromagnet outage after molten metal solidifies the formation foundry goods; Treat that foundry goods cools off after 15 minutes at least, carries out knockout and Shot Blasting to foundry goods.
This process using metal molding sand need not mineral sand, thereby avoids consuming excessively mineral resources; Metal molding sand mechanical strength height is difficult for fragmentation, can not produce mineral sand dust in the production process, avoids production environment is polluted; In addition, because the metal sand in the metal molding sand is from great, profile rounding, need not big external force during moulding and can form steady and audible die cavity, therefore only need simple device can organize line production, thereby save a large amount of electric power, and reduce moulding, the noise when cleaning equipment turns round, improve the production scene working environment; Simultaneously, utilize electromagnetic force to strengthen casting mold, both can reduce the binding agent consumption, be convenient to foundry goods is carried out knockout and Shot Blasting, improved mold stiffness and hardness again, casting dimension accuracy is improved.
What need stress is, the applicant is after adopting this technology, the mechanical performance of finding foundry goods unexpectedly has conspicuousness to improve, and has improved 1-2 rank as ironcasting or steel-casting mechanical performance, and the aluminum casting mechanical performance can make product with permanent mold casting and compare favourably; Simultaneously, casting dimension accuracy also has remarkable lifting, has improved 1-2 grade.The applicant thinks after after further study, may be because the metal molding sand of this process using has the thermal conductivity higher than mineral sand on the one hand, can effectively improve the thermodynamic condition in the foundry goods crystallization process, may be because the electromagnetic force of this process using is not only strengthened casting mold on the other hand, also the foundry goods crystallization process has been produced favourable influence, significantly improved the inherent quality and the dimensional accuracy of foundry goods aspect two under the combined influence at this.
The further perfect technical scheme of the present invention is as follows:
Preferably, in the first step, described binding agent is sodium silicate binder, phosphate binders, cold setresin binding agent.
Preferably, in the first step, described metal sand is the ferromagnetic metal ball.More preferably, described metal sand is ZG1Cr13 ball, cast steel ball or rich chromium cast iron ball.
Preferably, in the 3rd step, the magnetic induction intensity that described electromagnet energising back produces electromagnetic force is 200-400 Gauss; In the 4th step, the magnetic induction intensity that described electromagnet energising back produces electromagnetic force is 160-250 Gauss.
Preferably, in the first step, the detailed process of mixing is as follows: earlier metal sand is put into wing mixer or rotator type mixer, put into binding agent behind the startup mixer, stir after at least 1.5 minutes, mixture is emitted promptly get described metal molding sand.
More preferably, in the mixing detailed process of the first step, mixing time is 1.5-5 minute; In the 3rd step, the vibration sandbox time is 5-10 second; In the 4th step, foundry goods cool time is 15-30 minute.
Preferably, in the 3rd step, described high-temperature resistant coating is made of following component:
270 order silica flours, 100 weight portions, activated bentonite 3 weight portions, syrup 5 weight portions, CMC4 weight portion, and water an amount of;
Perhaps, graphite powder 100 weight portions, sodium bentonite 6.5 weight portions, polyvinyl acetate emulsion 35 weight portions, water are an amount of;
Perhaps, bauxite powder 60 weight portions, waterglass 28 weight portions, glyceryl triacetate 1.6 weight portions, water are an amount of;
Perhaps, 270 order electric smelting haydite powder, 100 weight portions, waterglass 95 weight portions, activator 0.03 weight portion, defoamer 0.006 weight portion, water are an amount of;
Perhaps, 180 order electric smelting haydites, 100 weight portions, phenolic resins 2 weight portions, calcium stearate 0.12 weight portion, methenamine 0.1 weight portion, water are an amount of.
Preferably, also comprise: the 5th step, the 4th step knockout handled the old sand obtain and rolls, sieves, cools off after, be directly used in the Shot Blasting in the 4th step, the binding agent on old sand surface is ground off, obtain to be reused for the metal sand of the first step.
More preferably, in the 5th step, the order number that sieves used screen cloth is the 20-140 order.
After adopting technology of the present invention, can avoid production environment is polluted, and avoid consumption mineral resources, reduce and use plant equipment, simplify the production operation flow process, save electric power, reduce the production scene noise, can significantly improve foundry goods mechanical performance and dimensional accuracy simultaneously; Compare with traditional sand casting, production cost reduces 5-20%.
The specific embodiment
Below in conjunction with embodiment the present invention is described in further detail.But the invention is not restricted to given example.
Embodiment 1 adopts cast foundry goods of the present invention
The environmental protection and energy saving sand casting process of present embodiment may further comprise the steps:
The first step, metal sand, the 0.26-1.5 parts by weight of adhesive mixing of 100 weight portions made the metal molding sand; Metal sand is made by the magnetic metal material; Metal sand sieves before use, and sieve number is the 20-140 order.
Wherein, binding agent is sodium silicate binder, phosphate binders, cold setresin binding agent.Metal sand is ferromagnetic metal ball (preferred ZG1Cr13 ball, cast steel ball or rich chromium cast iron ball).The detailed process of mixing is as follows: earlier metal sand is put into wing mixer or rotator type mixer, puts into binding agent after starting mixer, stirs at least 1.5 minutes (preferably 1.5-5 minute) after, mixture emitted promptly gets described metal molding sand.
Second step, elder generation install sandbox and model group, charge into the metal molding sand again to trunkful; Sandbox, model are made by nonmagnetic substance respectively.
The 3rd step, sandbox outside are provided with electromagnet and vibrator, and sandbox is between two magnetic poles of electromagnet; Opened earlier vibrator vibration sandbox at least 5 seconds (preferred 5-10 second), close vibrator then and produce electromagnetic force to the electromagnet energising, the metal molding sand carries out cure process and makes sand mold simultaneously; Treat to remove electromagnet after sclerosis finishes or make the electromagnet outage; Trip out sand mold, and, promptly make casting mold at sand mold surface-coated high-temperature resistant coating.
Wherein, the magnetic induction intensity of electromagnet energising back generation electromagnetic force is 200-400 Gauss.
High-temperature resistant coating is made of following component:
270 order silica flours, 100 weight portions, activated bentonite 3 weight portions, syrup 5 weight portions, CMC4 weight portion, and water an amount of;
Perhaps, graphite powder 100 weight portions, sodium bentonite 6.5 weight portions, polyvinyl acetate emulsion 35 weight portions, water are an amount of;
Perhaps, bauxite powder 60 weight portions, waterglass 28 weight portions, glyceryl triacetate 1.6 weight portions, water are an amount of;
Perhaps, 270 order electric smelting haydite powder, 100 weight portions, waterglass 95 weight portions, activator 0.03 weight portion, defoamer 0.006 weight portion, water are an amount of;
Perhaps, 180 order electric smelting haydites, 100 weight portions, phenolic resins 2 weight portions, calcium stearate 0.12 weight portion, methenamine 0.1 weight portion, water are an amount of.
The 4th goes on foot, casting mold is placed between electromagnet two magnetic poles, after the electromagnet energising, injects molten metal in casting mold, treats to remove electromagnet or make the electromagnet outage after molten metal solidifies the formation foundry goods; After treating foundry goods cooling at least 15 minutes (preferred 15-30 minute), foundry goods is carried out knockout and Shot Blasting.
Wherein, the magnetic induction intensity of electromagnet energising back generation electromagnetic force is 160-250 Gauss.
The 5th step, the 4th step knockout handled the old sand obtain and rolls, sieves, cools off after, be directly used in the Shot Blasting in the 4th step, the binding agent on old sand surface is ground off, obtain to be reused for the metal sand of the first step.
Wherein, the order number that sieves used screen cloth is the 20-140 order.
The parameter of concrete application case is as shown in the table:
Table 1 application case parameter
Figure BDA00003071163000061
Embodiment 2 foundry goods mechanical performances and dimensional accuracy detect
Contrast case: adopt traditional sand casting process, utilize sandbox and the modelling casting mold identical, water respectively then and cast out material and identical ironcasting, steel-casting, the aluminum casting of embodiment 1 corresponding case with embodiment 1.
Measure embodiment 1 each case and contrast mechanical performance and the dimensional accuracy that case makes foundry goods by existing detection method, the result is as shown in the table.
Table 2 mechanical performance, dimensional accuracy testing result
Figure BDA00003071163000071
* the Brinell hardness of high manganese steel casting is good with the junior.
By table 2 result as can be known, compare with corresponding contrast case, ironcasting that embodiment 1 makes or steel-casting mechanical performance have improved 1-2 rank, and the aluminum casting mechanical performance also has conspicuousness to promote, can make product with permanent mold casting compares favourably; Simultaneously, casting dimension accuracy has also improved 1-2 grade.The foundry goods that this explanation adopts technology of the present invention to make all has conspicuousness to promote on mechanical performance and dimensional accuracy.
In addition to the implementation, the present invention can also have other embodiments.All employings are equal to the technical scheme of replacement or equivalent transformation formation, all drop on the protection domain of requirement of the present invention.

Claims (10)

1. an environmental protection and energy saving sand casting process is characterized in that, may further comprise the steps:
The first step, metal sand, the 0.26-1.5 parts by weight of adhesive mixing of 100 weight portions made the metal molding sand; Described metal sand is made by the magnetic metal material; Described metal sand sieves before use, and sieve number is the 20-140 order;
Second step, elder generation install sandbox and model group, charge into the metal molding sand again to trunkful; Described sandbox, model are made by nonmagnetic substance respectively;
The 3rd step, described sandbox outside are provided with electromagnet and vibrator, and sandbox is between two magnetic poles of electromagnet; Vibrator vibration sandbox was opened at least 5 seconds by elder generation, closed vibrator then and produced electromagnetic force to the electromagnet energising, and while metal molding sand carries out cure process and makes sand mold; Treat to remove electromagnet after sclerosis finishes or make the electromagnet outage; Trip out sand mold, and, promptly make casting mold at sand mold surface-coated high-temperature resistant coating;
The 4th goes on foot, casting mold is placed between electromagnet two magnetic poles, after the electromagnet energising, injects molten metal in casting mold, treats to remove electromagnet or make the electromagnet outage after molten metal solidifies the formation foundry goods; Treat that foundry goods cools off after 15 minutes at least, carries out knockout and Shot Blasting to foundry goods.
2. environmental protection and energy saving sand casting process according to claim 1 is characterized in that, in the first step, described binding agent is sodium silicate binder, phosphate binders, cold setresin binding agent.
3. environmental protection and energy saving sand casting process according to claim 2 is characterized in that, in the first step, described metal sand is the ferromagnetic metal ball.
4. environmental protection and energy saving sand casting process according to claim 3 is characterized in that, in the first step, described metal sand is ZG1Cr13 ball, cast steel ball or rich chromium cast iron ball.
5. environmental protection and energy saving sand casting process according to claim 3 is characterized in that, in the 3rd step, the magnetic induction intensity that described electromagnet energising back produces electromagnetic force is 200-400 Gauss; In the 4th step, the magnetic induction intensity that described electromagnet energising back produces electromagnetic force is 160-250 Gauss.
6. according to each described environmental protection and energy saving sand casting process of claim 1 to 5, it is characterized in that, in the first step, the detailed process of mixing is as follows: earlier metal sand is put into wing mixer or rotator type mixer, put into binding agent after starting mixer, stir after at least 1.5 minutes, mixture is emitted promptly get described metal molding sand.
7. environmental protection and energy saving sand casting process according to claim 6 is characterized in that, in the mixing detailed process of the first step, mixing time is 1.5-5 minute; In the 3rd step, the vibration sandbox time is 5-10 second; In the 4th step, foundry goods cool time is 15-30 minute.
8. according to each described environmental protection and energy saving sand casting process of claim 1 to 5, it is characterized in that in the 3rd step, described high-temperature resistant coating is made of following component:
270 order silica flours, 100 weight portions, activated bentonite 3 weight portions, syrup 5 weight portions, CMC4 weight portion, and water an amount of;
Perhaps, graphite powder 100 weight portions, sodium bentonite 6.5 weight portions, polyvinyl acetate emulsion 35 weight portions, water are an amount of;
Perhaps, bauxite powder 60 weight portions, waterglass 28 weight portions, glyceryl triacetate 1.6 weight portions, water are an amount of;
Perhaps, 270 order electric smelting haydite powder, 100 weight portions, waterglass 95 weight portions, activator 0.03 weight portion, defoamer 0.006 weight portion, water are an amount of;
Perhaps, 180 order electric smelting haydites, 100 weight portions, phenolic resins 2 weight portions, calcium stearate 0.12 weight portion, methenamine 0.1 weight portion, water are an amount of.
9. according to each described environmental protection and energy saving sand casting process of claim 1 to 5, it is characterized in that, also comprise: the 5th step, the 4th step knockout handled the old sand obtain and rolls, sieves, cools off after, be directly used in the Shot Blasting in the 4th step, the binding agent on old sand surface is ground off, obtain to be reused for the metal sand of the first step.
10. environmental protection and energy saving sand casting process according to claim 9 is characterized in that, in the 5th step, the order number that sieves used screen cloth is the 20-140 order.
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CN103447454A (en) * 2013-08-26 2013-12-18 宁夏共享集团有限责任公司 Water-based paint of lost foam for iron casting, and production method of water-based paint
CN103480794A (en) * 2013-09-13 2014-01-01 国营第六一六厂 Composite material used for casting aluminum alloy box body oil duct and method thereof
CN103909223A (en) * 2014-04-10 2014-07-09 国营第六一六厂 Collapsible cold iron composite material and application method thereof
CN104107880A (en) * 2014-04-13 2014-10-22 天长市铸缘铸造机械科技有限公司 Aluminum alloy electromagnetic metal shell mold casting process
CN106001416A (en) * 2016-07-14 2016-10-12 辽宁森远增材制造科技有限公司 Laser 3D printer capable of finishing high-precision sand mold manufacture at one step
CN107790639A (en) * 2017-09-29 2018-03-13 吴江市液铸液压件铸造有限公司 A kind of processing technology of spherical end cover casting
CN108273964A (en) * 2016-03-14 2018-07-13 扬州华铁铁路配件有限公司 A kind of production method for the cylinder jacket improving surface quality
CN108746488A (en) * 2018-06-14 2018-11-06 北京交通大学 The flexible metal mold casting device and method of the wear-resistant casting of plate class
CN109865797A (en) * 2019-03-14 2019-06-11 刘云峰 A kind of magnetic molding process machine
CN113695513A (en) * 2021-09-03 2021-11-26 王绍勤 Water glass steel sand casting mould and preparation method thereof
CN115069968A (en) * 2021-03-10 2022-09-20 西南科技大学 Casting green sand, environment-friendly carbonaceous additive and preparation process thereof

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CN103447454A (en) * 2013-08-26 2013-12-18 宁夏共享集团有限责任公司 Water-based paint of lost foam for iron casting, and production method of water-based paint
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CN108273964A (en) * 2016-03-14 2018-07-13 扬州华铁铁路配件有限公司 A kind of production method for the cylinder jacket improving surface quality
CN108273964B (en) * 2016-03-14 2019-07-26 扬州华铁铁路配件有限公司 A kind of production method for the cylinder jacket improving surface quality
CN106001416A (en) * 2016-07-14 2016-10-12 辽宁森远增材制造科技有限公司 Laser 3D printer capable of finishing high-precision sand mold manufacture at one step
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CN107790639A (en) * 2017-09-29 2018-03-13 吴江市液铸液压件铸造有限公司 A kind of processing technology of spherical end cover casting
CN108746488A (en) * 2018-06-14 2018-11-06 北京交通大学 The flexible metal mold casting device and method of the wear-resistant casting of plate class
CN108746488B (en) * 2018-06-14 2020-03-24 北京交通大学 Flexible metal mold casting device and method for plate wear-resistant castings
CN109865797A (en) * 2019-03-14 2019-06-11 刘云峰 A kind of magnetic molding process machine
CN115069968A (en) * 2021-03-10 2022-09-20 西南科技大学 Casting green sand, environment-friendly carbonaceous additive and preparation process thereof
CN115069968B (en) * 2021-03-10 2023-05-23 西南科技大学 Green casting sand, environment-friendly carbonaceous additive and preparation process thereof
CN113695513A (en) * 2021-09-03 2021-11-26 王绍勤 Water glass steel sand casting mould and preparation method thereof

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