CN103286262A - Environmentally-friendly lost-foam casting process - Google Patents
Environmentally-friendly lost-foam casting process Download PDFInfo
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- CN103286262A CN103286262A CN 201310184202 CN201310184202A CN103286262A CN 103286262 A CN103286262 A CN 103286262A CN 201310184202 CN201310184202 CN 201310184202 CN 201310184202 A CN201310184202 A CN 201310184202A CN 103286262 A CN103286262 A CN 103286262A
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Abstract
The invention relates to an environmentally-friendly lost-foam casting process. The environmentally-friendly lost-foam casting process comprises the following steps of: manufacturing a model cluster, coating the model, defoaming, shrinking, vibratory modeling, casting, cooling and cleaning. The step of manufacturing the model is as follows: designing and manufacturing a residue riser model, combining and bonding a foaming mold, a casting gate model and the residue riser model together to form a model cluster; the step of coating the model is as follows: coating a refractory paint on the surface of the model cluster by using a method of soaking, brushing, showering and spraying, and drying the coating into a shell; the step of defoaming and shrinking is as follows: adding the model cluster with the shell into a heating furnace, heating to enable the model to be defoamed and shrunk, and then taking out a defoamed and shrunk residual mold by adopting a traction or force-suctioning method. The environmentally-friendly lost-foam casting process has the advantages that the operation is simple, the quality of a casting piece is good and the environment is not polluted and the like.
Description
Technical field
The present invention relates to a kind of casting technique, relate in particular to a kind of environment-friendly type lost foam casting process.
Background technology
Lost foam casting, claim cavityless casting again, normally using foamed plastics (EPs, STMMA or EPMMA) macromolecular material to make becomes and the duplicate full mold mould of design of part, size of producing casting, after dip-coating fireproof coating and oven dry, be embedded in the dried quartz sand through the three-dimensional vibrating moulding, the casting molding flask pours into molten metal liquid under negative pressure state, the gasification of being heated of macromolecular material model is extracted out, and then replaced the novel casting method that the disposal molding New Casting Technique that formed after the cooled and solidified is produced foundry goods by liquid metals.
Compare with the conventional cast technology, the lost foam casting technology has following advantage: 1, casting quality is good, and cost is low; 2, precision height, any surface finish, saving machine add; 3, internal flaw significantly reduces, foundry goods dense structure; 4, can realize extensive, production in enormous quantities; 5, be applicable to manually-operated and automatic assembly line production run control; 6, can improve working condition, reduction labour intensity, the minimizing energy resource consumption of foundry production line greatly.
But also there is following shortcoming in existing this advanced person's lost foam casting process: 1, casting method with the vanishing pattern, be also referred to as full mold process, and it is to be embedded in the molding sand by the model that the synthetic resin foaming body is made, and directly is used as the technology of sand mold.This technology is come thermal decomposition synthetic resin foaming body by the liquation that injects, but produces a large amount of thermal decomposition gas that contains carbon black (coal smoke), produces foreign odor etc., contaminated environment; 2, because a large amount of gas exists, easily produce casting flaw, as pore; 3, foundry goods contains foam residues, reduces casting quality.
Summary of the invention
Advantages such as the present invention proposes a kind of environment-friendly type lost foam casting process in order to solve the deficiency that present technology exists, and that this new technology has is simple to operate, casting quality good, free from environmental pollution.
The present invention is achieved by following scheme: a kind of environment-friendly type lost foam casting process, comprise steps such as analogue formation, model coating, froth breaking capacity reducing, vibration molding, casting, cooling cleaning, and it is characterized in that:
Described analogue formation step is: design and produce a residue rising head model, and the mould that will foam, casting gate model and the combination of residue rising head model are bonded together the formation model cluster.
Described model coating step is: with the method for soaking, brush, drenching and spraying fireproof coating is coated in the surface of model cluster, coating layer thickness is 1～2mm, 40～50 ℃ times oven dry, makes coating be dried to shell.
Described froth breaking capacity reducing step is: the model cluster that has shell is put into heating furnace, be heated to 300～310 ℃, insulation is adopted the method for traction or suction again so that model cluster froth breaking capacity reducing, and the residual mould of froth breaking capacity reducing is taken out from the residue rising head.
Compare with existing lost foam casting process, the present invention has following distinguishing feature: the present invention has broken the technical process that the foaming mould gasifies and disappears in the lost foam casting traditional handicraft in casting process, allow foaming mould froth breaking capacity reducing, to reach the not purpose of exhaust emission gas, and recyclable or recycle, have the distinguishing feature of energy-saving and environment friendly; Simultaneously, the technical process of froth breaking capacity reducing does not have or has only very a spot of gas to exist, and has significantly reduced such as casting flaws such as pores; And, foaming mould froth breaking capacity reducing has also reduced the carbon content of cast(ing) surface, avoids the technology barrier of carburetting in the casting process, has broken the restriction that traditional lost foam casting only is used for cast iron, aluminium alloy casting production, enlarged the scope of lost foam casting application alloy, for example the steel alloy casting field; To sum up, the present invention makes disappearance mould technology be more widely used in China, has expanded its huge market prospects.
The specific embodiment
Below the present invention is described in further detail.
A kind of environment-friendly type lost foam casting process comprises the steps:
(1) modelling: two kinds of situations are arranged usually: first kind, adopt bubble to mould bead and make, through prefoam one slaking one foaming one cooling and mould unloading; Wherein, the bubble of lost foam casting special use is moulded bead three kinds: a. expandable polystyrene resin bead (being called for short EPS); B. expandability methymethacrylate and styrene copolymerized resin bead (be called for short STMMA); C. expandability polymethyl methacrylate resin beads (be called for short EPMMA).Expandable polystyrene resin bead (EPS) commonly used is used for casting nonferrous metal, gray iron and general cast steel.The bead characteristics: translucent bead, prefoam multiple 40～60, particle diameter are 0.18～0.80 millimeter (6 kinds of sizes), and the particle diameter of the original bead that one is selected for use is less than or equal to the l/9～l/10 of foundry goods minimum wall thickness (MINI W.).
Be example with EPS, specifically describe as follows to modelling technology: 1. prefoam: the EPS bead will carry out prefoam earlier, so that bead expand into certain size before adding mould.The prefoam process has determined density, dimensional stability and the precision of model, is one of key link.The method that is applicable to the prefoam of EPS bead has three kinds: hot water prefoam, steam prefoam and vacuum pre expansion.The bead frothing percentage height of vacuum pre expansion, the bead drying is used more.2. slaking: be placed on certain hour in the feed bin of drying, ventilation through the EPS of prefoam bead.In order to make extraneous pressure balance in the bead abscess, make bead have elasticity and swelliong power again, remove the moisture of surface of beads.Curing time was at 8～48 hours.3. foaming: the EPS bead of prefoam and slaking is filled in the die cavity of metal die, and heating reexpands bead, fills up the space that bead is asked, and makes between bead and merge mutually, forms smooth surface, i.e. model.Must cool off before the depanning, model is cooled to below the softening temperature, after the model sclerosis setting, could depanning.The time that model drying and dimensionally stable also should be arranged after the depanning.Equipment has two kinds of the make-up machines of digester (-tor) and automatic forming.
Second kind of situation, adopt bubble to mould board making: bubble is moulded sheet material one resistance wire cutting one bonding one model.For naive model, can utilize the resistance wire cutter sweep, bubble is moulded sheet material cut into required model.For complex model, at first use the resistance wire cutting device, model is divided into several sections, glue then, make it to become block mold.
Design and produce a residue rising head model, and the mould that will foam, casting gate model and the combination of residue rising head model are bonded together the formation model cluster.The present binding material that uses: rubber latex, resin solvent and PUR and adhesive tape.
(2) model applies: cavityless casting bubble moulding model surface must be coated with the certain thickness fireproof coating of one deck, forms the casting mold inner casing.The effect of its coating is in order to improve the strength and stiffness of EPS model, improves the anti-molding sand scouring capability of model surface, and the dimensional accuracy of foundry goods is guaranteed in the distortion of model when preventing from adding model surface breakage and vibration molding and negative pressure shaping in the sand process.The lost foam casting special-purpose fire-resistant coating of outsourcing adds water and stirs in mould wash mixer, make it obtain suitable viscosity.Fireproof coating after the stirring is put into container, with the method for soaking, brush, drenching and spraying model group is applied.One is coated with twice, and making coating layer thickness is 1～2mm.Different selected according to foundry goods alloy species, planform and size.Coating is dried into shell under 40～50 ℃.
(3) froth breaking capacity reducing: when 1. producing the simple shape foundry goods, the foaming mould that has shell is put into heating furnace, be heated to certain temperature range (froth breaking initial temperature to foaming mould heat decomposition temperature), insulation is so that foaming mould froth breaking capacity reducing, and makes the mould of froth breaking capacity reducing flow out housing automatically.When 2. producing medium intricate casting, the foaming mould that has shell is put into heating furnace, be heated to certain temperature range (the froth breaking initial temperature is to foaming mould heat decomposition temperature), insulation is so that foaming mould froth breaking capacity reducing adopts external force sucking-off froth breaking contracting
The residual mould that holds.When 3. producing intricate casting, the model cluster that has shell is put into heating furnace, be heated to 300～310 ℃, insulation is adopted the method for traction or suction again so that model cluster froth breaking capacity reducing, and the residual mould of froth breaking capacity reducing is taken out from the residue rising head.
(4) vibration molding: 1. casting bed preparation: the sandbox that will have aspirating chamber is placed on the shake table, and chucking.Certain thickness bed load is put in the bottom, and (one sand mold sand is binder free, does not have and dose thing, water-free dried quartz sand.Ferrous metal temperature height can be selected thicker sand for use, and aluminium alloy adopts than fine sand.Molding sand will use after treatment repeatedly.Sandbox is the single face opening, be provided with the sandbox of aspirating chamber or exhaust tube, lifting or walking mechanism.2. place the formwork of froth breaking capacity reducing, after the jolt ramming, place the formwork group of froth breaking capacity reducing according to technological requirement at casting bed, and training sand is fixed.3. back-up sand: add dry sand, impose vibration (X, Y, three directions of Z) simultaneously, the time was generally 30～60 seconds, made molding sand be full of each position of model, and the bulk density of molding sand is increased.4. sealing typing: the sandbox surface seals with plastic sheeting, will be pumped into certain vacuum in the sandbox with vavuum pump, by the difference of atmospheric pressure and casting mold internal pressure with sand grains " bonding " together, keeps the casting-up process and does not collapse diffusingly, is referred to as " negative pressure shaping ".
(5) cast: the pouring operation process adopts a slow Shan one slow.And the maintenance continuous pouring, prevent the casting process cutout.Water back casting mold vacuum and keep termination of pumping after 3～5 minutes.Pouring temperature is than high 30～50 ~ C of temperature of sand casting.
(6) cooling cleaning: after the cooling, the cavityless casting knockout is the simplest, sandbox is tilted to hang out foundry goods or directly from sandbox, hang out foundry goods all can, foundry goods and dry sand natural separation.Isolated dry sand is handled the back and is reused.
Process using froth breaking capacity reduction method of the present invention does not gasify the foaming mould in casting process, thereby reaches the purpose of green casting.
The above; only be the preferable specific embodiment of the present invention; but protection scope of the present invention is not limited thereto; anyly be familiar with those skilled in the art in the technical scope that the present invention discloses; be equal to replacement or change according to technical scheme of the present invention and inventive concept thereof, all should be encompassed within protection scope of the present invention.
Claims (3)
1. environment-friendly type lost foam casting process, comprise steps such as analogue formation, model coating, froth breaking capacity reducing, vibration molding, casting, cooling cleaning, it is characterized in that: described analogue formation step is: design and produce a residue rising head model, and the mould that will foam, casting gate model and the combination of residue rising head model are bonded together the formation model cluster.
2. a kind of environment-friendly type lost foam casting process according to claim 1, it is characterized in that: described model coating step is: the surface that fireproof coating is coated in model cluster with the method for soaking, brush, drenching and spraying, coating layer thickness is 1～2mm, 40～50 ℃ of oven dry down, makes coating be dried to shell.
3. a kind of environment-friendly type lost foam casting process according to claim 1, it is characterized in that: described froth breaking capacity reducing step is: the model cluster that has shell is put into heating furnace, be heated to 300～310 ℃, insulation is so that model cluster froth breaking capacity reducing, adopt the method for traction or suction again, the residual mould of froth breaking capacity reducing is taken out from the residue rising head.
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104139159A (en) * | 2014-07-25 | 2014-11-12 | 安徽省含山县皖中减速机械有限公司 | Casting process of pin wheel housing of speed reducer |
| CN104493080A (en) * | 2014-11-28 | 2015-04-08 | 柳州市正龙机械制造有限公司 | Technology for preparing model by lost foam casting |
| CN104874733A (en) * | 2015-05-06 | 2015-09-02 | 柳州科尔特锻造机械有限公司 | Lost foam casting process |
| CN104874738A (en) * | 2015-06-18 | 2015-09-02 | 山西威龙铁路机车制动配件制造有限公司 | Guide nut tooth lost foam casting method |
| CN104999035A (en) * | 2015-08-07 | 2015-10-28 | 天津大学 | Environment-friendly lost foam casting method |
| CN106001480A (en) * | 2016-07-30 | 2016-10-12 | 安徽全柴天和机械有限公司 | Evaporative pattern centrifugal casting process |
| CN106238675A (en) * | 2016-07-30 | 2016-12-21 | 安徽全柴天和机械有限公司 | A kind of technique improving yield of lost foam casting of engine cylinder block |
| CN106456294A (en) * | 2014-06-05 | 2017-02-22 | 伊沃克拉尔维瓦登特股份公司 | Dental restoration model |
| CN115945642A (en) * | 2023-01-04 | 2023-04-11 | 淄博水环真空泵厂有限公司 | EPS foaming mold casting process of dry screw vacuum pump rotor |
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2013
- 2013-05-19 CN CN 201310184202 patent/CN103286262A/en active Pending
Cited By (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106456294A (en) * | 2014-06-05 | 2017-02-22 | 伊沃克拉尔维瓦登特股份公司 | Dental restoration model |
| US10058405B2 (en) | 2014-06-05 | 2018-08-28 | Ivoclar Vivadent Ag | Dental restoration model |
| CN106456294B (en) * | 2014-06-05 | 2019-08-06 | 伊沃克拉尔维瓦登特股份公司 | Dental prosthetic model |
| CN104139159A (en) * | 2014-07-25 | 2014-11-12 | 安徽省含山县皖中减速机械有限公司 | Casting process of pin wheel housing of speed reducer |
| CN104493080A (en) * | 2014-11-28 | 2015-04-08 | 柳州市正龙机械制造有限公司 | Technology for preparing model by lost foam casting |
| CN104874733A (en) * | 2015-05-06 | 2015-09-02 | 柳州科尔特锻造机械有限公司 | Lost foam casting process |
| CN104874738A (en) * | 2015-06-18 | 2015-09-02 | 山西威龙铁路机车制动配件制造有限公司 | Guide nut tooth lost foam casting method |
| CN104999035A (en) * | 2015-08-07 | 2015-10-28 | 天津大学 | Environment-friendly lost foam casting method |
| CN106001480A (en) * | 2016-07-30 | 2016-10-12 | 安徽全柴天和机械有限公司 | Evaporative pattern centrifugal casting process |
| CN106238675A (en) * | 2016-07-30 | 2016-12-21 | 安徽全柴天和机械有限公司 | A kind of technique improving yield of lost foam casting of engine cylinder block |
| CN115945642A (en) * | 2023-01-04 | 2023-04-11 | 淄博水环真空泵厂有限公司 | EPS foaming mold casting process of dry screw vacuum pump rotor |
| CN115945642B (en) * | 2023-01-04 | 2024-05-28 | 淄博水环真空泵厂有限公司 | EPS foaming die casting process of dry screw vacuum pump rotor |
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Application publication date: 20130911 |