CN103447462A - Manufacturing process of intermediate casting of diesel engine - Google Patents
Manufacturing process of intermediate casting of diesel engine Download PDFInfo
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- CN103447462A CN103447462A CN2013104136928A CN201310413692A CN103447462A CN 103447462 A CN103447462 A CN 103447462A CN 2013104136928 A CN2013104136928 A CN 2013104136928A CN 201310413692 A CN201310413692 A CN 201310413692A CN 103447462 A CN103447462 A CN 103447462A
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Abstract
The invention discloses a manufacturing process of an intermediate casting of a diesel engine. The manufacturing process is characterized by comprising the following basic steps of: designing the manufacturing process; manufacturing a die; assembling the die; smelting; pouring; opening a box; shaking out; shoveling sand; cutting a feed head; supplementing; coarsely cleaning; spraying; performing shot blasting; performing hogging machining; performing comprehensive MT and UT; remedying defects; thermally processing; spraying; performing shot blasting; roughly machining; inspecting by classification society; and finally inspecting. According to the manufacturing process, PROCAST casting process simulating die software is utilized to perform simulated calculation, the casting process can be optimized based on the simulation result, and thus the inner quality of the casting can meet the technical requirement; and the smelting process, welding process, thermal processing process, formulation of rough processing process, research and development of an inspection route, and other works are accomplished.
Description
Technical field
The present invention relates to casting technology field, is specifically a kind of diesel engine intermediate foundry goods manufacturing process.
Background technology
Cast steel intermediate product of diesel engine is one of critical component of marine low-speed high-power diesel engine.Intermediate through bolt hole belongs to elongated hole, and the elongated hole casting is a difficult problem of Foundry Production always.Existing casting method, its method is to adopt thick-walled seamless steel pipes to make the water-cooled arbor, passes through the water flowing of water-cooled arbor during casting-up or after cast cooling.Weak point is: water resource waste is serious, has increased cost.
The intermediate wall thickness differs larger, foundry goods produces larger shrinkage stress in process of setting, easily produce fire check, particularly at arc transition place, through bolt pipe both sides, be through bolt pipe and welded plate circular arc junction and through bolt pipe and middle pectoral plate circular arc junction, produce more serious fire check.Prior art is to strengthen this place's fillet, controls the pouring molten steel temperature and improve the whole deformability of sand mold to reduce shrinkage stress, reduces the generation of crackle.But because this place is heat energy-saving position, solidify more lately, if can not get the feeding of molten steel, produce shrinkage cavity and porosity in centre, form formation of crack; On the other hand, this place, because stress is concentrated, is easy to produce fire check.Prior art can not be eliminated the crackle at this place fully, after only taking magnetic powder inspection and removing this place's defect, by soldering, eliminates crackle fully.
Part is diesel oil office heavy mail, requires highly, and difficulty is large, and concrete difficult point is as follows:
1) chemical composition controlled range narrow (nonstandard with respect to GB and machinery), the C content scope control is in 0.05%, the si content scope control is 0.10%, be controlled at 0.16% containing the Mn weight range, control to residual elements has exceeded the GB requirement, increase the elements such as Mo, Nb, also will carry out by calculating carbon equivalent the welding performance of evaluating material simultaneously;
2) the cast properties requirement is high, and the material trademark of intermediate is S17F, and its composition is with respect to (GB/T11325-89), and performance requirement reaches ZG230-450, and the chemical composition of 15 steel reaches the performance of 25 steel;
3) non-destructive testing standard is high, and body need to be done magnetic powder inspection and ultrasonic inspection, must meet the different flaw detection class requirement of technological document to different parts;
4) heat treatment difficulty is large, casting section thickness, and as cast condition easily occurs and eliminates difficulty, easily produces coarse grains, the even difficult point of tissue odds, this also can bring certain difficulty for follow-up flaw detection work simultaneously.
Summary of the invention
The object of the invention is to provides a kind of diesel engine intermediate foundry goods manufacturing process at this.The present invention is achieved in that a kind of diesel engine intermediate foundry goods manufacturing process of structure; It is characterized in that: its basic process is as follows:
1) casting Technology Design: by the ProCast of casting technique simulation software, carried out low-speed diesel engine bearing block (intermediate) design of Forming Technology and Optimization Work;
2) Mold Making: press structure and size that foundary methods drawing is made apperance, core box, inspection apperance, core box
Moulding moulding, coremaking are pressed foundary methods drawing and are made sand mold and core;
3) mould assembly: check sand mold core size, check test lug quantity, guarantee that die cavity is clean, the size accuracy;
4) melting: adopt the electric arc furnaces oxidation smelting, with fast thermodetector, measure liquid steel temperature in stove;
5) cast: 1600 ℃～1620 ℃ of tapping temperatures, Argon in bag, 1530 ℃～1560 ℃ of pouring temperatures, argon for protecting pouring; Aim at slowly cast early stage, Quick pouring, slowly pour into a mould Slow cooling in sand mold after upper rising head afterwards;
6) unpack: strictly by operational procedure, unpack, guarantee strand because of the generation of the casting flaws such as the improper crackle caused of temperature control, shrink of unpacking and can not damage the foundry goods body;
7) knockout: be incubated 60 hours, the case temperature that falls is less than 300 ℃, with land surface pyrometer, is confirmed;
8) shovel sand: guarantee surface smoothness, be strictly on guard against shovel trace, shovel wound;
9) cutting rising head, subsidy: adopt the Methods of OFC-A remove feeders, running channel, fash and subsidy, the body sample can partly cut off foundry goods;
10) thick cleaning: remove excess metal and scab;
11) spray, ball blast: guarantee that surface smoothness reaches customer need;
12) waste processing: guarantee that surface smoothness meets the UT+MT examination requirements;
13) comprehensive MT+UT: test, conscientiously carry out the Non-Destructive Testing record;
14) defect mending: repaired, according to the Non-Destructive Testing record, the defect of some permissions is repaired.
15) heat treatment: firing rate :≤80 ℃/h; Insulation: 550～620 ℃; Temperature retention time: at least 6 hours; Cooling velocity: stove is cold≤75 ℃/h; Be down to≤300 ℃ come out of the stove;
16) spray, ball blast: foundry goods is carried out to Shot Blasting, make cast(ing) surface reach Requirements of Nondestructive Testing;
17) roughing: by drawing, carry out roughing;
18) classification society's check: according to the Product Acceptance Review technical protocol, invite relevant classification surveyor to test to product;
19) final inspection: client finally checks and accepts.
For many years, the main dependence on import of China's marine low speed diesel engine bearing block (intermediate), domestic only one or two manufacturer also just only meets self-sufficient substantially, and recent year marine diesel complete machine manufacturer increases severely.Introduced the world-class ProCast of casting technique simulation software, low-speed diesel engine bearing block (intermediate) design of Forming Technology and Optimization Work have been carried out, effectively raise product quality, shortened trial-produce period simultaneously, saved production cost, the production of complicated steel-casting more peculiar to vessel lays the foundation.
The invention has the advantages that: carry out analog computation by PROCAST cast technology analogy mould software, according to analog result, carried out casting process optimization, guarantee that Internal Quality of Cast meets specification requirement; Smelting technology, welding and Technology for Heating Processing have been completed, the R&D work etc. of roughing technics institution and check route, and clear and definite pass key control main points and control measure in each operation.
The specific embodiment
Below the present invention is described in detail, the technical scheme in the embodiment of the present invention is clearly and completely described, obviously, described embodiment is only the present invention's part embodiment, rather than whole embodiment.Embodiment based in the present invention, those of ordinary skills, not making under the creative work prerequisite the every other embodiment obtained, belong to the scope of protection of the invention.
A kind of diesel engine intermediate foundry goods manufacturing process; Its basic process is as follows:
1) casting Technology Design: introduced the world-class ProCast of casting technique simulation software, low-speed diesel engine bearing block (intermediate) design of Forming Technology and Optimization Work have been carried out, effectively raise product quality, shortened trial-produce period simultaneously, saved production cost, the production of complicated steel-casting more peculiar to vessel lays the foundation.
2) Mold Making: press structure and size that foundary methods drawing is made apperance, core box, inspection apperance, core box
Moulding moulding, coremaking are pressed foundary methods drawing and are made sand mold and core.
3) mould assembly: check sand mold core size, check test lug quantity, guarantee that die cavity is clean, the size accuracy.
4) melting: adopt the electric arc furnaces oxidation smelting, with fast thermodetector, measure liquid steel temperature in stove;
5) cast: 1600 ℃～1620 ℃ of tapping temperatures, Argon in bag, 1530 ℃～1560 ℃ of pouring temperatures, argon for protecting pouring; Aim at slowly cast early stage, Quick pouring, slowly pour into a mould Slow cooling in sand mold after upper rising head afterwards;
6) unpack: strictly by operational procedure, unpack, guarantee strand because of the generation of the casting flaws such as the improper crackle caused of temperature control, shrink of unpacking and can not damage the foundry goods body.
7) knockout: be incubated 60 hours (the case temperature that falls is less than 300 ℃, is confirmed with land surface pyrometer)
8) shovel sand: guarantee surface smoothness, be strictly on guard against shovel trace, shovel wound.
9) cutting rising head, subsidy: adopt the Methods of OFC-A remove feeders, running channel, fash and subsidy etc., the body sample can partly cut off foundry goods.
10) thick cleaning: remove excess metal and scab.
11) spray, ball blast: guarantee that surface smoothness reaches customer need.
12) waste processing: guarantee that surface smoothness meets the UT+MT examination requirements.
13) comprehensive MT+UT: test, conscientiously carry out the Non-Destructive Testing record.
14) defect mending: repaired, according to the Non-Destructive Testing record, the defect of some permissions is repaired.
15) heat treatment: firing rate :≤80 ℃/h; Insulation: 550～620 ℃; Temperature retention time: at least 6 hours; Cooling velocity: stove is cold≤75 ℃/h; Be down to≤300 ℃ come out of the stove
16) spray, ball blast: foundry goods is carried out to Shot Blasting, make cast(ing) surface reach Requirements of Nondestructive Testing.
17) roughing: by drawing, carry out roughing.
18) classification society's check: according to the Product Acceptance Review technical protocol, invite relevant classification surveyor to test to product.
19) final inspection: client finally checks and accepts.
To the above-mentioned explanation of the disclosed embodiments, make professional and technical personnel in the field can realize or use the present invention.Multiple modification to these embodiment will be apparent for those skilled in the art, and General Principle as defined herein can be in the situation that do not break away from the spirit or scope of the present invention, realization in other embodiments.Therefore, the present invention will can not be restricted to these embodiment shown in this article, but will meet the widest scope consistent with principle disclosed herein and features of novelty.
Claims (1)
1. a diesel engine intermediate foundry goods manufacturing process; It is characterized in that: its basic process is as follows:
Step 1) casting Technology Design: by the ProCast of casting technique simulation software, carried out low-speed diesel engine bearing block (intermediate) design of Forming Technology and Optimization Work;
Step 2) Mold Making: press that foundary methods drawing is made the structure of apperance, core box, inspection apperance, core box and size moulding, foundary methods drawing making sand mold and core press in coremaking;
Step 3) mould assembly: check sand mold core size, check test lug quantity, guarantee that die cavity is clean, the size accuracy;
Step 4) melting: adopt the electric arc furnaces oxidation smelting, with fast thermodetector, measure liquid steel temperature in stove;
Step 5) cast: 1600 ℃～1620 ℃ of tapping temperatures, Argon in bag, 1530 ℃～1560 ℃ of pouring temperatures, argon for protecting pouring; Aim at slowly cast early stage, Quick pouring, slowly pour into a mould Slow cooling in sand mold after upper rising head afterwards;
Step 6) is unpacked: strictly by operational procedure, unpack, guarantee strand because of the generation of the casting flaws such as the improper crackle caused of temperature control, shrink of unpacking and can not damage the foundry goods body;
The step 7) knockout: be incubated 60 hours, the case temperature that falls is less than 300 ℃, with land surface pyrometer, is confirmed;
Step 8) shovel sand: guarantee surface smoothness, be strictly on guard against shovel trace, shovel wound;
Step 9) cutting rising head, subsidy: adopt the Methods of OFC-A remove feeders, running channel, fash and subsidy, the body sample can partly cut off foundry goods;
Step 10) is slightly cleared up: remove excess metal and scab;
Step 11) spray, ball blast: guarantee that surface smoothness reaches needs;
The waste processing of step 12): guarantee that surface smoothness meets the UT+MT examination requirements;
The comprehensive MT+UT of step 13): test, carry out the Non-Destructive Testing record;
Step 14) defect mending: repaired, according to the Non-Destructive Testing record, the defect of some permissions is repaired;
Step 15) heat treatment: firing rate :≤80 ℃/h; Insulation: 550～620 ℃; Temperature retention time: at least 6 hours; Cooling velocity: stove is cold≤75 ℃/h; Be down to≤300 ℃ come out of the stove;
Step 16) spray, ball blast: foundry goods is carried out to Shot Blasting, make cast(ing) surface reach Requirements of Nondestructive Testing;
Step 17) carry out roughing;
Step 18) test.
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| CN2013104136928A CN103447462A (en) | 2013-09-12 | 2013-09-12 | Manufacturing process of intermediate casting of diesel engine |
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| CN2013104136928A CN103447462A (en) | 2013-09-12 | 2013-09-12 | Manufacturing process of intermediate casting of diesel engine |
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Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104399881A (en) * | 2014-11-21 | 2015-03-11 | 宜昌船舶柴油机有限公司 | Casting method for steel casting of bearing pedestal of low-speed diesel engine for large-cylinder-diameter ship |
| CN104439090A (en) * | 2014-11-26 | 2015-03-25 | 山东省源通机械股份有限公司 | Manufacturing technique of high-strength single-cylinder diesel engine body |
| CN104439147A (en) * | 2014-11-21 | 2015-03-25 | 柳州金特机械有限公司 | Method for treating casting contraction cavities |
| CN105855465A (en) * | 2016-04-15 | 2016-08-17 | 滁州市鑫鼎机械模具制造有限公司 | Vacuum-free casting technology for metal dies |
| CN106238700A (en) * | 2016-07-29 | 2016-12-21 | 宁波遵航汽车零部件有限公司 | A kind of front-bank rotor housing casting technique |
| CN106270410A (en) * | 2015-06-24 | 2017-01-04 | 天津建筑机械厂 | A kind of casting technique of wheel hub |
| CN107262679A (en) * | 2017-07-04 | 2017-10-20 | 合肥择浚电气设备有限公司 | A kind of manufacture method of mining cone crusher |
| CN108044033A (en) * | 2017-12-06 | 2018-05-18 | 湖南三路面机械有限公司 | Preparation method, milling and planing drum, the preparation method of milling machine and the milling machine of milling and planing drum |
| CN108356436A (en) * | 2017-12-28 | 2018-08-03 | 江苏朗锐茂达铸造有限公司 | A kind of steel-casting process for welding repair Reliability Assessment Method |
| CN108927492A (en) * | 2018-08-16 | 2018-12-04 | 全椒县全动机械有限公司 | A kind of cast steel intermediate product of diesel engine manufacturing process |
| CN109261899A (en) * | 2018-11-27 | 2019-01-25 | 汪学军 | The casting method of the mechanical dedicated high-alloy steel creeper tread of large-scale mine |
| CN111168044A (en) * | 2020-01-19 | 2020-05-19 | 四川省犍为恒益铝业有限公司 | Machining method for oil pipe shell after casting forming |
| CN112536420A (en) * | 2020-11-19 | 2021-03-23 | 湖北恩腾机械有限公司 | Preparation process of eccentric casting wear-resistant bent pipe |
| CN112906187A (en) * | 2021-01-16 | 2021-06-04 | 大连环友屏蔽泵有限公司 | Casting process of double-suction pump body |
| CN114042873A (en) * | 2021-11-03 | 2022-02-15 | 上海艾诺特殊钢铸造有限公司 | Casting process of paper machine rotor |
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Cited By (19)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104439147A (en) * | 2014-11-21 | 2015-03-25 | 柳州金特机械有限公司 | Method for treating casting contraction cavities |
| CN104399881B (en) * | 2014-11-21 | 2017-03-29 | 宜昌船舶柴油机有限公司 | The casting method of low-speed diesel for large-bore vessel bearing block steel-casting |
| CN104399881A (en) * | 2014-11-21 | 2015-03-11 | 宜昌船舶柴油机有限公司 | Casting method for steel casting of bearing pedestal of low-speed diesel engine for large-cylinder-diameter ship |
| CN104439090A (en) * | 2014-11-26 | 2015-03-25 | 山东省源通机械股份有限公司 | Manufacturing technique of high-strength single-cylinder diesel engine body |
| CN106270410B (en) * | 2015-06-24 | 2018-12-18 | 天津移山工程机械有限公司 | A kind of casting technique of wheel hub |
| CN106270410A (en) * | 2015-06-24 | 2017-01-04 | 天津建筑机械厂 | A kind of casting technique of wheel hub |
| CN105855465A (en) * | 2016-04-15 | 2016-08-17 | 滁州市鑫鼎机械模具制造有限公司 | Vacuum-free casting technology for metal dies |
| CN106238700A (en) * | 2016-07-29 | 2016-12-21 | 宁波遵航汽车零部件有限公司 | A kind of front-bank rotor housing casting technique |
| CN107262679A (en) * | 2017-07-04 | 2017-10-20 | 合肥择浚电气设备有限公司 | A kind of manufacture method of mining cone crusher |
| CN108044033A (en) * | 2017-12-06 | 2018-05-18 | 湖南三路面机械有限公司 | Preparation method, milling and planing drum, the preparation method of milling machine and the milling machine of milling and planing drum |
| CN108044033B (en) * | 2017-12-06 | 2020-01-07 | 湖南三一路面机械有限公司 | Preparation method of milling drum, preparation method of milling machine and milling machine |
| CN108356436A (en) * | 2017-12-28 | 2018-08-03 | 江苏朗锐茂达铸造有限公司 | A kind of steel-casting process for welding repair Reliability Assessment Method |
| CN108927492A (en) * | 2018-08-16 | 2018-12-04 | 全椒县全动机械有限公司 | A kind of cast steel intermediate product of diesel engine manufacturing process |
| CN109261899A (en) * | 2018-11-27 | 2019-01-25 | 汪学军 | The casting method of the mechanical dedicated high-alloy steel creeper tread of large-scale mine |
| CN111168044A (en) * | 2020-01-19 | 2020-05-19 | 四川省犍为恒益铝业有限公司 | Machining method for oil pipe shell after casting forming |
| CN112536420A (en) * | 2020-11-19 | 2021-03-23 | 湖北恩腾机械有限公司 | Preparation process of eccentric casting wear-resistant bent pipe |
| CN112906187A (en) * | 2021-01-16 | 2021-06-04 | 大连环友屏蔽泵有限公司 | Casting process of double-suction pump body |
| CN112906187B (en) * | 2021-01-16 | 2024-02-23 | 大连环友屏蔽泵有限公司 | Casting process of pump body of double suction pump |
| CN114042873A (en) * | 2021-11-03 | 2022-02-15 | 上海艾诺特殊钢铸造有限公司 | Casting process of paper machine rotor |
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Application publication date: 20131218 |