CN103468893A - Quenching equipment used for large complex thin-wall aluminum alloy castings and application method thereof - Google Patents
Quenching equipment used for large complex thin-wall aluminum alloy castings and application method thereof Download PDFInfo
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- CN103468893A CN103468893A CN2013103020445A CN201310302044A CN103468893A CN 103468893 A CN103468893 A CN 103468893A CN 2013103020445 A CN2013103020445 A CN 2013103020445A CN 201310302044 A CN201310302044 A CN 201310302044A CN 103468893 A CN103468893 A CN 103468893A
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- 238000010791 quenching Methods 0.000 title claims abstract description 37
- 238000005266 casting Methods 0.000 title claims abstract description 36
- 230000000171 quenching effect Effects 0.000 title claims abstract description 28
- 238000000034 method Methods 0.000 title claims abstract description 25
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 24
- 238000001816 cooling Methods 0.000 claims abstract description 19
- 230000008569 process Effects 0.000 claims abstract description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 22
- 239000007788 liquid Substances 0.000 claims description 20
- 238000010438 heat treatment Methods 0.000 claims description 10
- 239000003795 chemical substances by application Substances 0.000 claims description 8
- 230000008878 coupling Effects 0.000 claims description 6
- 238000010168 coupling process Methods 0.000 claims description 6
- 238000005859 coupling reaction Methods 0.000 claims description 6
- 230000003287 optical effect Effects 0.000 claims description 6
- 239000007787 solid Substances 0.000 claims description 6
- 239000007921 spray Substances 0.000 claims description 6
- 238000005507 spraying Methods 0.000 claims description 5
- 230000003750 conditioning effect Effects 0.000 claims description 4
- 238000012545 processing Methods 0.000 claims description 4
- 238000007669 thermal treatment Methods 0.000 claims description 4
- 230000000694 effects Effects 0.000 claims description 3
- 238000012546 transfer Methods 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 2
- 230000002457 bidirectional effect Effects 0.000 claims description 2
- 230000015572 biosynthetic process Effects 0.000 claims description 2
- 230000008859 change Effects 0.000 claims description 2
- 238000009434 installation Methods 0.000 claims description 2
- 238000012544 monitoring process Methods 0.000 claims description 2
- 229920000642 polymer Polymers 0.000 claims description 2
- 239000006104 solid solution Substances 0.000 claims description 2
- 239000000243 solution Substances 0.000 claims description 2
- 239000010959 steel Substances 0.000 claims description 2
- 238000003466 welding Methods 0.000 claims description 2
- 238000010586 diagram Methods 0.000 description 6
- 238000013461 design Methods 0.000 description 4
- 230000009471 action Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 230000002929 anti-fatigue Effects 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 210000003205 muscle Anatomy 0.000 description 1
- 230000000399 orthopedic effect Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 229920003169 water-soluble polymer Polymers 0.000 description 1
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Abstract
The invention provides a set of equipment used for realizing rapid and uniform cooling of castings, reducing deformation of castings and improving mechanical properties in quenching processes of large complex thin-wall aluminum alloy castings.
Description
Technical field
The present invention relates to a set of device and using method thereof for realizing that Complex Aluminum Alloy Casting with Thin Wall Thickness quenching process Quick uniform is cooling.
Background technology
In fields such as aerospace, weaponry, automobile, boats and ships, large-scale complex thin-wall foundry goods, the especially demand of large-scale complex thin-wall aluminum alloy cabin, box casting and application are just more and more extensive.
Generally all will carry out the subsequent heat treatment modification after the Complex Aluminum Alloy Casting with Thin Wall Thickness moulding, purpose is to improve its intensity, hardness, anti-fatigue performance etc.But due to complex structure, thin-walled, large-scale, and in heat treatment process because relating to the many factors comprehensive actions such as heating, cooling, stress, usually cause casting deformation serious, even the process multi-pass is manually orthopedic, casting qualified rate is still lower, is difficult to meet the design requirements of product to high-quality, high precision foundry goods.At present, the domestic problem serious for the Complex Aluminum Alloy Casting with Thin Wall Thickness heat treatment deformation also launched correlative study, mainly concentrating on preferred quenchant and quenching mode reduces the massive casting distorsion during quenching, carries out the thermal treatment after strain and proofread and correct the aspects such as novel process, and obtained certain effect, but the thermal treatment after strain is still larger, can not meet dimension precision requirement.Foundry goods quench cooled mode, on cast properties and larger, the reasonable in design splash cooling system of dimensional precision impact, contributes to realize that foundry goods thin and thick position Quick uniform is cooling, Reducing distortion amount when improving mechanical castings.
summary of the invention:
The object of the invention is to provide a set of and realizes that for the Complex Aluminum Alloy Casting with Thin Wall Thickness quenching process foundry goods Quick uniform is cooling, reduces the device of casting deformation and raising mechanical property.
Another object of the present invention is to provide the method for a kind of said apparatus for the Complex Aluminum Alloy Casting with Thin Wall Thickness quenching process.
The object of the present invention is achieved like this, a kind of device quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness, it is characterized in that comprising following five integral parts: base support, splash pipe assembly, water tank, catch tray and shield cap, intelligent control system, welding middle jet pipe in base support centre is installed dull and stereotyped; Splash pipe assembly is divided into outer splash pipe assembly and middle splash pipe assembly; Catch tray is mainly used in collecting the medium after quenching, then controls back the liquid water pump by liquid level valve medium is withdrawn into to water tank; Shield cap is the baffle plate of energy opening and closing, spraying and splashing facility is surrounded to water liquid splash everywhere while preventing from quenching.
Preferably, base support is totally circular, by round steel, is welded.
Preferably, intelligent control system comprises that processing parameter setting module, ejection medium matching module, dynamic Decoupling Control of Load Torque, medium control, nozzle and foundry goods dynamic control section divide, set up the models for temperature field in process of cooling according to heat-eliminating medium proportioning and quench rates relation, by the feedback of temperature signal, the flow of control agent, temperature and concentration etc.
Said apparatus splash pipe component design principle: outer splash pipe is for the splash of part outside surface, adopt 1 cun galvanized pipe, according to foundry goods physical dimension, the useful area that can cover according to every nozzle, consider the heavy wall boss on part simultaneously, on every jet pipe, solid nozzle is set, outer nozzle is divided into the two groups of jet pipe groups in left and right, every group is staggered installation of by 3 long jet pipes and 3 short jet pipes respectively, every group is fixed on semi-circular support, every group of jet pipe hinge is on base, the discerptible jet pipe group of formation activity, facilitate picking and placeing of part, it is some that long jet pipe arranges nozzle, it is some that short spray section arranges nozzle.Middle jet pipe for the accessory inner surface splash, adopts 2 cun galvanized pipes, and according to area and the length of internal surface, it is some that middle jet pipe axial direction due arranges respectively nozzle, on every jet pipe, solid nozzle is set, and it is some that every group of nozzle radially is uniformly distributed nozzle.Middle jet pipe with base support on adjustable-height.
The said apparatus nozzle can produce the solid cone shaped spray shapes, and inlet zone is rounded, and spray angle is adjustable between 43 ° to 120 °.Such nozzle can produce and be evenly distributed under large-scale flow rate and pressure, droplet size is waited until spraying bigger than normal in being, spraying can realize that the gross area in border circular areas covers, and this uniform spray shapes distributes and derives from its unique blade design and large and unimpeded runner and good control characteristic.Simultaneously, the ball joint that it has universal position adjustable, facilitate the injection direction of Control Nozzle.
Above-mentioned intelligent control system can realize that flow, temperature and the state of medium control automatically by the following method.Thermopair, by temperature transmitter, optical coupling isolator, constantly sends the cooling temperature changing value to A/D(simulation/numerical value) module, and feed back to PLC(controllable logic programmer) main frame.Use PID(proportional integral derivative setter) instruction, after given temperature control curve and thermopair feedback signal are carried out to the PID computing, the output control signal is through D/A(numerical value/simulation) be converted to analog quantity, by optical coupling isolator, over-zero trigger as the SCR(silicon-controlled rectifier) conditioning signal, now proportional valve changes the flow of medium under the D/A module controls, temperature control modules changes temperature in stove under bidirectional thyristor is controlled, nozzle changes the state of medium under the medium control module, and then effectively controls the foundry goods rate of cooling.
Above-mentioned each piping system is provided with many valves, the central processing unit of PLC according to inner sequence of control can realize to device start, each valve folding flexibly, rate-of flow and mode control, and mean by the LED signal lamp of its output terminal the action completion status that output is controlled, carry out corresponding output and drive, and the register system parametric line.
Said apparatus, by reasonable Arrangement nozzle location, the performance perameter of regulation and control heat-eliminating medium and different splash modes etc., makes the different sites cooling rates such as foundry goods heavy wall place, thin-walled place and stiffening web even, obtains the premium casting of few distortion.
Another object of the present invention is achieved in that a kind of using method of Complex Aluminum Alloy Casting with Thin Wall Thickness quenching device, it is characterized in that comprising the following steps:
The first step, carry out solution treatment to Complex Aluminum Alloy Casting with Thin Wall Thickness in the heat treatment furnace in be controlled in the thermal treatment temp precision ± 5 ℃ of scopes, is heated to 535 ± 5 ℃, is incubated 12 ~ 14h;
Second step, heating PAG Polymer quenching medium to 35 in liquid-storing box ~ 40 ℃, hang in the foundry goods after solid solution in the splash refrigerating unit by driving, is controlled at transfer time in 15s;
The 3rd step, open the splash refrigerating unit by the PLC Controlling System and carry out the foundry goods quench treatment, and the hydrojet water pump is started working, and device starts hydrojet, and hydraulic pressure can reach 0.05 ~ 0.3MPa;
The 4th step, the temperature of thermocouple monitoring foundry goods, send temperature change value to the A/D module, conditioning signal by optical coupling isolator, over-zero trigger as SCR, the passing ratio valve is the flow of control agent at any time, the temperature of liquid-storing box control agent, the state of Jet control medium;
The 5th step, return the liquid water pump under the control of liquid level valve, the water collected in catch tray after quenching is withdrawn into to water tank, until casting temperature is cooled to 80 ± 5 ℃, time length 25 ~ 35s;
The 6th step, quench and finish, and PLC Controlling System automatic operation electromagnet cut off valve stop gear hydrojet, hang out foundry goods.
the present invention has following beneficial effect:
1, apparatus of the present invention level of automation is high, and main operational steps is as hydrojet, the flow of medium, temperature and mode control, and medium returns liquid, and stopping the hydrojet process can control fast, accurately complete by PLC, easy and simple to handle; Main processing parameter all can vividly show on display unit as casting temperature, medium temperature, hydraulic pressure, rate of cooling, and output temperature curve and cooling-rate curves, is convenient to quenching process is analyzed.
This device can pass through flow, temperature, the state of the accurate control agent of PLC Controlling System, according to foundry goods different sites dimensional thickness, provides different rate of cooling, and the Quick uniform that is conducive to foundry goods is cooling, reduces the deflection of foundry goods, guarantees the quenching quality;
This device is furnished with back the liquid water pump, the quenchant collected in catch tray can be withdrawn in liquid-storing box, makes whole splash process in a working cycle, improves the utilization ratio of quenchant, the investment of having saved equipment;
This device liquid-storing box is furnished with heating unit, can guarantee that quenchant temperature in quenching process can regulate, and by controlling quench media temperature, improves precision and performance after foundry goods quenches;
The shield cap of this device can surround spraying and splashing facility, and water liquid splash everywhere while preventing from quenching guarantees that quenching process is on-the-spot clean, guarantees the person, device security;
This device continuity is strong, and high efficiency, avoid too much time, goods and materials loss, and application value is higher, and industrial potential is huge.
2, in the splash refrigerating unit that the foundry goods under technique of the present invention is controlled at PLC, carry out quench treatment, thermopair monitors casting temperature constantly, feed back to Controlling System, flow, temperature, the state of accurate control agent, the Quick uniform of realizing foundry goods is cooling, has guaranteed the quality of foundry goods, has reached the quenching requirement, realize batch production, improved production efficiency.
For large thin-wall Complex Aluminum Alloy foundry goods, casting dimension thin and thick position difference, conventional quenching technique is difficult to realize the evenly cooling of foundry goods different positions, causes foundry goods quenching after strain amount serious, internal residual stress is also very large, even there will be the situations such as hardening crack.This technique can thoroughly address the above problem, and obtains the premium casting that distortion is little, performance is good, has solved a puzzlement quenching field difficult problem for many years, serves aerospace, automobile boats and ships and national defence association area.
The accompanying drawing explanation
Fig. 1 is for the splash quenching device structural representation of Complex Aluminum Alloy Casting with Thin Wall Thickness;
In figure: 1. outer nozzle is 1 group; 2. middle jet pipe; 3. workpiece; 4. thermopair; 5. outer nozzle is 2 groups; 6. electromagnet cut off valve; 7. pressure unit; 8. proportional valve; 9. liquid level valve; 10. catch tray; 11. shield cap; 12. return the liquid water pump; 13. hydrojet water pump; 14. liquid-storing box; 15. signal amplifier; 16.PLC control device;
Fig. 2 chassis supporting stand structure schematic diagram;
Nozzle component structural representation in Fig. 3;
The long outer nozzle unit construction of Fig. 4 schematic diagram;
The short outer nozzle unit construction of Fig. 5 schematic diagram;
Fig. 6 liquid level valve is controlled schematic diagram;
In figure: when liquid level, during in No. 1 position, close back the liquid water pump; During in No. 2 positions, open back the liquid water pump when liquid level;
Fig. 7 shield cap schematic diagram;
The cooling control system schematic diagram of Fig. 8 based on the PLC programming.
Embodiment
Embodiment, it is application that the present embodiment be take certain large complicated Al-alloy casing foundry goods, concrete overall size: high 750mm, small end circle Φ 286.5mm, large end moment shape 376.7mm * 413.4mm, main body wall thickness 2.9mm, the many boss of inner chamber, muscle, material: ZL114A.
Operation steps is shown in summary of the invention.
S main working parameters is as follows: 535 ± 5 ℃ of foundry goods solid solubility temperatures; Soaking time 12 ~ 14h; 35 ~ 40 ℃ of PAG water-soluble polymers Heating temperatures; In foundry goods 15s transfer time; Splash hydraulic pressure 0.05 ~ 0.3MPa; Cool time 25 ~ 35s.
Claims (8)
1. the device quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness, it is characterized in that comprising following five integral parts: base support, splash pipe assembly, water tank, catch tray and shield cap, intelligent control system, welding middle jet pipe in base support centre is installed dull and stereotyped; Splash pipe assembly is divided into outer splash pipe assembly and middle splash pipe assembly; Catch tray is mainly used in collecting the medium after quenching, controls back the liquid water pump by liquid level valve quenchant is withdrawn into to water tank; Shield cap is the baffle plate of energy opening and closing, spraying and splashing facility is surrounded to water liquid splash everywhere while preventing from quenching.
2. the device quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness as claimed in claim 1 is characterized in that: base support totally, for circular, is welded by round steel.
3. the device quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness as claimed in claim 1 or 2, it is characterized in that: intelligent control system comprises that processing parameter setting module, ejection medium matching module, dynamic Decoupling Control of Load Torque, medium control, nozzle and foundry goods dynamic control section divide, set up the models for temperature field in process of cooling according to heat-eliminating medium proportioning and quench rates relation, by the feedback of temperature signal, the flow of control agent, temperature and state etc.
4. the device as quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness as described in claim 1 or 2 or 3, it is characterized in that: described intelligent control system realizes that flow, temperature and the state of medium control automatically by the following method, thermopair is by temperature transmitter, optical coupling isolator, constantly send the cooling temperature changing value to the A/D module, and feed back to the PLC main frame; Use the PID instruction, after given temperature control curve and thermopair feedback signal are carried out to the PID computing, the output control signal is converted to analog quantity through D/A, conditioning signal by optical coupling isolator, over-zero trigger as SCR, now proportional valve changes the flow of medium under the D/A module controls, temperature control modules changes temperature in stove under bidirectional thyristor is controlled, and nozzle changes the state of medium under the medium control module, and then effectively controls the foundry goods rate of cooling.
5. the device quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness as claimed in claim 1, it is characterized in that: outer splash pipe is for the splash of part outside surface, adopt 1 cun galvanized pipe, according to foundry goods physical dimension, the useful area that can cover according to every nozzle, consider the heavy wall boss on part simultaneously, on every jet pipe, solid nozzle is set, outer nozzle is divided into the two groups of jet pipe groups in left and right, every group is staggered installation of by 3 long jet pipes and 3 short jet pipes respectively, every group is fixed on semi-circular support, every group of jet pipe hinge is on base, the discerptible jet pipe group of formation activity, facilitate picking and placeing of part, it is some that long jet pipe arranges nozzle, it is some that short spray section arranges nozzle.
6. the device quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness as claimed in claim 1, it is characterized in that: middle jet pipe is for the accessory inner surface splash, adopt 2 cun galvanized pipes, area and length according to internal surface, it is some that middle jet pipe axial direction due arranges respectively nozzle, on every jet pipe, solid nozzle is set, it is some that every group of nozzle radially is uniformly distributed nozzle, middle jet pipe with base support on adjustable-height.
7. the device as quenched for Complex Aluminum Alloy Casting with Thin Wall Thickness as described in claim 5-6, is characterized in that described nozzle spray angle is adjustable between 43 ° to 120 °.
8. the using method of the described Complex Aluminum Alloy Casting with Thin Wall Thickness quenching device of claim 1-7 is characterized in that comprising the following steps:
The first step, carry out solution treatment to Complex Aluminum Alloy Casting with Thin Wall Thickness in the heat treatment furnace in be controlled in the thermal treatment temp precision ± 5 ℃ of scopes, is heated to 535 ± 5 ℃, is incubated 12 ~ 14h;
Second step, heating PAG Polymer quenching medium to 35 in liquid-storing box ~ 40 ℃, hang in the foundry goods after solid solution in the splash refrigerating unit by driving, is controlled at transfer time in 15s;
The 3rd step, open the splash refrigerating unit by the PLC Controlling System and carry out the foundry goods quench treatment, and the hydrojet water pump is started working, and device starts hydrojet, and hydraulic pressure can reach 0.05 ~ 0.3MPa;
The 4th step, the temperature of thermocouple monitoring foundry goods, send temperature change value to the A/D module, conditioning signal by optical coupling isolator, over-zero trigger as SCR, the passing ratio valve is the flow of control agent at any time, the temperature of liquid-storing box control agent, the state of Jet control medium;
The 5th step, return the liquid water pump under the control of liquid level valve, the water collected in catch tray after quenching is withdrawn into to water tank, until casting temperature is cooled to 80 ± 5 ℃, time length 25 ~ 35s;
The 6th step, quench and finish, and PLC Controlling System automatic operation electromagnet cut off valve stop gear hydrojet, hang out foundry goods.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104498847A (en) * | 2014-12-03 | 2015-04-08 | 北京航星机器制造有限公司 | Method for controlling deformation of thin-walled aluminum alloy bracket with cavity structure during heat treatment |
| CN104531974A (en) * | 2014-12-17 | 2015-04-22 | 中国第一重型机械股份公司 | Large forging quenching heat treatment process |
| CN108517398A (en) * | 2018-06-26 | 2018-09-11 | 安徽马钢设备检修有限公司 | A kind of Large Diameter Pipeline thin-wall tube post weld heat treatment device and its application method |
| CN109321716A (en) * | 2018-11-20 | 2019-02-12 | 上海电气上重铸锻有限公司 | A kind of large size medium and low carbon steel forging shaft surface hardening heat-treating methods |
| CN117802294A (en) * | 2024-02-28 | 2024-04-02 | 大连理工大学 | Cooling method and device for non-closed complex aluminum alloy thin-wall part |
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| CN117802294A (en) * | 2024-02-28 | 2024-04-02 | 大连理工大学 | Cooling method and device for non-closed complex aluminum alloy thin-wall part |
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Effective date of registration: 20240409 Address after: 400039 Chongqing Jiulongpo Yuzhou Road No. 33 Patentee after: Southwest Institute of technology and engineering of China Ordnance Equipment Group Country or region after: China Address before: 400041 Yuzhou Road, Kowloon District, Chongqing, No. 33 Patentee before: NO 59 Research Institute OF CHINA ORDNACE INDUSTRY Country or region before: China |