CN103658599B - A kind ofly be applicable to the method for designing that electromagnetic pump low pressure casting fills type technique - Google Patents
A kind ofly be applicable to the method for designing that electromagnetic pump low pressure casting fills type technique Download PDFInfo
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Abstract
The present invention is a kind of is applicable to the method for designing that electromagnetic pump low pressure casting fills type technique, belong to electromagnetic pump Low Pressure Casting Technology field, technical problem to be solved is for providing a kind of in electromagnetic pump low pressure casting cavity filling process, filling velocity can be adjusted according to cross-sectional sizes, namely change the method for mold filling pressure in good time; The technical scheme adopted is: carry out in the steps below: the first step, make the casting technique threedimensional model of foundry goods, second step, namely foundry goods is poured into a mould direction along Z-direction and carries out slice analysis, the 3rd step, namely foundry goods is poured into a mould Directional Decomposition along Z-direction and becomes several parts, 4th step, form pressure-time curve P (t) of foundry goods entirety, the 5th step, is modified to P by the P (t) in the 4th step
mt (), the 6th step, by P
mt () pressure-time curve is converted to I (t) current versus time curve, the 7th step, is arranged on above aluminium liquid by high-temperature laser liquid level rangefinder, and opens, and the 8th step is tested and records liquid level initial position; 9th step, installs casting mold, performs low pressure casting and fills type technique.<pb pnum="1" />
Description
Technical field
The present invention is a kind of is applicable to the method for designing that electromagnetic pump low pressure casting fills type technique, belongs to electromagnetic pump Low Pressure Casting Technology field, particularly fills design and the control method of type technique in electromagnetic pump low pressure casting.
Background technology
Electromagnetic pump low pressure casting is different from traditional vapour-pressure type low pressure casting pressuring method.The air pressure that vapour-pressure type low pressure casting produces can directly be measured, perform foundry technology process time mold filling pressure and dwell pressure are gathered at any time, Real-time Feedback, realize closed-loop control, and electromagnetic pump in strict accordance with setting parameter carry out Output pressure.
The power that electromagnetic pump low pressure casting produces is realized by the acting in conjunction of Electric and magnetic fields.The aluminum alloy low-pressure casting device formed with electromagnetic pump and holding furnace, compared with traditional vapour-pressure type aluminum alloy low-pressure casting system, has pressure accurately adjustable, the advantages such as in continuous flow procedure, aluminium liquid inspiratory capacity is few, and casting quality is good.But directly cannot measure flow and the pressure of high-temperature liquid metal in cavity filling process, can only be opened loop control when performing casting technique route.Thus the accuracy that this technology performs casting technique is directly determined to the relation between extra electric field and magnetic field and molten metal flow and the pressure that produces and control method.
Low pressure casting process be generally divided into rise liquid, fill type, crust, supercharging, pressurize, six stages such as release, liter liquid and cavity filling process have important impact to casting quality, whether decision foundry goods be there will be the casting flaws such as volume gas, secondary inclusion, cold shut, misrun by the selection of its technological parameter, the setting of supercharging and packing stage is mainly used in feeding a casting, whether select the crust stage relevant with casting mold character, common metal type is without the need to the stage of crusting.Rising liquid process is the shaping first stage of foundry goods, with certain liquid speed that rises, metal is risen to stalk upper port from crucible; Cavity filling process is the shaping second stage of foundry goods, and concerning Filling Processes of Castings quality, mold filling pressure is excessive or too smallly all can produce much casting flaw (as volume gas, be mingled with, misrun, cold shut and sand holes etc.).Therefore, controlling cavity filling process is the important prerequisite condition obtaining premium casting.
In the calculating of traditional handicraft mold filling pressure, the value of mold filling resistance coefficient is the underrange of 1 ~ 1.5, and force value is only relevant with foundry goods height, have ignored the vicissitudinous situation of intricate casting sectional area.And in actual production, the cross-sectional area of most of foundry goods is not on all four at whole height, when utilizing traditional pressing technology specification to carry out filling type, this feature can not be embodied, if fill type by constant speed, easily produce liquid level at heavy in section place and rise and fall, produce secondary inclusion.
In low pressure casting, existing casting Technology Design method, to simple shape, highly not quite, transverse shape and the little foundry goods of area change, it is ideal to fill type effect.But in actual production, all kinds of cast shape differs, the foundry goods of the overwhelming majority can not ensure that its cross-sectional area is completely the same at whole height, and sometimes difference can be very large.If fill type by same speed, easily produce serious turbulent flow when heavy in section, reduce the quality of foundry goods.
Summary of the invention
The present invention overcomes the deficiency that prior art exists, and technical problem to be solved, for providing a kind of in electromagnetic pump low pressure casting cavity filling process, can adjust filling velocity according to cross-sectional sizes, namely change the method for mold filling pressure in good time.
In order to solve the problems of the technologies described above, the technical solution used in the present invention is: be a kind ofly applicable to the method for designing that electromagnetic pump low pressure casting fills type technique, carries out in the steps below:
The first step, makes the casting technique threedimensional model of foundry goods, comprises spray, running gate system, rising head;
Second step, according to the threedimensional model in the first step, namely pours into a mould direction by foundry goods along Z-direction and carries out slice analysis, calculates the height-sectional area distribution map A of foundry goods
c=f (z), height-area overlap ratio distribution map α
c=f (z) and height-volume integral Butut V
c=f (z), in described slice analysis, slice distance is 1-5mm;
3rd step, according to the height-area overlap ratio distribution map α calculated in second step
c=f (z) and height-volume integral Butut V
cautomatically namely foundry goods is poured into a mould Directional Decomposition along Z-direction becomes several parts, i.e. segmentation to=f (z), calculates the volume of each part respectively; The principle of described segmentation is: undergo mutation position in (a) cross section, i.e. the area ratio >1.2 of two next-door neighbour's sections or <0.8, (b) overlap ratio is less than 70%, described overlap ratio α
c=A
1/ A
min, wherein, A
1be the overlapping area of two next-door neighbour's sections, A
minbe the side that in two next-door neighbour's sections, area is less;
4th step, according to foundry goods segmentation result, generates the pressure-time curve of the every part of foundry goods, is then stitched together by the pressure-time curve of each several part and forms pressure-time curve P (t) of foundry goods entirety;
5th step, calculates the sectional area-height distribution map A of aluminum alloy low-pressure casting electromagnetic pump crucible used
f=f (z) and volume-height distribution map h=f (V
f), according to volume-height distribution map h=f (V
f), the P (t) in the 4th step is modified to P
m(t), P
m(t)=P (t)+Δ P, wherein Δ P=ρ
aluminiumgh, wherein, h is that in casting process, t residual Al liquid amasss V
fcorresponding level;
6th step, by aluminum alloy low-pressure casting electromagnetism pump characteristics by P
mt () pressure-time curve is converted to I (t) current versus time curve, and input control computer, use as low-pressure casting process curve;
7th step, is placed in electromagnetic pump crucible by the aluminium liquid after fusing, and aluminum anodizing is to liquid level light;
8th step, is adjusted to pouring temperature by temperature of aluminum liquid and is incubated, and opens the excitation con-trol switch on electromagnetic pump and current-controlled switch, liquid level is suspended into the stalk mouth of pipe;
9th step, installs casting mold, performs electric current export according to the low-pressure casting process curve drawn in the 6th step, performs low pressure casting and fills type technique.
In described 7th step, in addition high-temperature laser liquid level rangefinder is arranged on above aluminium liquid, and opens the step of high-temperature laser liquid level rangefinder;
In described 8th step, after liquid level is suspended into the stalk mouth of pipe, high-temperature laser liquid level rangefinder is tested and is recorded liquid level initial position;
Described 9th step performs low pressure casting and fills in the process of type technique, according to the liquid level position of high-temperature laser liquid level rangefinder real-time testing, calculates the aluminium liquid being filled with casting mold die cavity and amasss, according to foundry goods height-volume integral Butut V
c=f (z) inverse goes out liquid level in casting mold, by inverse value h
cwith pressure curve P
mt () contrasts, if h
cwith P
mt there is deviation in () correspondence position, to pressure curve P
mt () is finely tuned, and then finely tune current curve I (t), makes cavity filling process carry out filling type according to the curve after fine setting in real time, terminates until fill type.
Be set with protection tube outside high-temperature laser liquid level rangefinder in described 7th step, protection tube stretches in aluminium liquid, and is full of argon gas in protection tube.
When slice analysis being carried out to the casting technique three-dimensional model diagram of foundry goods in described second step, can accomplish with existing software, but pretty troublesome, the software of a slice analysis can be designed as required, thus raise the efficiency.
The inventive method is except being applied to aluminum alloy low-pressure casting electromagnetic pump, and what slightly also can be applicable to other alloy low pressure casting electromagnetic pump after adjustment fills type technological design; Also vapour-pressure type low-pressure die casting plant is gone under the condition can predicting vapour-pressure type low pressure casting flow.
The present invention compared with prior art has following beneficial effect.
1, the inventive method is carried out segmentation for foundry goods and has been pressurizeed and fill the technique of type, the type stage is filled at low pressure casting, segmentation pressure changeable is adopted to fill type technique, in good time change mold filling pressure, completely fill on the basis of type meeting, utilize direct current planar electromagnetism pump characteristics, control the electric current of exerting pressure and fill type flow, effectively control filling velocity, complete Stable Filling.Namely fill the type stage for intricate casting low pressure casting, at foundry goods small bore, place suitably increases filling velocity, and in foundry goods heavy in section, place suitably reduces filling velocity.Effectively can avoid injection and the splashing of molten metal like this, reduce the turbulent flow of metal liquid and being involved in of gas in cavity filling process, thus reach successively Stable Filling, at utmost reduce the defect of foundry goods, realize cast form accurately to control, ensure the forming quality of foundry goods.
2, in the inventive method, for the feature of aluminum alloy low-pressure casting electromagnetic pump, laser liquid level rangefinder is adopted to carry out record to liquid volume change in crucible in cavity filling process, and according to liquid level falling head, pressure compensation is carried out to mold filling pressure, realize closed-loop control, thus self adaptation can be carried out according to casting structure feature and fill type technological design, ensure casting stable filling type.
3, in the inventive method, for low pressure casting part complicated arbitrarily, according to its part feature, the pressure-time curve of its cavity filling process can be drawn out, the current versus time curve of electromagnetic pump low-pressure casting, thus its cavity filling process is accurately controlled.
Accompanying drawing explanation
Below in conjunction with accompanying drawing, the present invention will be further described in detail.
Fig. 1 is the three-dimensional model diagram of box casting in embodiment one.
Fig. 2 is the PRELIMINARY RESULTS figure in embodiment one after box casting section.
Fig. 3 is the comparison diagram filling type technique filling type technique and design by the inventive method to the existing method design of box casting in embodiment one.
Fig. 4 is the working curve between the hydraulic head height H of aluminum alloy low-pressure casting electromagnetic pump in the present invention and electric current I.
In figure: 1 is that foundry goods sectional area is with height change curve, 2 is that foundry goods sectional area is with height change slope, 3 for filling type process curve to box casting in embodiment one with existing method design, 4 fill type process curve for what design box casting the inventive method in embodiment one, and 5 is the working curve between the hydraulic head height H of aluminum alloy low-pressure casting electromagnetic pump and electric current I.
Detailed description of the invention
The present invention is when carrying out casting pouring, the foundry goods outstanding by pair cross-section change carries out equitable subsection, utilize the critical speed that different foundry goods sectional area ratio allows, speed-time curve is converted to controllable pressure-time curve, with variable slope pressing technology specification curve in the cavity filling process set up, complete cavity filling process.
Embodiment one
As Figure 1-Figure 4, wall thickness is comparatively even, is highly the method for designing of filling type technique of the aluminium alloy box that the sectional area of 750mm is changed significantly:
The first step, makes the casting technique threedimensional model of casing, comprises tank body blank, running gate system, rising head;
Second step, according to the threedimensional model in the first step, namely pours into a mould direction by foundry goods along Z-direction and carries out slice analysis, as shown in Figure 2, calculates the height-sectional area distribution map A of casing
c=f (z), height-area overlap ratio distribution map α
c=f (z) and height-volume integral Butut V
c=f (z), in described slice analysis, slice distance is 1mm, or is 3mm, or is 5mm;
3rd step, according to the height-area overlap ratio distribution map α calculated in second step
c=f (z) and height-volume integral Butut V
cautomatically namely casing is poured into a mould Directional Decomposition along Z-direction becomes three parts to=f (z), is namely divided into three sections, calculates the volume of each part respectively; The principle of described segmentation is: undergo mutation position in (a) cross section, i.e. the area ratio >1.2 of two next-door neighbour's sections or <0.8, (b) overlap ratio is less than 70%, described overlap ratio α
c=A
1/ A
min, wherein, A
1be the overlapping area of two next-door neighbour's sections, A
minbe the side that in two next-door neighbour's sections, area is less;
4th step, according to foundry goods segmentation result, generates the pressure-time curve of the every part of foundry goods, is then stitched together by the pressure-time curve of each several part and forms pressure-time curve P (t) of foundry goods entirety, as shown in curve in Fig. 34;
In this step, be utilize different area than the critical speed allowed, thus calculate the pressing technology curve of foundry goods.The pressing technology curve of low pressure casting is pressure P-time t curve, and slope of a curve is exactly pressing speed, and object of the present invention changes the flow velocity of molten metal in cavity filling process by changing pressing speed.
5th step, calculates the sectional area-height distribution map A of aluminum alloy low-pressure casting electromagnetic pump crucible used
f=f (z) and volume-height distribution map h=f (V
f), according to volume-height distribution map h=f (V
f), the P (t) in the 4th step is modified to P
m(t), P
m(t)=P (t)+Δ P, wherein Δ P=ρ
aluminiumgh, wherein, h is that in casting process, t residual Al liquid amasss V
fcorresponding level;
6th step, by aluminum alloy low-pressure casting electromagnetism pump characteristics by P
mt () pressure-time curve is converted to I (t) current versus time curve, and input control computer, use as low-pressure casting process curve;
Different electromagnetic pump structures has different electric current I-pressure P working curve, but is linear relationship substantially between the electric current I-pressure P of all electromagnetic pumps, meets following formula:
P=KI+C
Wherein P is operating pressure, and I is output current, and K is proportionality coefficient, the constant relevant with electromagnetic pump structure, and C is constant, relevant with electromagnet and level;
In order to the convenience calculated, also represent pressure with fall head H, the both sides of above-mentioned formula all can be obtained the working curve of electromagnetic pump hydraulic head height H and electric current I divided by ρ g:
H=K
1I+C
1
Wherein H is that the working water of electromagnetic pump defeats grease head highness, K
1=K/ ρ g, C
1=C/ ρ g;
Working curve in the present invention between the hydraulic head height H of aluminum alloy low-pressure casting electromagnetic pump and electric current I is:
H=1.4505I – 25.469; As shown in Figure 4;
7th step, is placed in electromagnetic pump crucible by the aluminium liquid after fusing, and high-temperature laser liquid level rangefinder, to liquid level light, is arranged on above aluminium liquid, and opens high-temperature laser liquid level rangefinder by aluminum anodizing;
8th step, is adjusted to pouring temperature by temperature of aluminum liquid and is incubated, and opens the excitation con-trol switch on electromagnetic pump and current-controlled switch, liquid level is suspended into the stalk mouth of pipe, and high-temperature laser liquid level rangefinder is tested and recorded liquid level initial position;
9th step, installs casting mold, performs electric current export according to the low-pressure casting process curve drawn in the 6th step, performs low pressure casting and fills type technique;
Fill in type technical process at execution low pressure casting, according to the liquid level position of high-temperature laser liquid level rangefinder real-time testing, calculate the aluminium liquid being filled with casting mold die cavity and amass, according to foundry goods height-volume integral Butut V
c=f (z) inverse goes out liquid level in casting mold, by inverse value h
cwith pressure curve P
mt () contrasts, if h
cwith P
mt there is deviation in () correspondence position, to pressure curve P
mt () is finely tuned, and then finely tune current curve I (t), makes cavity filling process carry out filling type according to the curve after fine setting in real time, terminates until fill type.
Claims (3)
1. be applicable to the method for designing that electromagnetic pump low pressure casting fills type technique, it is characterized in that carrying out in the steps below:
The first step, makes the casting technique threedimensional model of foundry goods, comprises spray, running gate system, rising head;
Second step, according to the threedimensional model in the first step, namely pours into a mould direction by foundry goods along Z-direction and carries out slice analysis, calculates the height-sectional area distribution map A of foundry goods
c=f (z), height-area overlap ratio distribution map α
c=f (z) and height-volume integral Butut V
c=f (z), in described slice analysis, slice distance is 1-5mm;
3rd step, according to the height-area overlap ratio distribution map α calculated in second step
c=f (z) and height-volume integral Butut V
cautomatically namely foundry goods is poured into a mould Directional Decomposition along Z-direction becomes several parts, i.e. segmentation to=f (z), calculates the volume of each part respectively; The principle of described segmentation is: undergo mutation position in (a) cross section, i.e. the area ratio >1.2 of two next-door neighbour's sections or <0.8, (b) overlap ratio is less than 70%, described overlap ratio α
c=A
1/ A
min, wherein, A
1be the overlapping area of two next-door neighbour's sections, A
minbe the side that in two next-door neighbour's sections, area is less;
4th step, according to foundry goods segmentation result, generates the pressure-time curve of the every part of foundry goods, is then stitched together by the pressure-time curve of each several part and forms pressure-time curve P (t) of foundry goods entirety;
5th step, calculates the sectional area-height distribution map A of aluminum alloy low-pressure casting electromagnetic pump crucible used
f=f (z) and volume-height distribution map h=f (V
f), according to volume-height distribution map h=f (V
f), by the 4th step P (
t) be modified to P
m(t), P
m(t)=P (t)+Δ P, wherein Δ P=ρ
aluminiumgh, wherein, h is that in casting process, t residual Al liquid amasss V
fcorresponding level;
6th step, by aluminum alloy low-pressure casting electromagnetism pump characteristics by P
mt () pressure-time curve is converted to I (t) current versus time curve, and input control computer, use as low-pressure casting process curve;
7th step, is placed in electromagnetic pump crucible by the aluminium liquid after fusing, and aluminum anodizing is to liquid level light;
8th step, is adjusted to pouring temperature by temperature of aluminum liquid and is incubated, and opens the excitation con-trol switch on electromagnetic pump and current-controlled switch, liquid level is suspended into the stalk mouth of pipe;
9th step, installs casting mold, performs electric current export according to the low-pressure casting process curve drawn in the 6th step, performs low pressure casting and fills type technique.
2. be according to claim 1ly a kind ofly applicable to the method for designing that electromagnetic pump low pressure casting fills type technique, it is characterized in that:
In described 7th step, in addition high-temperature laser liquid level rangefinder is arranged on above aluminium liquid, and opens the step of high-temperature laser liquid level rangefinder;
In described 8th step, after liquid level is suspended into the stalk mouth of pipe, high-temperature laser liquid level rangefinder is tested and is recorded liquid level initial position;
Described 9th step performs low pressure casting and fills in the process of type technique, according to the liquid level position of high-temperature laser liquid level rangefinder real-time testing, calculates the aluminium liquid being filled with casting mold die cavity and amasss, according to foundry goods height-volume integral Butut V
c=f (z) inverse goes out liquid level in casting mold, by inverse value h
cwith pressure curve P
mt () contrasts, if h
cwith P
mt there is deviation in () correspondence position, to pressure curve P
mt () is finely tuned, and then finely tune current curve I (t), makes cavity filling process carry out filling type according to the curve after fine setting in real time, terminates until fill type.
3. be according to claim 2ly a kind ofly applicable to the method for designing that electromagnetic pump low pressure casting fills type technique; it is characterized in that: outside the high-temperature laser liquid level rangefinder in described 7th step, be set with protection tube; protection tube stretches in aluminium liquid, and is full of argon gas in protection tube.
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CN109202040B (en) * | 2018-07-20 | 2020-06-09 | 福建浦汇科技发展有限公司 | Method for casting aluminum on rotor |
CN114599465A (en) * | 2019-12-23 | 2022-06-07 | 本田金属技术株式会社 | Aluminum casting method and mold |
CN113434984A (en) * | 2021-07-08 | 2021-09-24 | 上海交通大学 | Method and device for adjusting filling stage, electronic equipment and storage medium |
CN113458362B (en) * | 2021-08-03 | 2022-12-30 | 重庆大学 | Steady-state mold filling control method in low-pressure casting process |
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DE3214922A1 (en) * | 1982-04-22 | 1983-11-03 | Norsk Hydro Magnesiumgesellschaft mbH, 4300 Essen | Method for casting molten metals, in particular magnesium, with a low-pressure casting device |
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CN102266933A (en) * | 2010-06-03 | 2011-12-07 | 北京北方恒利科技发展有限公司 | Variable flow electromagnetic low pressure filling method for aluminum alloy molten solution |
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JP3614598B2 (en) * | 1997-02-07 | 2005-01-26 | ヤマハ発動機株式会社 | Casting device filter and casting device |
JP4355612B2 (en) * | 2004-05-25 | 2009-11-04 | 株式会社東京軽合金製作所 | Control method of low pressure casting machine |
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Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3214922A1 (en) * | 1982-04-22 | 1983-11-03 | Norsk Hydro Magnesiumgesellschaft mbH, 4300 Essen | Method for casting molten metals, in particular magnesium, with a low-pressure casting device |
CN1569363A (en) * | 2003-07-21 | 2005-01-26 | 陆仁志 | Liquid surface suspension pressurization control method for low-pressure casting machine |
CN101117669A (en) * | 2007-09-15 | 2008-02-06 | 中北大学 | D.C. electromagnetic purifying method for molten aluminum silicon alloy |
CN102266933A (en) * | 2010-06-03 | 2011-12-07 | 北京北方恒利科技发展有限公司 | Variable flow electromagnetic low pressure filling method for aluminum alloy molten solution |
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