CN103831579A - Machining method of complex casting with non-circular cross section - Google Patents
Machining method of complex casting with non-circular cross section Download PDFInfo
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- CN103831579A CN103831579A CN201210473172.1A CN201210473172A CN103831579A CN 103831579 A CN103831579 A CN 103831579A CN 201210473172 A CN201210473172 A CN 201210473172A CN 103831579 A CN103831579 A CN 103831579A
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Abstract
The invention discloses a machining method of a complex casting with a non-circular cross section. In the casting machining surface, through setting and machining of process margin and removal of the machining margin, the size and shape relationship between complex surfaces is established; through the measurement of wall thickness, a machined outer surface is used as a standard, layout inspection is conducted on the casting, and whether the size accuracy of a non-machined surface of the casting meets the requirements of subsequent machining or not is judged; a special tool is used for reducing heat treatment deformation of the casting; a rough machining standard of the casting is determined according to heat treatment detection data, and subsequent machining is conducted; analysis is conducted on the deformation trend and the deformation amount of all processes for casting manufacturing, anti-deformation design is conducted on the casting in advance, and the pass percent of the sizes of castings is improved. The machining method belongs to the field of casting, is high in universality and suitable for complex castings manufactured through various materials and various methods; the casting accuracy of the machining method is improved by one to three levels on the basis of an original casting method, the machining finished product rate is increased, energy consumption and the part manufacturing cost are lowered, and the manufacturing cycle is shortened.
Description
Technical field
The present invention relates to a kind of processing method of foundry goods, relate more specifically to a kind of processing method of on-circular cross-section intricate casting, it is applicable to the ferrous metal intricate casting manufacture fields such as the non-ferrous metal such as aluminium alloy, magnesium alloy and cast iron, cast steel, high temperature alloy.
Background technology
Along with manufacturing development such as Aeronautics and Astronautics, boats and ships, weapons, automobiles, past, many discrete parts were by welding or riveted the parts of composition, for alleviating construction weight, reduce costs or increase the needs such as integral rigidity and reliability, requirement changes monoblock cast into, and the requirement of foundry goods is more and more accurate, complicated, large-scale.
For on-circular cross-section class complex parts, the high-precision surfaces such as outer mold surface, fitting surface generally ensure by follow-up machining, and the surface such as inner chamber profile, difficult working position, by cast form, is part wall thickness between interior outer mold surface.Due to abnormal shape, the asymmetry of this body structure, casting dimension accuracy ensures that difficulty is large, and reason is as follows:
1, in castings production, technological process is long, and processing quality control difficulty is large, and the each position of process of setting medium casting solidification sequence, thermal environment and casting mold deformation drag are all different, and casting dimension accuracy is difficult to ensure card;
2, in the follow-up technical process such as heat treatment, machining, affected by force, also can there is distortion in various degree in foundry goods, and deformation tendency and size are difficult to prediction.
In general, after the machined removal machine-finish allowance of foundry goods, obtain part, but for on-circular cross-section intricate casting, because each portion structure dimension relationship is strong, in each process inspection, there is blind area in traditional chi inspection, the line equidimension method of inspection, cannot be comprehensively, accurate response foundry goods actual size precision and form and position tolerance, therefore, often there is the thin problem of partial wall in part after machining, cannot meet detail drawing requirement, and the thin position of wall presents very large dispersiveness, immediate cause often be can not determine.Caused on-circular cross-section intricate casting in casting and following process process, very easily, because dimension overproof causes scrapping, finished part rate is low, and manufacturing cost is high.If the mode of taking non-processing casting plane to increase technique subsidy can cause again pts wt significantly to exceed design objective, even can affect the use of part.So in such Mechanical processing of casting process, casting dimension detects and precision control is the difficult point of casting field.
Summary of the invention
The invention discloses a kind of on-circular cross-section intricate casting processing method, aim to provide a kind of difficult point that can effectively overcome intricate casting size detection and precision control, ensure each process dimension required precision, the Mechanical processing of casting method of highly versatile.
Adopting process method of the present invention is to be undertaken by following step:
(1) process allowance design: in casting design, except arranging machine-finish allowance at part machined surface routinely, at the machined surface of foundry goods, the more certain thickness metal level surplus of extra increase is as process allowance, and process allowance is also additionally set again.The factors such as the size of process allowance and the complexity of casting structure, processing complexity are relevant, meeting on the basis that step (2) requires, choose minimum of a value as far as possible.Process allowance is traditionally arranged to be 0.1mm～6mm.
(2) process allowance is removed: after foundry goods casts out, before heat treatment, increase by a procedure foundry goods roughing, by machining benchmark, the each machined surface of foundry goods is carried out to machining, remove the process allowance that step (1) arranges, cast outer surface is all machined to without casting casting skin, by machining, make the each machined surface of foundry goods set up size associated with morpheme, form accurate machining profile at the each machined surface of foundry goods.
This machining profile can be used as the datum level of follow-up measurement, in conjunction with the measurement data of casting section thickness, compares with theoretical wall thickness, judges whether foundry goods as cast condition, heat treatment state machine-finish allowance meet following process requirement.
(3) foundry goods detects: after processing taking step (2), the machining profile of foundry goods is as benchmark, adopt the testing tools such as line, chi inspection, ultrasonic wave, clamp, foundry goods is carried out to layout inspection, in conjunction with the measurement data of casting section thickness, by actual wall thickness and theoretical wall thickness, also be part wall thickness and machine-finish allowance sum, compare, judge whether the non-size of finished face precision of foundry goods meets following process and require: if local actual wall thickness is less than theoretical wall thickness, according to manufacturing acceptance requirement, take the measures such as school shape or repair welding to remedy for this partial wall is thin; If local actual wall thickness is greater than theoretical wall thickness, can take the measures such as polishing to carry out loss of weight for the super thick point in this part; Scrap at casting process for the foundry goods that cannot remedy.
(4) heat treatment and Deformation control: definite machining profile is brought convenience to heat treatment deformation control and school shape.Step (3) is processed to foundry goods after treatment heat-treats; After heat treatment, according to detecting the testing tools such as model, edge of a knife chi, flat board, machining profile is measured, according to size of finished face deviation, judge whether heat treating castings Deformation control meets following process requirement, proofread and correct for overproof foundry goods, timing can adopt special school shape, dimension shape frock to proofread and correct casting dimension, scraps at heat treatment step for saving foundry goods.
Can design, use special tooling to suppress heat treating castings distortion.When heat treatment, for machining outer mold surface, can utilize special heat treatment tooling, detection frock, school shape frock, dimension shape frock etc., reduce heat treating castings distortion.The machining profile forming in step (2), also can be used as the datum level of subsequent heat treatment frock, school shape, dimension shape.
(5) machining: detect data by heat treatment and determine roughing benchmark, carry out follow-up machining.
On the basis of such scheme, also can carry out technological compensa tion:
Detection data to some foundry goods gather, analyze, can react comprehensively, accurately like this change in size situation of foundry goods, present the regular position changing for casting dimension, in step (1), adjust shape and the size of non-processing casting profile in casting design by amendment, carry out pre-reversible deformation technological compensa tion, improve by process cycles, improve constantly the dimensional accuracy of subsequent production foundry goods.
Beneficial effect of the present invention:
1,, because the present invention increases certain thickness process allowance in foundry goods outer mold surface, after machining is removed, thereby can set up size and the morpheme relation between each complex profile, thereby also greatly reduce the overproof scrappage causing of casting dimension.
2, set up after the size and morpheme relation between each complex profile, by the measurement of actual wall thickness, can reflect non-processing casting surface dimensional accuracy and the accuracy of form and position comprehensively, quantize the examination requirements of each operation, dimensional problem is judged in advance, processed, reduce after-cost.
3, after roughing outer mold surface size accurately, smooth surface, for heat treatment tooling designs, is installed and brings convenience; And according to definite profile can design specialized detection limit utensil, school shape and dimension shape frock, by machine being added to the Quick Measurement of profile, the deformation tendency of indirect reaction foundry goods and school shape effect, improve the utilization rate of product.
4, this method has improved the detection quality of foundry goods as cast condition and following process process thereof, and detection data provide Data support for subsequent technique, frock optimization.
5, this method highly versatile, be applicable to the intricate casting of various materials, produced in several ways, dimensional accuracy can improve 1-3 grade on former methodical basis, improve the processed finished products rate of intricate casting, significantly reduce the cost of goods manufactured of complex parts, reduce energy consumption, shortened the manufacturing cycle.
Brief description of the drawings
Fig. 1 is the undressed starting section of Complex Aluminum Alloy foundry goods schematic diagram
Fig. 2 is the partial enlarged drawing of Fig. 1
Fig. 3 is schematic cross-section after the roughing of Complex Aluminum Alloy foundry goods
Fig. 4 is the partial enlarged drawing of Fig. 3
Figure acceptance of the bid score not Biao Shi: 1-parts profile, 2-machine-finish allowance, 3-process allowance.
Detailed description of the invention
Below, by reference to the accompanying drawings and specific embodiment, working of an invention mode is further described.
Now with a possible embodiments coordinate accompanying drawing to be described in detail as follows preferably:
Taking shape of a saddle aluminum alloy part as typical parts, material ZL114A, T6 heat treatment, length is 1100mm, as shown in Figure 1, part is made up of inside and outside two circular arcs and three planes typical section size, and inner chamber is long and narrow, covering wall thickness 2.5 ± 0.5mm, facet wall thickness 2.5 ± 0.5mm, large flat wall thickness 4 ± 0.5mm, external diameter R270mm, internal diameter R220mm, inside and outside circular arc decentraction.Because casting structure size is large, cross section special-shaped, in casting, heat treatment and following process process, easily there is actuating and the distortion of plane of arc surface, while causing by theoretical contour machining, part wall unevenness is even, and often due to thin overproof the scrapping of part that cause of partial wall, part passing rate of processing is low.
Detailed description of the invention is undertaken by following processing step:
(1) process allowance design: inner cavity of component is narrow and small, cannot process, and inner chamber profile is by casting direct forming, outer mold surface is machining surface entirely, as shown in Figure 1,, except having increased machine-finish allowance+5mm, design routinely also increased+process allowance layer that 2mm is thick at part outer surface.Foundry goods theoretical size: external diameter R277mm, internal diameter R213mm, covering, facet wall thickness are 9.5mm, large flat wall thickness is 11mm; According to casting design figure, carry out casting technique and casting Fixture Design, after the neat cover of frock, organize castings production.
(2) process allowance is removed: after foundry goods casts out, foundry goods actual size and theoretical size exist certain deviation, therefore, before heat treatment, increase foundry goods roughing operation, by benchmark centering, by operations such as car, boring, millings, remove process allowance+2mm, cross sectional shape as shown in Figure 2.After roughing, set up accurate size associated with morpheme between each outer mold surface: foundry goods external diameter is R275mm, internal diameter is R215mm, and the theoretical wall thickness of covering and facet is that 7.5mm, large plane theory wall thickness are 9mm.
(3) foundry goods detects: adopt line, chi inspection to determine foundry goods boss, rib position dimension, adopt ultrasonic wall thickness measuring instrument to measure foundry goods covering and flat wall thickness, by discussing wall ratio with various foliation, judge whether the non-processing surface of internal cavity of foundry goods meets following process requirement.For overproof foundry goods, according to testing result and acceptance requirement, the processing such as carry out repair welding, school shape, polish, scrap.
(4) heat treatment detection and Deformation control: foundry goods carries out T6 heat treatment, use heat treatment special to retrain each machine and add outer mold surface, rear end face uses stifled dish fixing, use from back to front 4 chucks, between stifled dish and chuck, use pull bar to be linked as entirety, preset clearance 0.5mm, retrains radially and torsional deformation; After solid solution, adopt R275.5 and R214.5 model inspection+clearance gauge Quick Measurement arc surface degree of conformity, adopt edge of a knife chi, the large plane of platform fast detecting and faceted flatness, can adopt the instruments such as pull bar, strut, moulding backing plate, hydraulic press to correct shape for overproof position; After packing dimension shape frock after the shape of school into, carry out Ageing Treatment, large plane position integral plaster applies, external arc, interior circular arc and facet preset clearance 0.3mm.Heat treating castings distortion can be controlled in 0.5mm;
(5) machining: detect data by heat treatment and determine benchmark, carry out the roughing of foundry goods, subsequent handling can detect data cases according to wall thickness, fine setting fine finishining benchmark, carries out wall thickness compensation;
(6) technological compensa tion: after this part is processed 10, each operation is detected to data and analyze, part circular arc presents the trend of outwards opening; Core cavity casting profile is adjusted, and internally circular arc thickens 0.5mm～1.5mm, external arc attenuate 0.5mm～1 mm by the subsidy of distortion size.Through producing checking, casting dimension meets following process and manufactures requirement.Mechanical processing of casting qualification rate is brought up to more than 80% by 25%.
This method, through actual production test, for the development of on-circular cross-section intricate casting, can produce very large economic benefit, has very strong application prospect.
The foregoing is only better possible embodiments of the present invention, not thereby limit to the scope of the claims of the present invention, therefore the equivalent structure that every utilization description of the present invention and accompanying drawing content are done changes, be all contained in protection scope of the present invention.
Claims (6)
1. an on-circular cross-section intricate casting processing method, comprises the steps:
(1) process allowance design: in casting design, except arranging machine-finish allowance at part machined surface routinely, at the machined surface of foundry goods, then process allowance is additionally set;
(2) process allowance is removed: after foundry goods casts out, by machining benchmark, the each machined surface of foundry goods is carried out to machining, remove the process allowance that step (1) arranges, make the each machined surface of foundry goods set up size associated with morpheme, form accurate machining profile at the each machined surface of foundry goods;
(3) foundry goods detects: after processing taking step (2), the machining profile of foundry goods, as benchmark, is carried out layout inspection to foundry goods, judges whether the non-size of finished face precision of foundry goods meets following process requirement;
(4) heat treatment and Deformation control: step (3) is processed to foundry goods after treatment and heat-treat, machining profile is measured, according to size of finished face deviation, judge that whether heat treating castings Deformation control meets following process requirement, proofreaies and correct for overproof foundry goods;
(5) machining: detect data by heat treatment and determine roughing benchmark, carry out follow-up machining.
2. on-circular cross-section intricate casting processing method according to claim 1, is characterized in that,
Process allowance described in step (1) is set to 0.1mm～6mm.
3. on-circular cross-section intricate casting processing method according to claim 1, is characterized in that,
Machining profile described in step (2) can be used as the datum level of follow-up measurement, in conjunction with the measurement data of casting section thickness, compares with theoretical wall thickness, judges whether foundry goods as cast condition, heat treatment state machine-finish allowance meet following process requirement.
4. on-circular cross-section intricate casting processing method according to claim 1, is characterized in that,
In step (3), foundry goods is carried out after layout inspection, actual wall thickness and theoretical wall thickness are compared, if local actual wall thickness is less than theoretical wall thickness, take school shape or repair welding measure to remedy to this partial wall is thin; If local actual wall thickness is greater than theoretical wall thickness, take polishing measure to carry out loss of weight to the super thick point in this part.
5. on-circular cross-section intricate casting processing method according to claim 1, is characterized in that, the machining profile forming in step 2, as the datum level of subsequent heat treatment frock, school shape, dimension shape.
6. on-circular cross-section intricate casting processing method according to claim 1, it is characterized in that, present the regular position changing for casting dimension, in step (1), adjust shape and the size of non-processing casting profile in casting design by amendment, carry out pre-reversible deformation technological compensa tion.
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104439977A (en) * | 2014-12-03 | 2015-03-25 | 北京航星机器制造有限公司 | Rapid manufacturing method of symmetric apron board type casting aluminum alloy parts |
| 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 |
| CN105643193A (en) * | 2014-11-14 | 2016-06-08 | 陕西飞机工业（集团）有限公司 | Optimization method for aluminum alloy forging blank in hot forging state |
| CN105974882A (en) * | 2016-04-28 | 2016-09-28 | 北京小米移动软件有限公司 | Processing method, device, apparatus and product to be processed |
| CN111975303A (en) * | 2020-08-27 | 2020-11-24 | 西藏大学 | Method for manufacturing supporting seat for separating effective ingredients of plant medicines |
| CN112008341A (en) * | 2020-08-28 | 2020-12-01 | 成都凯迪精工科技有限责任公司 | Method for improving machining quality of wing-shaped part |
| CN114046757A (en) * | 2021-11-09 | 2022-02-15 | 中国电子科技集团公司第二十九研究所 | Method for accurately controlling wall thickness of fine liquid cooling runner |
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| CN102319989A (en) * | 2011-09-06 | 2012-01-18 | 上海交通大学 | Manufacturing method of airplane horizontal tail beam edge strip |
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Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105643193A (en) * | 2014-11-14 | 2016-06-08 | 陕西飞机工业（集团）有限公司 | Optimization method for aluminum alloy forging blank in hot forging state |
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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 |
| CN105974882A (en) * | 2016-04-28 | 2016-09-28 | 北京小米移动软件有限公司 | Processing method, device, apparatus and product to be processed |
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| CN111975303A (en) * | 2020-08-27 | 2020-11-24 | 西藏大学 | Method for manufacturing supporting seat for separating effective ingredients of plant medicines |
| CN112008341A (en) * | 2020-08-28 | 2020-12-01 | 成都凯迪精工科技有限责任公司 | Method for improving machining quality of wing-shaped part |
| CN112008341B (en) * | 2020-08-28 | 2022-05-13 | 成都凯迪精工科技有限责任公司 | Method for improving machining quality of wing-shaped part |
| CN114046757A (en) * | 2021-11-09 | 2022-02-15 | 中国电子科技集团公司第二十九研究所 | Method for accurately controlling wall thickness of fine liquid cooling runner |
| CN114046757B (en) * | 2021-11-09 | 2022-07-15 | 中国电子科技集团公司第二十九研究所 | Method for accurately controlling wall thickness of fine liquid cooling runner |
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Application publication date: 20140604 |