CN104439086A - Design method for risers during sand mould casting of non-axisymmetric complex castings - Google Patents

Abstract

The invention discloses a design method for risers during sand mould casting of non-axisymmetric complex castings, and relates to a design method for risers during sand mould casting. The method disclosed by the invention comprises the following steps: 1. obtaining shrinkage defect distribution characteristics; 2. using single risers for shrinkage defects which are distributed in an aggregating manner and located in a lower sand mould; 3. calculating the dimensions of the risers of the shrinkage defects which are distributed in the aggregating manner and located in the lower sand mould; 4. using single risers for shrinkage defects which are distributed in an aggregating manner and located in an upper sand mould; 5. calculating the dimensions of the risers of the shrinkage defects which are distributed in the aggregating manner and located in the upper sand mould; 6. properly moving an inner gate according to a mode of sequentially cooling from bottom to top, and designing the position of the inner gate at the mass equalization part of the non-axisymmetric complex castings, thus finishing a design for the risers during sand mould casting of the non-axisymmetric complex castings. The method disclosed by the invention is applied to the field of sand mould casting.

Description

The method for designing of rising head in a kind of non-axis symmetry intricate casting sand casting process

Technical field

The present invention relates to the method for designing of rising head in a kind of sand casting process.

Background technology

In non-axis symmetry intricate casting (such as, automobile engine, train hitch, ship cylinder) sand casting forming process, and easily produce shrinkage defect.Shrinkage porosite is very large to the Effect on Mechanical Properties of foundry goods.If the shrinkage porosite of certain volume mark appears in crucial loading end, scrap directly causing foundry goods.Because cast shape is complicated, the position producing shrinkage porosite is very scattered, and casting technique developer is difficult to the judgement position that shrinkage porosite may occur being had to a clear and definite, therefore there is blind spot when technological design.

Adopt experiment trial-and-error method analysis and control shrinkage defect in non-axis symmetry intricate casting casting process and formed, cause the waste of great human and material resources, financial resources and the energy, improve the added value of cast product, weaken Chinese Foundry producer competitiveness in the international market.

Along with computer simulation technique and the theoretical development of modern casting, Casting Numerical Simulation technology Flow Field Distribution and thermo parameters method thus enter the practical stage in prediction Formation of Shrinkage Porosity position in simulation study casting process.Develop a lot of casting simulation software (such as, ProCast, ViewCast, MagmaSoft) commercialization in the world.Position is produced according to the shrinkage defect adopting conventional casting techniques Computer Simulation to obtain, casting system is revised, technology of numerical simulation is utilized to instruct casting process, not only can shorten the trial-produce period of cast product, reduce costs, energy-saving and emission-reduction, also meet " high-tech leads Green foundry process " such Scientific Outlook on Development.

The method of current extensive adopted elimination shrinkage defect is: iron chill shock chilling method, pouring technology adjusting method and riser feeding method.Iron chill shock chilling method is not suitable for the production of non-axis symmetry intricate casting because manufacture that the complex-curved chill difficulty of laminating is large, machine adds that cost is high, waste man-hour.Namely pouring technology adjusting method improves pouring temperature, and the method requires high to casting equipment, and alloy pouring temperature is high, easily produces air-breathing problem, improves the risk producing gas hole defect.Rising head method is extensive adopted method, and the method not only can control shrinkage porosite and produce region (shrinkage defect being moved apart foundry goods key job face), also has the effect of exhaust collection slag.But Problems existing is in the use procedure of rising head method: Riser Dimensions designed conference waste metal material, thus increased production cost; Riser Dimensions design is too small, can not carry out effective feeding, uncontrollable shrinkage defect; Riser Dimensions design is excessive, also can increase local solidification time, cause local solidification to organize thick, reduces mechanical castings and foundry goods machinability.

Summary of the invention

The present invention be to solve existing rising head method cannot the technical problem of careful design Riser Dimensions, thus provide the method for designing of rising head in a kind of non-axis symmetry intricate casting sand casting process.

In a kind of non-axis symmetry intricate casting sand casting process of the present invention, the method for designing of rising head is carried out according to the following steps:

One, shrinkage defect distribution characteristics is obtained: the Riser Dimensions formulated in employing conventional casting techniques, number and position, carry out the Computer Simulation of the three-dimensional cavity filling process of cast casting process and Three-dimensional Heat-transfer process, by thermoisopleth enclosed region be shrinkage porosite produce district, be greater than according to shrinkage porosite rate the standard that 0.7% is shrinkage defect, the distribution of display shrinkage defect in foundry goods simultaneously;

Two, single rising head is adopted for Assembled distribution, the shrinkage defect be in the sand mold of bottom

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}}{h}_{\mathrm{rejie}-\mathrm{cylinder}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}}+h_{\mathrm{rejie}-\mathrm{cylinder}})},$ Wherein, r _{rejie-cylinder}for thermal center bottom cylindrical face radius, h _{rejie-cylinder}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-max}=1.1M _{rejie-cylinder}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -1}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylingder}}={\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{cylinder}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein, η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-1}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -1}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -1})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-1=1.2d _maokou-1; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-1=d _maokou-max-1, riser height h _maokou-1=1.2d _maokou-1;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, adopt thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _rejie-spherefor the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-max}=1.1M _rejie-sphere; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -2}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\max }}{0.178};$

The volume of thermal center ball if be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-2}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -2}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -2})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-2=1.2d _maokou-2; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-2=d _maokou-max-2, riser height h _maokou-2=1.2d _maokou-2;

Three, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of bottom

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N1 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-3-i}, rising head diameter d _{maokou-cylinder-3-i}with riser height h _{maokou-cylinder-3-i}, i value 1 ~ N1; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N2 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-3-j}, rising head diameter d _{maokou-sphere-3-j}with riser height h _{maokou-sphere-3-j}, j value 1 ~ N2; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head.Overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-3}={({\mathrm{\Σ}}_{i=1}^{N1}{M}_{\mathrm{maokou}-\mathrm{cylinder}-3-i}^2+{\mathrm{\Σ}}_{j=1}^{N2}{M}_{\mathrm{maokou}-\mathrm{sphere}-3-j})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-3=1.2d _maokou-all-3;

Four, single rising head is adopted for integrated distribution, the shrinkage defect be in the sand mold of top

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}+h_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}})},$ Wherein, r _{rejie-cylinder-up}for thermal center bottom cylindrical face radius, h _{rejie-cylinder-up}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-up-max}=1.1M _{rejie-cylinder-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -4}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylingder}-\mathrm{up}}={\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-4}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -4}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -4})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-4=1.2d _maokou-4; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-4=d _maokou-max-4, riser height h _maokou-4=1.2d _maokou-4; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-4}if add extended height h _{maokou-yanshen-4}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-4with extended height h _{maokou-yanshen-4}sum; Otherwise, final riser height for riser height h _maokou-4;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, utilize thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _{rejie-sphere-up}for the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-up-max}=1.1M _{rejie-sphere-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -5}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center ball $V_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}=\frac{4}{3}{\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}^3,$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit $d_{\mathrm{maokou}-\min -5}={\left(\frac{{\mathrm{\ηV}}_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}}{0.811}\right)}^{1/3},$ Wherein, η is solidification shrinkage rate, wherein ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-5}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -5}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -5})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-5=1.2d _maokou-5; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-5=d _maokou-max-5, riser height h _maokou-5=1.2d _maokou-5; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-5}if add extended height h _{maokou-yanshen-5}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-5with extended height h _{maokou-yanshen-5}sum; Otherwise, final riser height for riser height h _maokou-5;

Five, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of top

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N3 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-6-k}, rising head diameter d _{maokou-cylinder-6-k}with riser height h _{maokou-cylinder-6-k}, k value 1 ~ N3; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N4 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-6-t}, rising head diameter d _{maokou-sphere-6-t}with riser height h _{maokou-sphere-6-t}, t value 1 ~ N4; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head, overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-6}={({\mathrm{\Σ}}_{k=1}^{N3}{M}_{\mathrm{maokou}-\mathrm{cylinder}-6-k}^2+{\mathrm{\Σ}}_{t=1}^{N4}{M}_{\mathrm{maokou}-\mathrm{sphere}-6-t})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-6=1.2d _maokou-all-6; The top end face of rising head preferably should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-6}if add extended height h _{maokou-yanshen-6}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-all-6with extended height h _{maokou-yanshen-6}sum; Otherwise, final riser height for riser height h _maokou-all-6;

Six, the basis order type of cooling from bottom to top, suitably moved by ingate, ingate Position Design, in the equal office of non-axis symmetry intricate casting quality, namely completes the design of rising head in non-axis symmetry intricate casting sand casting process.

The present invention includes following beneficial effect:

The present invention can careful design Riser Dimensions, thus develops the method for designing of rising head in a kind of non-axis symmetry intricate casting sand casting process, for actual production provides foundation, in theoretical and practical application, all there is significance.

The present invention is non-axis symmetry intricate casting, for the cast of non-axis symmetry foundry goods, require that the position of ingate wants to ensure that the right and left fills type liquid and respectively reaches 50%, the generation of cold shut to be avoided simultaneously and make foundry goods uneven, for this reason, ingate is made suitable movement, and move right 97mm on the original basis, and move up 57mm.Ingate diameter is Ф 60mm, and the filling velocity in ingate is V=0.76m/s, produces expulsion events, so this speed meets the requirement of Stable Filling when filling velocity reaches 2.3m/s.

Accompanying drawing explanation

Fig. 1 is the 3-D view of sandbox and foundry goods; Wherein, 1-1 is die joint, and 1-2 is top sandbox, and 1-3 is bottom sandbox, and 1-4 is parting;

Fig. 2 is conventional casting techniques 3 dimensional drawing front view; Wherein, 2-1 is ingate;

Fig. 3 is the casting technique 3 dimensional drawing front view after optimizing; Wherein, 3-1 is ingate, and 3-2 is rising head 1,3-3 be rising head 2,3-4 be rising head 3,3-5 be rising head 5,3-6 is rising head 6;

Fig. 4 is conventional casting techniques 3 dimensional drawing rearview; Wherein, 4-1 is ingate;

Fig. 5 is the casting technique 3 dimensional drawing rearview after optimizing; Wherein, 5-1 is ingate, and 5-2 is rising head 4;

Fig. 6 is conventional casting techniques defect shrinkage defect Target area rearview;

Fig. 7 is the casting technique shrinkage defect Target area rearview after optimizing;

Fig. 8 is conventional casting techniques defect shrinkage defect Target area top view;

Fig. 9 is the casting technique shrinkage defect Target area top view after optimizing;

Figure 10 is conventional casting techniques defect shrinkage defect Target area front view;

Figure 11 is the casting technique shrinkage defect Target area front view after optimizing;

The gathering shrinkage defect location of Figure 12 corresponding to rising head 1;

The foundry goods position of the gathering shrinkage defect of Figure 13 corresponding to rising head 1; Wherein, 13-1 is the cast outer surface of rising head 1,13-2 corresponding to defect is regular curved surface and plane;

The gathering shrinkage defect location of Figure 14 corresponding to rising head 2;

The foundry goods position of the gathering shrinkage defect of Figure 15 corresponding to rising head 2; Wherein, 15-1 is that the cast outer surface of rising head 2,15-2 corresponding to defect exists projection (irregular face);

The discrete shrinkage defect S1 location of Figure 16 corresponding to rising head 4; Wherein, 16-1 is S1 location;

The discrete shrinkage defect S2 location of Figure 17 corresponding to rising head 4; Wherein, 17-1 is S2 location;

The discrete shrinkage defect S3 location of Figure 18 corresponding to rising head 4; Wherein, 18-1 is S3 location;

The foundry goods position of the discrete shrinkage defect of Figure 19 corresponding to rising head 4; Wherein, 19-1 is the cast outer surface of rising head 4,19-2 corresponding to defect is ruled surface;

The discrete shrinkage defect T1 location of Figure 20 corresponding to rising head 5; Wherein, 20-1 is T1 location;

The discrete shrinkage defect T2 location of Figure 21 corresponding to rising head 5; Wherein, 21-1 is T2 location;

The discrete shrinkage defect T3 location of Figure 22 corresponding to rising head 5; Wherein, 22-1 is T3 location;

The foundry goods position of the discrete shrinkage defect of Figure 23 corresponding to rising head 5; Wherein, 23-1 is the cast outer surface of rising head 5,23-2 corresponding to defect T1 is ruled surface; The cast outer surface of 23-3 corresponding to defect T2 is regular planar; The cast outer surface of 23-4 corresponding to defect T3 is regular planar.

Detailed description of the invention

Detailed description of the invention one: in a kind of non-axis symmetry intricate casting sand casting process of present embodiment, the method for designing of rising head is carried out according to the following steps:

One, shrinkage defect distribution characteristics is obtained: the Riser Dimensions formulated in employing conventional casting techniques, number and position, carry out the Computer Simulation of the three-dimensional cavity filling process of cast casting process and Three-dimensional Heat-transfer process, by thermoisopleth enclosed region be shrinkage porosite produce district, be greater than according to shrinkage porosite rate the standard that 0.7% is shrinkage defect, the distribution of display shrinkage defect in foundry goods simultaneously;

Two, single rising head is adopted for Assembled distribution, the shrinkage defect be in the sand mold of bottom

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}}{h}_{\mathrm{rejie}-\mathrm{cylinder}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}}+h_{\mathrm{rejie}-\mathrm{cylinder}})},$ Wherein, r _{rejie-cylinder}for thermal center bottom cylindrical face radius, h _{rejie-cylinder}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-max}=1.1M _{rejie-cylinder}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -1}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylingder}}={\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{cylinder}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein, η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-1}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -1}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -1})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-1=1.2d _maokou-1; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-1=d _maokou-max-1, riser height h _maokou-1=1.2d _maokou-1;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, adopt thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _rejie-spherefor the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-max}=1.1M _rejie-sphere; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -2}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\max }}{0.178};$

The volume of thermal center ball if be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-2}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -2}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -2})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-2=1.2d _maokou-2; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-2=d _maokou-max-2, riser height h _maokou-2=1.2d _maokou-2;

Three, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of bottom

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N1 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-3-i}, rising head diameter d _{maokou-cylinder-3-i}with riser height h _{maokou-cylinder-3-i}, i value i ~ N1; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N2 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-3-j}, rising head diameter d _{maokou-sphere-3-j}with riser height h _{maokou-sphere-3-j}, j value 1 ~ N2; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head.Overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-3}={({\mathrm{\Σ}}_{i=1}^{N1}{M}_{\mathrm{maokou}-\mathrm{cylinder}-3-i}^2+{\mathrm{\Σ}}_{j=1}^{N2}{M}_{\mathrm{maokou}-\mathrm{sphere}-3-j})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-3=1.2d _maokou-all-3;

Four, single rising head is adopted for integrated distribution, the shrinkage defect be in the sand mold of top

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}+h_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}})},$ Wherein, r _{rejie-cylinder-up}for thermal center bottom cylindrical face radius, h _{rejie-cylinder-up}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-up-max}=1.1M _{rejie-cylinder-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -4}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylingder}-\mathrm{up}}={\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-4}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -4}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -4})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-4=1.2d _maokou-4; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-4=d _maokou-max-4, riser height h _maokou-4=1.2d _maokou-4; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-4}if add extended height h _{maokou-yanshen-4}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-4with extended height h _{maokou-yanshen-4}sum; Otherwise, final riser height for riser height h _maokou-4;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, utilize thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _{rejie-sphere-up}for the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-up-max}=1.1M _{rejie-sphere-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -5}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center ball $V_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}=\frac{4}{3}{\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}^3,$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit $d_{\mathrm{maokou}-\min -5}={\left(\frac{{\mathrm{\ηV}}_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}}{0.811}\right)}^{1/3},$ Wherein, η is solidification shrinkage rate, wherein ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-5}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -5}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -5})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-5=1.2d _maokou-5; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-5=d _maokou-max-5, riser height h _maokou-5=1.2d _maokou-5; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-5}if add extended height h _{maokou-yanshen-5}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-5with extended height h _{maokou-yanshen-5}sum; Otherwise, final riser height for riser height h _maokou-5;

Five, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of top

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N3 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-6-k}, rising head diameter d _{maokou-cylinder-6-k}with riser height h _{maokou-cylinder-6-k}, k value 1 ~ N3; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N4 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-6-t}, rising head diameter d _{maokou-sphere-6-t}with riser height h _{maokou-sphere-6-t}, t value 1 ~ N4; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head, overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-6}={({\mathrm{\Σ}}_{k=1}^{N3}{M}_{\mathrm{maokou}-\mathrm{cylinder}-6-k}^2+{\mathrm{\Σ}}_{t=1}^{N4}{M}_{\mathrm{maokou}-\mathrm{sphere}-6-t})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-6=1.2d _maokou-all-6; The top end face of rising head preferably should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-6}if add extended height h _{maokou-yanshen-6}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-all-6with extended height h _{maokou-yanshen-6}sum; Otherwise, final riser height for riser height h _maokou-all-6;

Six, the basis order type of cooling from bottom to top, suitably moved by ingate, ingate Position Design, in the equal office of non-axis symmetry intricate casting quality, namely completes the design of rising head in non-axis symmetry intricate casting sand casting process.

By following verification experimental verification beneficial effect of the present invention:

Test one: in a kind of non-axis symmetry intricate casting sand casting process of this test, the method for designing of rising head realizes according to the following steps:

One, shrinkage defect distribution characteristics is obtained: the Riser Dimensions formulated in employing conventional casting techniques, number and position, carry out the Computer Simulation of the three-dimensional cavity filling process of cast casting process and Three-dimensional Heat-transfer process, by thermoisopleth enclosed region be shrinkage porosite produce district, be greater than according to shrinkage porosite rate the standard that 0.7% is shrinkage defect, the distribution of display shrinkage defect in foundry goods simultaneously;

Two, single rising head is adopted for Assembled distribution, the shrinkage defect be in the sand mold of bottom

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}}{h}_{\mathrm{rejie}-\mathrm{cylinder}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}}+h_{\mathrm{rejie}-\mathrm{cylinder}})},$ Wherein, r _{rejie-cylinder}for thermal center bottom cylindrical face radius, h _{rejie-cylinder}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-max}=1.1M _{rejie-cylinder}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -1}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylingder}}={\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{cylinder}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein, η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-1}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -1}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -1})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-1=1.2d _maokou-1; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-1=d _maokou-max-1, riser height h _maokou-1=1.2d _maokou-1;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, adopt thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _rejie-spherefor the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-max}=1.1M _rejie-sphere; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -2}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\max }}{0.178};$

The volume of thermal center ball if be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-2}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -2}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -2})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-2=1.2d _maokou-2; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-2=d _maokou-max-2, riser height h _maokou-2=1.2d _maokou-2;

Three, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of bottom

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N1 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-3-i}, rising head diameter d _{maokou-cylinder-3-i}with riser height h _{maokou-cylinder-3-i}, i value 1 ~ N1; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N2 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-3-j}, rising head diameter d _{maokou-sphere-3-j}with riser height h _{maokou-sphere-3-j}, j value 1 ~ N2; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head.Overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-3}={({\mathrm{\Σ}}_{i=1}^{N1}{M}_{\mathrm{maokou}-\mathrm{cylinder}-3-i}^2+{\mathrm{\Σ}}_{j=1}^{N2}{M}_{\mathrm{maokou}-\mathrm{sphere}-3-j})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-3=1.2d _maokou-all-3;

Four, single rising head is adopted for integrated distribution, the shrinkage defect be in the sand mold of top

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}+h_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}})},$ Wherein, r _{rejie-cylinder-up}for thermal center bottom cylindrical face radius, h _{rejie-cylinder-up}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-up-max}=1.1M _{rejie-cylinder-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -4}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylingder}-\mathrm{up}}={\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-4}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -4}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -4})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-4=1.2d _maokou-4; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-4=d _maokou-max-4, riser height h _maokou-4=1.2d _maokou-4; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-4}if add extended height h _{maokou-yanshen-4}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-4with extended height h _{maokou-yanshen-4}sum; Otherwise, final riser height for riser height h _maokou-4;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, utilize thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _{rejie-sphere-up}for the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-up-max}=1.1M _{rejie-sphere-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -5}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center ball $V_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}=\frac{4}{3}{\mathrm{\πr}}_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}^3,$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit $d_{\mathrm{maokou}-\min -5}={\left(\frac{{\mathrm{\ηV}}_{\mathrm{rejie}-\mathrm{sphere}-\mathrm{up}}}{0.811}\right)}^{1/3},$ Wherein, η is solidification shrinkage rate, $\mathrm{\η}=\frac{{\mathrm{\ρ}}_s-{\mathrm{\ρ}}_l}{{\mathrm{\ρ}}_s},$ Wherein ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-5}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -5}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -5})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-5=1.2d _maokou-5; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-5=d _maokou-max-5, riser height h _maokou-5=1.2d _maokou-5; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-5}if add extended height h _{maokou-yanshen-5}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-5with extended height h _{maokou-yanshen-5}sum; Otherwise, final riser height for riser height h _maokou-5;

Five, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of top

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N3 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-6-k}, rising head diameter d _{maokou-cylinder-6-k}with riser height h _{maokou-cylinder-6-k}, k value 1 ~ N3; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N4 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-6-t}, rising head diameter d _{maokou-sphere-6-t}with riser height h _{maokou-sphere-6-t}, t value 1 ~ N4; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head, overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-6}={({\mathrm{\Σ}}_{k=1}^{N3}{M}_{\mathrm{maokou}-\mathrm{cylinder}-6-k}^2+{\mathrm{\Σ}}_{t=1}^{N4}{M}_{\mathrm{maokou}-\mathrm{sphere}-6-t})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-6=1.2d _maokou-all-6; The top end face of rising head preferably should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-6}if add extended height h _{maokou-yanshen-6}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-all-6with extended height h _{maokou-yanshen-6}sum; Otherwise, final riser height for riser height h _mankou-all-6;

Six, the basis order type of cooling from bottom to top, suitably moved by ingate, ingate Position Design, in the equal office of non-axis symmetry intricate casting quality, namely completes the design of rising head in non-axis symmetry intricate casting sand casting process.

This test is track train hitch, and this hitch adopts E level steel making, and composition is as follows: C content 0.26%, Si content 0.47%, Mn content 1.32%, P content 0.03%, S content 0.03%, Cu content 0.2%, Ni content 0.5%, Cr content 0.4%, Mo content 0.2%.Adopt actual measurement cooling curve-numerical value anti-inference method to determine 1560 DEG C-1300 DEG C time, the interface heat exchange coefficient of E level steel-resin sand is about 813.72W/m ²k.Determine that pouring temperature is 1580 DEG C, filling time is 20s-25s, and sandbox material is resin sand, and sandbox is of a size of 1300 × 1000 × 800mm ³.Fig. 1 is the 3-D view of sandbox and foundry goods; Wherein, 1-1 is die joint, and 1-2 is top sandbox, and 1-3 is bottom sandbox, and 1-4 is parting.

This test is non-axis symmetry intricate casting, for the cast of non-axis symmetry foundry goods, require that the position of ingate wants to ensure that the right and left fills type liquid and respectively reaches 50%, the generation of cold shut to be avoided simultaneously and make foundry goods uneven, for this reason, ingate is made suitable movement (Fig. 2 and Fig. 3, Fig. 4 and Fig. 5), move right 97mm on the original basis, and move up 57mm.Ingate diameter is Ф 60mm, and the filling velocity in ingate is V=0.76m/s, produces expulsion events, so this speed meets the requirement of Stable Filling when filling velocity reaches 2.3m/s.

Fig. 6 is conventional casting techniques defect shrinkage defect Target area rearview; Fig. 7 is the casting technique shrinkage defect Target area rearview after optimizing; Fig. 8 is conventional casting techniques defect shrinkage defect Target area top view; Fig. 9 is the casting technique shrinkage defect Target area top view after optimizing; Figure 10 is conventional casting techniques defect shrinkage defect Target area front view; Figure 11 is the casting technique shrinkage defect Target area front view after optimizing; As can be seen from Fig., under optimizing Feeder Design condition, shrinkage defect is moved in rising head, ensure that casting quality.

The gathering shrinkage defect location of Figure 12 corresponding to rising head 1; The foundry goods position of the gathering shrinkage defect of Figure 13 corresponding to rising head 1; Wherein, 13-1 is the cast outer surface of rising head 1,13-2 corresponding to defect is regular curved surface and plane; The radius r of thermal center cylinder _{rejie-cylinder}and height h _{rejie-cylinder}can be measured by casting simulation software, wherein r _{rejie-cylinder}=0.044m, h _{rejie-cylinder}=0.0416m, the modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}}{h}_{\mathrm{rejie}-\mathrm{cylinder}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}}+h_{\mathrm{rejie}-\mathrm{cylinder}})}=0.0107m.$ Rising head 1 upper limit modulus M _{maokou-cylinder-max}=1.1M _{rejie-cylinder}=0.0118m.Rising head 1 upper limit diameter $d_{\mathrm{maokou}-\max -1}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\max }}{0.178}=0.066m.$ The volume of thermal center cylinder do not need to adopt feeding liquid measure method to calculate rising head 1 lower limit.Rising head 1 diameter d _maokou-1=d _maokou-max-1=0.066m, rising head 1 height h _maokou-1=1.2d _maokou-1=0.0792m.

The gathering shrinkage defect location of Figure 14 corresponding to rising head 2; The foundry goods position of the gathering shrinkage defect of Figure 15 corresponding to rising head 2; Wherein, 15-1 is that the cast outer surface of rising head 2,15-2 corresponding to defect exists projection (irregular face); The radius r of thermal center ball _reijie-ball=0.021m, the modulus of thermal center ball rising head 2 upper limit modulus M _{maokou-sphere-max}=1.1M _rejie-ball=0.0077m.Rising head 2 upper limit diameter $d_{\mathrm{maokou}-\max -2}=$ $\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\max }}{0.178}0.043m.$ The volume of thermal center ball so adopt feeding liquid measure method to calculate rising head 2 lower limit.Rising head 2 diameter limit $d_{\mathrm{maokou}-\min -2}={\left(\frac{{\mathrm{\ηV}}_{\mathrm{rejie}-\mathrm{ball}}}{0.811}\right)}^{1/3}=0.012m,$ Wherein η is solidification shrinkage rate $\mathrm{\η}=\frac{{\mathrm{\ρ}}_s-{\mathrm{\ρ}}_1}{{\mathrm{\ρ}}_s}=0.04.$ Rising head 2 diameter $d_{\mathrm{maokou}-2}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -2}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -2})}{(\mathrm{\α}+\mathrm{\β})}=0.035m,$ α and β be greater than 1 integer and β > α (α=1, β=3), rising head 2 height h _maokou-2=1.2d _maokou-2=0.042.

In test, there is another and locate single thermal center (not shown) in the position of closing on that hitch is positioned at drag box collar place, its concrete condition distributes consistent with the thermal center in Figure 15, then the design and calculation method of corresponding rising head 3 is identical with rising head 2, so no longer specifically set forth.By can be calculated rising head 3 diameter d _maokou-2=0.0305m, rising head 3 height h _maokou-2=1.2d _maokou-2=0.0366m.

The discrete shrinkage defect S1 location of Figure 16 corresponding to rising head 4; Wherein, 16-1 is S1 location; The discrete shrinkage defect S2 location of Figure 17 corresponding to rising head 4; Wherein, 17-1 is S2 location; The discrete shrinkage defect S3 location of Figure 18 corresponding to rising head 4; Wherein, 18-1 is S3 location; The foundry goods position of the discrete shrinkage defect of Figure 19 corresponding to rising head 4; Wherein, 19-1 is the cast outer surface of rising head 4,19-2 corresponding to defect is ruled surface; M _{maokou-cylinder-3-S1}=0.01m, M _{maokou-cylinder-3-S2}=0.013m, M _{maokou-cylinder-3-S3}=0.016m.Rising head diameter is respectively d _{maokou-cylinder-3-S1}=0.056m, d _{maokou-cylinder-3-S2}=0.073m, d _{maokou-cylinder-3-S3}=0.09m.With riser height h _{maokou-cylinder-3-S1}=0.067m, h _{maokou-cylinder-3-S2}=0.088m, h _{maokou-cylinder-3-S3}=0.108m.Between these adjacent rising heads, beeline is less than 0.01m, and these rising heads are merged as a whole rising head 4.Overall rising head 4 modulus $M_{\mathrm{maokou}-\mathrm{all}-3-S}={\left({\mathrm{\Σ}}_{i=1}^3{M}_{\mathrm{maokou}-\mathrm{cylinder}-3-i-S}^2\right)}^{1/2}=0.023m,$ Overall rising head 4 diameter $d_{\mathrm{maokou}-\mathrm{all}-3-S}=\frac{M_{\mathrm{maokou}-\mathrm{all}-3-S}}{0.178}=0.129m,$ Overall rising head 4 height h _{maokou-all-3-S}=1.2d _{maokou-all-3-S}=0.1548m.

The discrete shrinkage defect T1 location of Figure 20 corresponding to rising head 5; Wherein, 20-1 is T1 location; The discrete shrinkage defect T2 location of Figure 21 corresponding to rising head 5; Wherein, 21-1 is T2 location; The discrete shrinkage defect T3 location of Figure 22 corresponding to rising head 5; Wherein, 22-1 is T3 location; The foundry goods position of the discrete shrinkage defect of Figure 23 corresponding to rising head 5; Wherein, 23-1 is the cast outer surface of rising head 5,23-2 corresponding to defect T1 is ruled surface; The cast outer surface of 23-3 corresponding to defect T2 is regular planar; The cast outer surface of 23-4 corresponding to defect T3 is regular planar; M _{maokou-cylinder-6-T1}=0.011m, M _{maokou-cylinder-6-T2}=0.0037m, M _{maokou-cylinder-6-T3}=0.004m.Rising head diameter is respectively d _{maokou-cylinder-6-T1}=0.062m, d _{maokou-cylinder-6-T2}=0.021m, d _{maokou-cylinder-6-T3}=0.023m.Riser height is respectively h _{maokou-cylinder-6-T1}=0.075m, h _{maokou-cylinder-6-T2}=0.025m, h _{maokou-cylinder-6-T3}=0.028m.Between these adjacent rising heads, beeline is less than 0.01m, and these rising heads are merged as a whole rising head 5.Overall rising head 5 modulus $M_{\mathrm{maokou}-\mathrm{all}-6-T}={\left({\mathrm{\Σ}}_{k=1}^3{M}_{\mathrm{maokou}-\mathrm{cylinder}-6-k-T}^2\right)}^{1/2}=0.0123m,$ Overall rising head 5 diameter $d_{\mathrm{maokou}-\mathrm{all}-6-T}=\frac{M_{\mathrm{maokou}-\mathrm{all}-6-T}}{0.178}=0.0691m,$ Overall rising head 5 height h _{maokou-all-6-T}=1.2d _{maokou-all-6-T}=0.083m.Because rising head is in top sandbox, wish that it not only plays the effect of feeding, play simultaneously and prevent the effect of tired gas slag inclusion, therefore the top end face of rising head preferably should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-6-T}.At interpolation extended height h _{maokou-yanshen-6-T}front and back, rising head 5 differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height

In test, foundry goods head is in defect distribution situation (rising head 6 correspondence in the left side at sandbox position, top, not shown) identical with the defect distribution situation corresponding to rising head 5, also there is discrete distribution, be in the sand mold of top, shrinkage defect that cast outer surface that residing space is corresponding is regular face, overall rising head 6 pairs of shrinkage defects are set and carry out feeding.Rising head 6 computational methods are identical with rising head 5, solve overall rising head 6 modulus $M_{\mathrm{maokou}-\mathrm{all}-6-G}={\left({\mathrm{\Σ}}_{k=1}^3{M}_{\mathrm{maokou}-\mathrm{cylinder}-6-k-G}^2\right)}^{1/2}=0.014m$ Diameter $d_{\mathrm{maokou}-\mathrm{all}-6-G}=\frac{M_{\mathrm{maokou}-\mathrm{all}-6-G}}{0.178}=0.079m,$ Rising head 6 differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height

Claims (1)

1. the method for designing of rising head in non-axis symmetry intricate casting sand casting process, is characterized in that the method for designing of rising head in non-axis symmetry intricate casting sand casting process is carried out according to the following steps:

One, shrinkage defect distribution characteristics is obtained: the Riser Dimensions formulated in employing conventional casting techniques, number and position, carry out the Computer Simulation of the three-dimensional cavity filling process of cast casting process and Three-dimensional Heat-transfer process, by thermoisopleth enclosed region be shrinkage porosite produce district, be greater than according to shrinkage porosite rate the standard that 0.7% is shrinkage defect, the distribution of display shrinkage defect in foundry goods simultaneously;

Two, single rising head is adopted for Assembled distribution, the shrinkage defect be in the sand mold of bottom

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}}{h}_{\mathrm{rejie}-\mathrm{cylinder}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}}+h_{\mathrm{rejie}-\mathrm{cylinder}})},$ Wherein, r _{rejie-cylinder}for thermal center bottom cylindrical face radius, h _{rejie-cylinder}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-max}=1.1M _{rejie-cylinder}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -1}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylinder}}=\mathrm{\π}{r}_{\mathrm{rejie}-\mathrm{cylinder}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein, η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-1}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -1}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -1})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-1=1.2d _maokou-1; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-1=d _maokou-max-1, riser height h _maokou-1=1.2d _maokou-1;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, adopt thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _rejie-spherefor the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-max}=1.1M _rejie-sphere; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -2}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\max }}{0.178};$

The volume of thermal center ball if be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-2}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -2}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -2})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α; Riser height h _maokou-2=1.2d _maokou-2; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-2=d _maokou-max-2, riser height h _maokou-2=1.2d _maokou-2;

Three, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of bottom

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N1 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-3-i}, rising head diameter d _{maokou-cylinder-3-i}with riser height h _{maokou-cylinder-3-i}, i value 1 ~ N1; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N2 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-3-j}, rising head diameter d _{maokou-sphere-3-j}with riser height h _{maokou-sphere-3-j}, j value 1 ~ N2; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head.Overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-3}={({\mathrm{\Σ}}_{i=1}^{N_1}{M}_{\mathrm{maokou}-\mathrm{cylinder}-3-i}^2+{\mathrm{\Σ}}_{j=1}^{N_2}{M}_{\mathrm{maokou}-\mathrm{sphere}-3-j})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-3=1.2d _maokou-all-3;

Four, single rising head is adopted for integrated distribution, the shrinkage defect be in the sand mold of top

(1) when cast outer surface corresponding to space is regular face residing for shrinkage defect, adopt circumscribed cylinder to be wrapped up by shrinkage defect, adopt thermal center cylinder method to calculate Riser Dimensions;

The modulus of thermal center cylinder $M_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}=\frac{r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}}{2(r_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}+h_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}})},$ Wherein, r _{rejie-cylinder-up}for thermal center bottom cylindrical face radius, h _{rejie-cylinder-up}for thermal center cylinder is high, unit is rice; Rising head upper limit modulus M _{maokou-cylinder-up-max}=1.1M _{rejie-cylinder-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -4}=\frac{M_{\mathrm{maokou}-\mathrm{cylinder}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center cylinder $V_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}=\mathrm{\π}{r}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}}^2{h}_{\mathrm{rejie}-\mathrm{cylinder}-\mathrm{up}},$ If be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein η is solidification shrinkage rate, wherein, ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-4}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -4}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -4})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-4=1.2d _maokou-4; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-4=d _maokou-max-4, riser height h _maokou-4=1.2d _maokou-4; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-4}if add extended height h _{maokou-yanshen-4}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-4with extended height h _{maokou-yanshen-4}sum; Otherwise, final riser height for riser height h _maokou-4;

(2) when cast outer surface corresponding to space is irregular residing for shrinkage defect, adopt outer cut to be wrapped up by shrinkage defect, utilize thermal center ball to calculate Riser Dimensions;

The modulus of thermal center ball wherein, r _{rejie-sphere-up}for the thermal center radius of a ball, unit is rice; Rising head upper limit modulus M _{maokou-sphere-up-max}=1.1M _{rejie-sphere-up}; Rising head upper limit diameter $d_{\mathrm{maokou}-\max -5}=\frac{M_{\mathrm{maokou}-\mathrm{sphere}-\mathrm{up}-\max }}{0.178};$

The volume of thermal center ball if be less than 5 × 10 ^-5m ³, adopt feeding liquid measure method to calculate rising head lower limit, rising head diameter limit wherein, η is solidification shrinkage rate, wherein ρ _sfor solid Density, ρ _lfor density of liquid phase; Rising head diameter $d_{\mathrm{maokou}-5}=\frac{({\mathrm{\αd}}_{\mathrm{maokou}-\min -5}+{\mathrm{\βd}}_{\mathrm{maokou}-\max -5})}{(\mathrm{\α}+\mathrm{\β})},$ α and β be greater than 1 integer and β > α, riser height h _maokou-5=1.2d _maokou-5; If be greater than 5 × 10 ^-5m ³, rising head diameter d _maokou-5=d _maokou-max-5, riser height h _maokou-5=1.2d _maokou-5; The top end face of rising head should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-5}if add extended height h _{maokou-yanshen-5}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-5with extended height h _{maokou-yanshen-5}sum; Otherwise, final riser height for riser height h _maokou-5;

Five, for discrete distribution, the calculating being in the Riser Dimensions of the shrinkage defect in the sand mold of top

Cast outer surface is the shrinkage defect in regular face corresponding to the residing space, altogether N3 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (1) feeder modulus M _{maokou-cylinder-6-k}, rising head diameter d _{maokou-cylinder-6-k}with riser height h _{maokou-cylinder-6-k}, k value 1 ~ N3; Cast outer surface is the shrinkage defect of irregular corresponding to the residing space, altogether N4 shrinkage defect, for each shrinkage defect, adopts the calculating of method described in step 2 (2) feeder modulus M _{maokou-sphere-6-t}, rising head diameter d _{maokou-sphere-6-t}with riser height h _{maokou-sphere-6-t}, t value 1 ~ N4; If beeline is less than 0.01m between adjacent rising head, these rising heads are merged as a whole rising head, overall feeder modulus $M_{\mathrm{maokou}-\mathrm{all}-6}={({\mathrm{\Σ}}_{k=1}^{N_3}{M}_{\mathrm{maokou}-\mathrm{cylinder}-6-k}^2+{\mathrm{\Σ}}_{t=1}^{N_4}{M}_{\mathrm{maokou}-\mathrm{sphere}-6-t})}^{1/2},$ Overall rising head diameter overall riser height h _maokou-all-6=1.2d _maokou-all-6; The top end face of rising head preferably should be concordant with the top end face of top sandbox, so design extended height h _{maokou-yanshen-6}if add extended height h _{maokou-yanshen-6}front and back, rising head differs with the longest setting time in foundry goods interface place and is no more than 100s, then final riser height for riser height h _maokou-all-6with extended height h _{maokou-yanshen-6}sum; Otherwise, final riser height for riser height h _maokou-all-6;

Six, the basis order type of cooling from bottom to top, suitably moved by ingate, ingate Position Design, in the equal office of non-axis symmetry intricate casting quality, namely completes the design of rising head in non-axis symmetry intricate casting sand casting process.