CN104826997A - Casting riser induction heating device, and casting riser induction heating method - Google Patents
Casting riser induction heating device, and casting riser induction heating method Download PDFInfo
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Abstract
Description
技术领域 technical field
本发明涉及机械制造业，具体来说是一种适用于铸造领域铸件生产用的冒口感应加热方法及其工艺装置，通过调节电磁感应线圈的输入功率，对不同尺寸冒口内的金属液进行感应加热，从而可以提高冒口的补缩效率，减小冒口尺寸，节省材料和能源，并减少铸件产生缩孔和缩松缺陷，提高铸件的内部质量。尤其适用于大型铸钢件的冒口。 The present invention relates to the machinery manufacturing industry, in particular to a riser induction heating method and its process device suitable for casting production in the foundry field. By adjusting the input power of the electromagnetic induction coil, the molten metal in the riser of different sizes is induced. Heating can improve the feeding efficiency of the riser, reduce the size of the riser, save materials and energy, reduce the shrinkage cavity and shrinkage defects of the casting, and improve the internal quality of the casting. Especially suitable for risers of large steel castings.
背景技术 Background technique
在铸件生产过程中，一般要设置一定数量和大小的冒口，以补充铸件凝固收缩时所需的金属熔液，避免铸件产生缩孔、缩松缺陷，确保获得具有良好内部质量的铸件。冒口的体积和数量一般由铸件的结构形状和体积来确定，冒口中补充熔液的总量一般占铸件重量的30%～60%，而实际熔液补充使用量只占10%左右，补充熔液的剩余量高达90%左右。而且，冒口需切割与铸件分离后做为回炉料再次熔化，因此浪费大量能源，增加铸件生产成本。如目前国内生产的大型螺旋桨，为了实现补缩，其冒口尺寸很大，冒口占铸件重量的22%～30%，浪费原材料，导致工艺出口率低；且冒口大，切割困难，重新利用也很困难。 In the casting production process, generally a certain number and size of risers should be set up to supplement the molten metal required for the casting to solidify and shrink, to avoid shrinkage cavities and shrinkage defects in the casting, and to ensure castings with good internal quality. The volume and quantity of the riser are generally determined by the structural shape and volume of the casting. The total amount of supplementary melt in the riser generally accounts for 30% to 60% of the weight of the casting, while the actual supplementary use of melt only accounts for about 10%. The remaining amount of melt is as high as about 90%. Moreover, the riser needs to be cut and separated from the casting to be melted again as a return charge, thus wasting a lot of energy and increasing the production cost of the casting. For example, in the large propellers currently produced in China, in order to achieve feeding, the riser size is very large, and the riser accounts for 22% to 30% of the weight of the casting, which wastes raw materials and leads to a low process export rate; and the riser is large, difficult to cut, and reused It is also difficult.
为了提高冒口的补缩效率，提高铸件工艺出品率，目前已经由普通冒口技术发展到应用多种特殊冒口技术，如保温冒口、发热冒口、加热冒口和加压冒口等，现在铸件生产中比较常用的方法是采用保温冒口和发热冒口。保温冒口和发热冒口使用方便，在一定程度上提高了冒口的补缩效率，但对于大型铸件来说，由于铸件凝固时间比较长，因此要求冒口内金属液的凝固时间也需要比较长，这样保温冒口和发热冒口作用就不明显，冒口的补缩效率仍然较低。 In order to improve the feeding efficiency of the riser and improve the yield rate of the casting process, the ordinary riser technology has been developed to apply a variety of special riser technologies, such as thermal insulation risers, heating risers, heating risers and pressurized risers, etc. , the more commonly used method in casting production is to use heat preservation riser and heating riser. The insulation riser and heating riser are easy to use, which improves the feeding efficiency of the riser to a certain extent, but for large castings, the solidification time of the molten metal in the riser is also required to be relatively long due to the long solidification time of the casting , so that the effect of the heat preservation riser and the heating riser is not obvious, and the feeding efficiency of the riser is still low.
目前工业生产中也用加热冒口的方法来进行铸件生产。加热冒口又分为电阻加热冒口、电弧加热冒口、电渣加热冒口等。这些现有技术通过电弧、等离子或化学加热方法对冒口加热保温，以补偿冒口热量损失，提高冒口的补缩能力，但它们输入的热量主要集中在加热体附近，存在加热面积小、热效率低和污染钢液等问题。近年来，还出现了感应加热冒口，主要利用感应加热原理，对冒口内的金属液进行加热，提高了冒口的补缩效率。 At present, in industrial production, the method of heating riser is also used for casting production. Heating risers are further divided into resistance heating risers, arc heating risers, electroslag heating risers, etc. These existing technologies use electric arc, plasma or chemical heating methods to heat and insulate the riser to compensate the heat loss of the riser and improve the feeding capacity of the riser. However, the heat input by them is mainly concentrated near the heating body, and the heating area is small, Problems such as low thermal efficiency and contamination of molten steel. In recent years, induction heating risers have also appeared, which mainly use the principle of induction heating to heat the molten metal in the riser and improve the feeding efficiency of the riser.
中国专利CN102350485A发明了一种中频电加热钢胚铸造补缩孔装置及工艺，用于钢胚铸造补缩。该专利在钢模上部装配浇注冒口，冒口用石英砂混合泡花碱压制，在冒口外套有感应加热线圈，与中频感应加热配电柜连接。钢水在浇铸注满后及时将感应线圈通电加热，然后逐步降低电流，使冒口内钢水温度按每分钟100℃~120℃速度降温直到凝固完毕。此发明有效地降低了冒口冷却速度，使产品合格率得到大幅度提高。但此发明专利仅适用于钢锭生产，且钢水是直接从冒口浇注进入钢模型腔内的，只有在钢水浇注满后才通电加热。而且，该专利中发散的磁力线通过铁模时会对铁模感应加热，降低铁模的冷却能力。 Chinese patent CN102350485A has invented a medium-frequency electric heating billet casting shrinkage hole filling device and process, which is used for billet casting shrinkage feeding. In this patent, a pouring riser is assembled on the upper part of the steel mold, and the riser is pressed with quartz sand mixed with sodium bicarbonate, and an induction heating coil is arranged on the riser jacket, which is connected with a medium frequency induction heating power distribution cabinet. After the molten steel is filled, the induction coil is energized and heated in time, and then the current is gradually reduced, so that the temperature of the molten steel in the riser is lowered at a rate of 100 ° C to 120 ° C per minute until the solidification is completed. The invention effectively reduces the cooling speed of the riser and greatly improves the qualified rate of products. But this invention patent is only applicable to the production of steel ingots, and the molten steel is directly poured into the steel mold cavity from the riser, and the electric heating is only performed after the molten steel is poured. Moreover, when the divergent magnetic force lines in this patent pass through the iron mold, it will inductively heat the iron mold, reducing the cooling capacity of the iron mold.
中国专利CN103212675A发明了一种钢锭冒口感应加热及电磁搅拌装置，用于黑色及有色金属材料铸锭冒口部位的加热保温及电磁搅拌。该专利在钢锭的冒口保温套外部垂直放置多组感应线圈，通过水冷电缆连接三相工频电源柜。接通电源后，对冒口中的钢液进行感应加热，补偿钢锭凝固过程中冒口金属液的热量损失，延缓冒口的凝固进程，提高冒口的补缩能力，同时在冒口周围形成磁场，在此磁场的作用下对金属熔体产生电磁搅拌的效果，有利于排除金属熔体中的气体和夹杂物，提高钢锭质量。此发明专利同样也仅是适用于钢锭生产，而且也是在钢水从冒口顶部浇注完毕后才开始通电加热。 Chinese patent CN103212675A has invented a steel ingot riser induction heating and electromagnetic stirring device, which is used for heating, heat preservation and electromagnetic stirring of black and non-ferrous metal material ingot riser parts. In this patent, multiple sets of induction coils are vertically placed outside the riser insulation cover of the steel ingot, and are connected to a three-phase power frequency power cabinet through a water-cooled cable. After the power is turned on, the molten steel in the riser is heated by induction to compensate the heat loss of the riser molten metal during the solidification of the steel ingot, delay the solidification process of the riser, improve the feeding capacity of the riser, and form a magnetic field around the riser , Under the action of this magnetic field, the effect of electromagnetic stirring on the metal melt is generated, which is beneficial to eliminate the gas and inclusions in the metal melt and improve the quality of the steel ingot. This invention patent is also only applicable to the production of steel ingots, and it also starts to be energized and heated after the molten steel has been poured from the top of the riser.
中国实用新型专利CN202316980U公开了一种铸造冒口感应加热装置，该专利在逆变电源输出电路中串联电容器和至少一副感应线圈，每副感应线圈对应套设在一只冒口杯外壁上，从而可以使用比正常冒口要小的较小型号冒口杯，这样能减少金属熔液的总量和冒口中金属的剩余量，冒口中金属熔液利用率可达95%以上，大大减少热能浪费并节约电能。该专利也是在金属液浇注完毕后，启动感应加热电源，对冒口杯内的金属熔液进行感应加热。 Chinese utility model patent CN202316980U discloses a casting riser induction heating device. In this patent, a capacitor and at least one pair of induction coils are connected in series in the output circuit of the inverter power supply. Each pair of induction coils is correspondingly sleeved on the outer wall of a riser cup. Therefore, a smaller type riser cup that is smaller than the normal riser can be used, which can reduce the total amount of molten metal and the remaining amount of metal in the riser, and the utilization rate of the molten metal in the riser can reach more than 95%, greatly reducing heat energy Waste and save electricity. In this patent, after the pouring of the molten metal is completed, the induction heating power supply is started to inductively heat the molten metal in the riser cup.
可见，目前的感应加热冒口方法和装置均是在金属液浇注完毕后才启动感应加热电源，从而利用感应加热原理对冒口中金属液进行感应加热保温。而由于冒口材料为非导电材料，如果冒口中未充入金属液，则即使在浇注之前启动感应加热电源，冒口也不会被感应加热。事实上，在铸件生产过程中，当浇注金属液时，高温的金属液遇到低温的冒口杯，受其激冷作用，会在冒口杯外壁附近形成一层固态金属壳层，直接降低冒口内金属液的补缩效率，同时此凝固壳层还会阻碍金属液的向下流动而影响补缩效果。另外，在浇注金属液时，冒口内金属液在充满过程中也会有大量热量散失，导致冒口内金属液温度下降较快，尤其是大型铸件生产，往往需要较长的浇注时间。这些均将大大降低冒口的补缩效率。 It can be seen that the current induction heating riser method and device all start the induction heating power supply after the molten metal is poured, so that the induction heating and heat preservation of the molten metal in the riser is carried out by using the principle of induction heating. And because the riser material is a non-conductive material, if the metal liquid is not filled in the riser, even if the induction heating power supply is started before pouring, the riser will not be heated by induction. In fact, in the casting production process, when the molten metal is poured, the high-temperature molten metal encounters the low-temperature riser cup, and is subjected to its chilling effect, forming a solid metal shell near the outer wall of the riser cup, which directly reduces the The feeding efficiency of the molten metal in the riser, at the same time, the solidified shell will also hinder the downward flow of the molten metal and affect the feeding effect. In addition, when pouring molten metal, a large amount of heat will be lost during the filling process of the molten metal in the riser, resulting in a rapid drop in the temperature of the molten metal in the riser, especially for the production of large castings, often requiring a long pouring time. These will greatly reduce the feeding efficiency of the riser.
发明内容 Contents of the invention
发明目的：本发明提供一种铸造冒口感应加热装置及铸造冒口感应加热方法，其目的是克服现有冒口技术补缩效率仍然较低的不足。 Purpose of the invention: The present invention provides a casting riser induction heating device and a casting riser induction heating method, the purpose of which is to overcome the disadvantage that the feeding efficiency of the existing riser technology is still low.
技术方案： Technical solutions:
一种铸造冒口感应加热装置，其特征在于：该装置包括冒口套、石墨套、钢套或其他导电材料做成的圆环套、感应线圈、热电偶、水冷电缆、温度记录仪和感应加热电源箱；圆环套设置在冒口套外围，感应线圈设置在圆环套外围，感应线圈的两端通过水冷电缆与感应加热电源箱连接，温度记录仪连接热电偶，热电偶与冒口套内壁接触。 An induction heating device for a casting riser, characterized in that the device includes a riser sleeve, a graphite sleeve, a steel sleeve or a ring sleeve made of other conductive materials, an induction coil, a thermocouple, a water-cooled cable, a temperature recorder and an induction heater. Heating power supply box; the ring sleeve is set on the periphery of the riser sleeve, and the induction coil is set on the periphery of the ring sleeve. Inner wall contact.
在感应线圈和圆环套之间放置绝热绝缘材料。 A heat-insulating insulating material is placed between the induction coil and the ring sleeve.
利用上述的铸造冒口感应加热装置所实施的铸造冒口感应加热方法，其特征在于：该方法在冒口套外部放置石墨套、钢套或其他导电材料做成的圆环套，在圆环套外部再放置感应线圈，通过感应线圈对冒口套外部的导电材料圆环套进行加热，进而对冒口套和冒口内的金属液进行加热，减小冒口内金属液和冒口套之间的温度差，减少冒口内金属液热量的散失，达到延缓冒口内金属液凝固的效果。 The casting riser induction heating method implemented by the above-mentioned casting riser induction heating device is characterized in that: the method places a graphite sleeve, a steel sleeve or a ring sleeve made of other conductive materials outside the riser sleeve, An induction coil is placed outside the sleeve, and the conductive material ring sleeve outside the riser sleeve is heated by the induction coil, and then the riser sleeve and the molten metal in the riser are heated to reduce the gap between the molten metal in the riser and the riser sleeve. The temperature difference in the riser reduces the heat loss of the molten metal in the riser, and achieves the effect of delaying the solidification of the molten metal in the riser.
在金属液浇注前，首先利用感应加热线圈对圆环套进行加热，然后利用热量传递原理，使空的冒口套温度升高，这样在浇注金属液后当金属液进入冒口中时可以减小冒口内金属液和冒口套之间的温度差，达到延缓冒口内金属液凝固的效果，从而提高铸件冒口的补缩效率和铸件工艺出口率。 Before the molten metal is poured, first use the induction heating coil to heat the ring sleeve, and then use the principle of heat transfer to increase the temperature of the empty riser sleeve, so that after pouring the molten metal, when the molten metal enters the riser, it can be reduced. The temperature difference between the molten metal in the riser and the riser sleeve achieves the effect of delaying the solidification of the molten metal in the riser, thereby improving the feeding efficiency of the riser of the casting and the export rate of the casting process.
针对不同尺寸的冒口可采用不同规格的圆环套和与之相对应的感应线圈，或者只采用一个较大的感应线圈，然后通过改变圆环套的结构尺寸来适应实际生产中不同尺寸冒口的需求。 For risers of different sizes, ring sleeves of different specifications and corresponding induction coils can be used, or only a larger induction coil can be used, and then the structural size of the ring sleeve can be changed to adapt to different sizes of risers in actual production. oral needs.
感应加热电源箱采用IGBT电源，其冷却方式可用水冷或风冷，或者电源箱采用可控硅调节，可控硅电源采用水冷方式，通过调节电源输出功率来改变感应线圈功率的大小，从而控制圆环套的预热温度以及浇注后冒口内金属液的温度。 The induction heating power supply box adopts IGBT power supply, and its cooling method can be water-cooled or air-cooled, or the power supply box is regulated by thyristor, and the thyristor power supply is water-cooled. The preheating temperature of the ring sleeve and the temperature of the molten metal in the riser after pouring.
热电偶与圆环套内壁接触，由热电偶测得的温度信号传输给多点温度记录仪，通过观察温度记录仪上的指示信息来调节电源输出功率，进而调节圆环套的温度。 The thermocouple is in contact with the inner wall of the ring sleeve, and the temperature signal measured by the thermocouple is transmitted to the multi-point temperature recorder. By observing the indication information on the temperature recorder, the output power of the power supply is adjusted, and then the temperature of the ring sleeve is adjusted.
圆环套所采用的其它导电性材料为石墨、钢、铁、铜活铝，对于铸钢件生产，选择石墨材料作圆环套，对于低熔点有色合金材料铸件生产，选择其它导电性材料，圆环套其材料的熔点比浇注的金属液温度高。 Other conductive materials used in ring sleeves are graphite, steel, iron, copper or aluminum. For the production of steel castings, graphite materials are selected as ring sleeves. For the production of non-ferrous alloy castings with low melting points, other conductive materials are selected. The melting point of the material of the ring sleeve is higher than the temperature of the poured molten metal.
该方法利用感应加热线圈对圆环套加热来实现冒口套的预热效果，并在金属液浇注进入冒口套后利用感应加热线圈对冒口套中的金属液进行直接加热，从而最大程度地使冒口中金属液起到补缩作用，避免铸件产生收缩缺陷。 In this method, the induction heating coil is used to heat the ring sleeve to realize the preheating effect of the riser sleeve, and the induction heating coil is used to directly heat the molten metal in the riser sleeve after the molten metal is poured into the riser sleeve, thereby maximizing Make the molten metal in the riser play a feeding role, and avoid shrinkage defects in castings.
在感应线圈和圆环套之间放置绝热绝缘材料；电源频率采用中频。 An insulating material is placed between the induction coil and the ring sleeve; the power frequency adopts an intermediate frequency.
优点效果：本发明研究出一种感应加热冒口方法，采用中频感应加热，不仅在浇注前就已经对冒口套进行加热，而且在浇注过程和浇注完毕后一直对冒口及冒口内的金属液进行加热，从而大大减少冒口内金属液的热量散失，显著提高了冒口的补缩效率。本发明所提供的铸造冒口装置，包括冒口套、石墨套、钢套或其他导电材料做成的圆环套、感应线圈、水冷电缆、感应加热电源箱、热电偶和温度记录仪，在金属液浇注前，首先利用感应加热线圈对石墨套、钢套或其他导电材料做成的圆环套进行加热，然后利用热量传递原理，使空的冒口套温度升高，这样在浇注金属液后当金属液进入冒口中时可以减小冒口内金属液和冒口套之间的温度差，达到延缓冒口内金属液凝固的效果，从而提高铸件冒口的补缩效率和铸件工艺出口率。 Advantages and effects: The present invention develops a method for induction heating of the riser, which adopts medium frequency induction heating, not only to heat the riser sleeve before pouring, but also to heat the riser and the metal inside the riser during the pouring process and after the pouring is completed. The liquid is heated, thereby greatly reducing the heat loss of the molten metal in the riser, and significantly improving the feeding efficiency of the riser. The casting riser device provided by the present invention includes a riser sleeve, a graphite sleeve, a steel sleeve or a ring sleeve made of other conductive materials, an induction coil, a water-cooled cable, an induction heating power supply box, a thermocouple and a temperature recorder. Before pouring the molten metal, first use the induction heating coil to heat the ring sleeve made of graphite sleeve, steel sleeve or other conductive materials, and then use the principle of heat transfer to increase the temperature of the empty riser sleeve, so that when the molten metal is poured Finally, when the molten metal enters the riser, the temperature difference between the molten metal in the riser and the riser sleeve can be reduced to achieve the effect of delaying the solidification of the molten metal in the riser, thereby improving the feeding efficiency of the casting riser and the export rate of the casting process.
本发明所述的铸造冒口感应加热方法利用感应加热原理，加热过程在浇注前进行，减小了冒口套对进入冒口内的金属液的激冷作用，并在金属液浇注进入冒口中后，同时对冒口套和冒口中金属液进行加热，从而可以大大延长冒口内金属液的凝固时间。 The casting riser induction heating method of the present invention utilizes the principle of induction heating, and the heating process is carried out before pouring, which reduces the chilling effect of the riser sleeve on the molten metal entering the riser, and after the molten metal is poured into the riser At the same time, the riser sleeve and the molten metal in the riser are heated, so that the solidification time of the molten metal in the riser can be greatly prolonged.
本发明所述的铸造冒口感应加热方法，针对不同尺寸的冒口可采用不同规格的圆环套和与之相对应的感应线圈。为了提高铸造冒口感应加热装置的适用性，也可以只采用一个较大的感应线圈，然后通过改变圆环套的结构尺寸来适应实际生产中不同尺寸冒口的需求。 In the casting riser induction heating method described in the present invention, ring sleeves of different specifications and corresponding induction coils can be used for risers of different sizes. In order to improve the applicability of the casting riser induction heating device, only one larger induction coil can be used, and then the structural size of the ring sleeve can be changed to meet the needs of different sizes of risers in actual production.
本发明所述的铸造冒口感应加热方法，电源箱采用IGBT电源，其冷却方式可用水冷或风冷。电源箱也可采用可控硅调节，可控硅电源采用水冷方式。通过调节电源输出功率来改变感应线圈功率的大小，从而控制圆环套和冒口套的预热温度以及浇注后冒口内金属液的温度。 In the casting riser induction heating method described in the present invention, the power supply box adopts IGBT power supply, and its cooling method can be water cooling or air cooling. The power box can also be regulated by silicon controlled rectifier, and the silicon controlled silicon power supply is water-cooled. The power of the induction coil is changed by adjusting the output power of the power supply, thereby controlling the preheating temperature of the ring sleeve and the riser sleeve and the temperature of the molten metal in the riser after pouring.
本发明所述的铸造冒口感应加热方法，电源频率采用中频。由于金属液承受的电磁力是与电源频率的平方根成反比，因此中频电源的电磁搅拌力比工频电源小得多。对于去除冒口中金属液的杂质和均匀化学成分、均匀温度来说，中频电源效果比较好。中频感应加热较好的电磁搅拌作用，也有利于冒口中金属液气体和夹杂物的上浮，而且也有利于减轻高温液态金属的氧化，从而可以提高冒口内金属液的质量，进而可以减少铸件中的气孔及夹杂类缺陷。 In the casting riser induction heating method described in the present invention, the power frequency adopts intermediate frequency. Since the electromagnetic force of the molten metal is inversely proportional to the square root of the power frequency, the electromagnetic stirring force of the intermediate frequency power supply is much smaller than that of the commercial frequency power supply. For the removal of impurities and uniform chemical composition and uniform temperature of the molten metal in the riser, the effect of the intermediate frequency power supply is better. The better electromagnetic stirring effect of intermediate frequency induction heating is also conducive to the floating of molten metal gas and inclusions in the riser, and is also conducive to reducing the oxidation of high-temperature liquid metal, thereby improving the quality of molten metal in the riser and reducing the amount of metal in the casting. porosity and inclusion defects.
本发明所述的铸造冒口感应加热方法，热电偶与冒口套内壁接触，由热电偶测得的温度信号传输给多点温度记录仪，通过观察温度记录仪上的指示信息来调节电源输出功率，进而调节圆环套和冒口套的温度。 In the casting riser induction heating method described in the present invention, the thermocouple is in contact with the inner wall of the riser sleeve, the temperature signal measured by the thermocouple is transmitted to the multi-point temperature recorder, and the power output is adjusted by observing the indication information on the temperature recorder Power, and then adjust the temperature of the ring sleeve and riser sleeve.
本发明所述的铸造冒口感应加热方法，圆环套的材料也可以采用其它导电性材料，如石墨、钢、铁、铜、铝及其它材料等。对于铸钢件生产，选择石墨材料作圆环套。对于低熔点有色合金材料铸件生产，可选择其它导电性材料。圆环套其材料的熔点比浇注的金属液温度高。 In the casting riser induction heating method of the present invention, the material of the ring sleeve can also be other conductive materials, such as graphite, steel, iron, copper, aluminum and other materials. For the production of steel castings, graphite material is selected as the ring sleeve. For the production of non-ferrous alloy castings with low melting point, other conductive materials can be selected. The melting point of the material of the ring sleeve is higher than the temperature of the poured molten metal.
本发明所述的铸造冒口感应加热装置，利用感应加热线圈对圆环套加热来实现冒口套的预热效果，并在金属液浇注进入冒口套后利用感应加热线圈对冒口套中的金属液进行直接加热，从而最大程度地使冒口中金属液起到补缩作用，避免铸件产生收缩缺陷。 The casting riser induction heating device of the present invention uses the induction heating coil to heat the ring sleeve to realize the preheating effect of the riser sleeve, and uses the induction heating coil to heat the riser sleeve after the molten metal is poured into the riser sleeve. The metal liquid in the riser is directly heated, so that the metal liquid in the riser can be fed to the greatest extent, and the shrinkage defect of the casting can be avoided.
本发明的具体有益效果如下：本发明采用感应加热方式，通过间接加热和直接加热相结合，即预先对冒口套进行间接加热，降低冒口套对进入冒口内金属液的激冷作用，以及对铸造过程中进入冒口内金属液进行直接感应加热，从而使冒口内的金属液的凝固时间大大延长，充分发挥冒口内金属液的补缩作用，显著提高冒口内金属液的补缩效率，大大缩减铸件的冒口尺寸，减小甚至避免铸件内部缩孔缩松缺陷的产生，最终实现改善铸件的内部质量和提高铸件的工艺出口率。由于本发明采用感应加热，设备组成简单可靠，容易实现，加热面积大，加热速度快，加热效率高，可适应于不同重量和尺寸的各类金属铸件的铸造生产，尤其适用于中大型铸件的生产。与现有的保温冒口和发热冒口相比，本发明具有如下优点：（1）延长冒口凝固时间效果比保温冒口和发热冒口显著；（2）可以实现对冒口内金属液温度的实时控制；（3）感应加热冒口可以循环利用，相对生产成本低；（4）使用过程中不会造成环境污染，更符合环保要求。与现有的电阻加热冒口、电弧加热冒口和电渣加热冒口相比，本发明的优点是：（1）加热效率更高；（2）节能减排效果更好；（3）铸造过程中，感应加热不会对冒口内的金属液造成污染，从而冒口内的金属液比较纯净，可以减少铸件内的夹杂等缺陷。 The specific beneficial effects of the present invention are as follows: the present invention adopts the induction heating method, through the combination of indirect heating and direct heating, that is, indirect heating of the riser sleeve in advance, reducing the chilling effect of the riser sleeve on the molten metal entering the riser, and Direct induction heating of the molten metal entering the riser during the casting process, thereby greatly prolonging the solidification time of the molten metal in the riser, giving full play to the feeding effect of the molten metal in the riser, significantly improving the feeding efficiency of the molten metal in the riser, and greatly Reduce the size of the riser of the casting, reduce or even avoid the occurrence of shrinkage cavity and shrinkage defects inside the casting, and ultimately improve the internal quality of the casting and increase the process export rate of the casting. Since the invention adopts induction heating, the equipment is simple and reliable, easy to implement, large heating area, fast heating speed, high heating efficiency, and can be adapted to the casting production of various metal castings with different weights and sizes, especially for medium and large castings. Production. Compared with the existing thermal riser and heating riser, the present invention has the following advantages: (1) The effect of prolonging the solidification time of the riser is more significant than that of the thermal insulation riser and the heating riser; (3) The induction heating riser can be recycled, and the production cost is relatively low; (4) It will not cause environmental pollution during use, and it is more in line with environmental protection requirements. Compared with the existing resistance heating riser, arc heating riser and electroslag heating riser, the advantages of the present invention are: (1) higher heating efficiency; (2) better effect of energy saving and emission reduction; (3) casting During the process, induction heating will not pollute the molten metal in the riser, so the molten metal in the riser is relatively pure, which can reduce defects such as inclusions in the casting.
附图说明：Description of drawings:
图１为感应加热冒口装置示意图。 Figure 1 is a schematic diagram of the induction heating riser device.
图２为感应加热冒口部分的俯视图。 Figure 2 is a top view of the induction heating riser part.
图3为实施例所用的杆状铸件模型。 Fig. 3 is the rod-shaped casting model used in the embodiment.
图4为实施例中冒口的实际补缩效果对比，其中图4a为直径为Φ100mm的普通冒口，图4b为直径为Φ60mm的普通冒口，图4c为直径为Φ60mm的感应加热冒口； Fig. 4 is the comparison of the actual feeding effect of the riser in the embodiment, wherein Fig. 4a is a common riser with a diameter of Φ 100mm, Fig. 4b is a common riser with a diameter of Φ 60mm, and Fig. 4c is an induction heating with a diameter of Φ 60mm Riser;
在上述附图中，各组成部分为：1. 冒口内的金属液；2. 冒口套；3. 圆环套；4. 感应线圈；5. 热电偶；6. 水冷电缆；7. 多点温度记录仪；8. 砂型；9. 感应加热电源箱；10. 浇口杯；11. 磁轭。 In the above drawings, the components are: 1. Liquid metal in the riser; 2. Riser sleeve; 3. Ring sleeve; 4. Induction coil; 5. Thermocouple; 6. Water-cooled cable; 7. Multi-point Temperature recorder; 8. Sand mold; 9. Induction heating power box; 10. Sprue cup; 11. Magnetic yoke.
具体实施方式：下面结合实施例及实验方法对本发明做进一步的说明： The specific embodiment: the present invention will be further described below in conjunction with embodiment and experimental method:
本发明一种铸造冒口感应加热装置，该装置包括冒口套2、石墨套、钢套或其他导电材料做成的圆环套3、感应线圈4、热电偶5、水冷电缆6、温度记录仪7和感应加热电源箱9；圆环套3设置在冒口套2外围，感应线圈4设置在圆环套3外围，感应线圈4的两端通过水冷电缆6与感应加热电源箱9连接，温度记录仪7连接热电偶5，热电偶5与冒口套2内壁接触。 The present invention is an induction heating device for a casting riser, which comprises a riser sleeve 2, a graphite sleeve, a steel sleeve or a ring sleeve 3 made of other conductive materials, an induction coil 4, a thermocouple 5, a water-cooled cable 6, and a temperature recorder. instrument 7 and induction heating power supply box 9; ring sleeve 3 is arranged on the periphery of riser sleeve 2, induction coil 4 is arranged on the periphery of ring sleeve 3, and the two ends of induction coil 4 are connected with induction heating power supply box 9 through water-cooled cable 6, The temperature recorder 7 is connected to the thermocouple 5, and the thermocouple 5 is in contact with the inner wall of the riser sleeve 2.
利用上述的铸造冒口感应加热装置所实施的铸造冒口感应加热方法，该方法在冒口套2外部放置石墨套、钢套或其他导电材料做成的圆环套3，在圆环套外部再放置感应线圈4，通过感应线圈对冒口套外部的导电材料圆环套进行加热，进而对冒口套和冒口内的金属液1进行加热，减小冒口内金属液和冒口套之间的温度差，减少冒口内金属液热量的散失，达到延缓冒口内金属液凝固的效果。 In the casting riser induction heating method implemented by the above-mentioned casting riser induction heating device, the method places a graphite sleeve, a steel sleeve or a ring sleeve 3 made of other conductive materials outside the riser sleeve 2, Place the induction coil 4 again, heat the conductive material ring sleeve outside the riser sleeve through the induction coil, and then heat the riser sleeve and the molten metal 1 in the riser, reducing the gap between the riser sleeve and the riser sleeve. The temperature difference in the riser reduces the heat loss of the molten metal in the riser, and achieves the effect of delaying the solidification of the molten metal in the riser.
在金属液浇注前，首先利用感应加热线圈4对圆环套3进行加热，然后利用热量传递原理，使空的冒口套2温度升高，这样在浇注金属液后当金属液进入冒口中时可以减小冒口内金属液和冒口套之间的温度差，达到延缓冒口内金属液凝固的效果，从而提高铸件冒口的补缩效率和铸件工艺出口率。 Before the molten metal is poured, first use the induction heating coil 4 to heat the ring sleeve 3, and then use the principle of heat transfer to increase the temperature of the empty riser sleeve 2, so that when the molten metal enters the riser after pouring the molten metal It can reduce the temperature difference between the molten metal in the riser and the riser sleeve, and achieve the effect of delaying the solidification of the molten metal in the riser, thereby improving the feeding efficiency of the riser of the casting and the export rate of the casting process.
本申请利用感应加热原理，加热过程在浇注前进行，减小了冒口套对进入冒口内的金属液的激冷作用，并在金属液浇注进入冒口中后，同时对冒口套和冒口中金属液进行加热，从而可以大大延长冒口内金属液的凝固时间。 This application uses the principle of induction heating, and the heating process is carried out before pouring, which reduces the chilling effect of the riser sleeve on the molten metal entering the riser, and after the molten metal is poured into the riser, it simultaneously cools the riser sleeve and the riser. The molten metal is heated, which can greatly prolong the solidification time of the molten metal in the riser.
针对不同尺寸的冒口可采用不同规格的圆环套3和与之相对应的感应线圈4，或者只采用一个较大的感应线圈，然后通过改变圆环套3的结构尺寸来适应实际生产中不同尺寸冒口的需求。 For risers of different sizes, ring sleeves 3 of different specifications and corresponding induction coils 4 can be used, or only a larger induction coil can be used, and then the structural size of the ring sleeve 3 can be changed to adapt to the actual production. Riser needs of different sizes.
感应加热电源箱9采用IGBT电源，其冷却方式可用水冷或风冷，或者电源箱9采用可控硅调节，可控硅电源采用水冷方式，通过调节电源输出功率来改变感应线圈4功率的大小，从而控制圆环套3的预热温度以及浇注后冒口内金属液的温度。 The induction heating power supply box 9 adopts IGBT power supply, and its cooling method can be water-cooled or air-cooled, or the power supply box 9 is regulated by a silicon controlled rectifier, and the thyristor power supply adopts a water-cooled mode, and the power of the induction coil 4 is changed by adjusting the output power of the power supply. Thereby controlling the preheating temperature of the ring sleeve 3 and the temperature of the molten metal in the riser after pouring.
热电偶5与圆环套3内壁接触，由热电偶测得的温度信号传输给多点温度记录仪7，通过观察温度记录仪7上的指示信息来调节电源输出功率，进而调节圆环套3的温度。 The thermocouple 5 is in contact with the inner wall of the ring sleeve 3, and the temperature signal measured by the thermocouple is transmitted to the multi-point temperature recorder 7. By observing the indication information on the temperature recorder 7, the output power of the power supply is adjusted, and then the ring sleeve 3 is adjusted. temperature.
圆环套3所采用的其它导电性材料为石墨、钢、铁、铜活铝，对于铸钢件生产，选择石墨材料作圆环套，对于低熔点有色合金材料铸件生产，可选择其它导电性材料。圆环套3其材料的熔点比浇注的金属液温度高。 Other conductive materials adopted by the ring sleeve 3 are graphite, steel, iron, copper or aluminum. For the production of steel castings, graphite materials are selected as the ring sleeve. For the production of non-ferrous alloy material castings with low melting point, other conductive materials can be selected. Material. The melting point of its material of the ring cover 3 is higher than the molten metal temperature of pouring.
圆环套3也可以采用其它导电性材料，如石墨、钢、铁、铜、铝及其它材料等。 The ring cover 3 can also adopt other conductive materials, such as graphite, steel, iron, copper, aluminum and other materials.
该方法利用感应加热线圈4对圆环套3加热来实现冒口套2的预热效果，并在金属液浇注进入冒口套后利用感应加热线圈4对冒口套2中的金属液进行直接加热，从而最大程度地使冒口中金属液起到补缩作用，避免铸件产生收缩缺陷。 The method uses the induction heating coil 4 to heat the ring sleeve 3 to realize the preheating effect of the riser sleeve 2, and uses the induction heating coil 4 to directly heat the molten metal in the riser sleeve 2 after the molten metal is poured into the riser sleeve. Heating, so as to maximize the feeding effect of the molten metal in the riser, and avoid shrinkage defects in castings.
在感应线圈4和圆环套3之间放置绝热绝缘材料；电源频率采用中频。 An insulating material is placed between the induction coil 4 and the ring sleeve 3; the power frequency adopts an intermediate frequency.
图1为本发明的感应加热冒口装置组成示意图。其中感应线圈内径为Φ255mm，采用截面为方形的紫铜管制作，方形截面的尺寸为23mm×25mm，中间通冷却水。感应线圈由方形截面纯铜管盘成螺旋状，外表面缠绕绝缘云母带。感应线圈磁轭外侧使用。由感应线圈构成的感应加热器的高度为160mm。圆环套3由石墨制成，其内径为Φ85mm，壁厚为20mm，高度为160mm。冒口套材质为陶瓷，其内径为Φ60mm，壁厚为7mm，高度为150mm。电源采用IGBT电源，最大功率100kW，功率可调。水冷电缆截面积为300mm2，最大承载电流达2400A。在感应线圈4和圆环套3之间放置绝热绝缘材料石棉。感应线圈4、圆环套3及它们之间的石棉均安放在一陶瓷板底座上。 Fig. 1 is a schematic diagram of the composition of the induction heating riser device of the present invention. The inner diameter of the induction coil is Φ 255mm, and it is made of a copper tube with a square section. The size of the square section is 23mm×25mm, and cooling water is passed through the middle. The induction coil is coiled into a helical shape by a pure copper tube with a square cross-section, and an insulating mica tape is wound on the outer surface. The induction coil is used outside the yoke. The height of the induction heater constituted by the induction coil is 160 mm. Ring cover 3 is made of graphite, and its inner diameter is Φ 85mm, and wall thickness is 20mm, and height is 160mm. The material of the riser sleeve is ceramic, its inner diameter is Φ 60mm, the wall thickness is 7mm, and the height is 150mm. The power supply adopts IGBT power supply, the maximum power is 100kW, and the power is adjustable. The water-cooled cable has a cross-sectional area of 300mm 2 and a maximum carrying current of 2400A. Asbestos, a thermal insulation material, is placed between the induction coil 4 and the ring sleeve 3 . The induction coil 4, the ring sleeve 3 and the asbestos between them are all placed on a ceramic plate base.
采用简单的板状铸件作为实施例模型，其尺寸为400mm×160mm×40mm。所用上、下砂箱尺寸均为700mm×700mm×200mm。采用开放式浇注系统。 A simple plate casting is used as the embodiment model, and its size is 400mm×160mm×40mm. The dimensions of the upper and lower sand boxes used are 700mm×700mm×200mm. Open gating system is adopted.
实施例操作过程如下：首先造型。采用酯硬化自硬水玻璃砂造型。其中下型只是一个平实的砂块，仅对上型起支承作用。上型造型需要模样。模样除包括直浇道、横浇道、内浇道和板状铸件模样外，还包括形成放置感应加热冒口空间用模样。模样均留有拔模斜度以便起模。造型前，涂刷好分模剂。先将直浇道、横浇道、内浇道和板状铸件模样在砂箱中放好，然后填砂紧实。待型砂紧实到一定厚度时，放入形成感应加热冒口空间用模样，继续填砂紧实，并刮平。等待一段时间后开始起模，先将直浇道模样和感应加热冒口空间用模样起出，然后将砂型翻转，再将横浇道、内浇道和板状铸件模样起出来，于是上型便造好。待上、下两个砂型硬化紧实后，接着进行合型，合型后将感应加热冒口装置放入上型内事先造好形成的圆筒形空间内。然后将陶瓷冒口套直接放入圆环套3内。如果冒口套和圆环套之间空隙较大，则可以填入干砂。 The operation process of the embodiment is as follows: firstly, modeling. It is molded with ester hardened self-hardening water glass sand. Among them, the lower type is just a flat sand block, which only supports the upper type. Styling needs look. In addition to the sprue, runner, ingate and plate casting patterns, the pattern also includes the pattern for forming the space for placing the induction heating riser. The patterns are left with a draft slope for easy mold removal. Before styling, apply the mold release agent. First put the sprue, runner, ingate and plate casting pattern in the sand box, and then fill the sand tightly. When the molding sand is compacted to a certain thickness, put it into the pattern for forming the induction heating riser space, continue to fill the sand compactly, and scrape it flat. After waiting for a period of time, the mold is started. First, the sprue pattern and the induction heating riser space are lifted out, and then the sand mold is turned over, and then the runner, the inner runner and the plate casting are lifted out, and then the upper mold It will be made. After the upper and lower sand molds are hardened and compacted, the molds are then closed. After the molds are closed, the induction heating riser device is placed in the cylindrical space formed in advance in the upper mold. Then the ceramic riser sleeve is directly put into the ring sleeve 3 . If there is a large gap between the riser sleeve and the ring sleeve, dry sand can be filled.
造好型后，进行合金材料的熔炼。实施例中板状铸件的材质采用收缩率较大的ZG35材料。采用50kg的电磁感应电炉进行熔炼。当合金熔炼温度达到1650℃出铁水，然后进行脱氧、造渣、扒渣等操作，最后于1560℃左右浇注进入浇口杯中。 After the model is made, the alloy material is smelted. In the embodiment, the plate casting is made of ZG35 material with a large shrinkage rate. A 50kg electromagnetic induction furnace is used for melting. When the alloy smelting temperature reaches 1650°C, molten iron is tapped, then deoxidation, slagging, slag removal and other operations are performed, and finally poured into the sprue cup at about 1560°C.
本申请在合金熔炼操作的同时，于浇铸前30分钟开始接通感应加热冒口装置的电源，感应线圈通电对圆环套3进行感应加热，圆环套温度可在20分钟之内提升至1500℃以上，进而对冒口套2进行间接预热。热电偶5与冒口套2内壁接触，由热电偶测得的温度信号传输给多点温度记录仪7，通过观察温度记录仪7上的指示信息来调节感应加热冒口装置的电源输出功率，进而调节圆环套3和冒口套2的预热温度。冒口套的预热温度设为1500℃，当达到温度后进行保温，等待浇铸。 In this application, at the same time as the alloy melting operation, the power supply of the induction heating riser device is turned on 30 minutes before casting, and the induction coil is energized to inductively heat the ring sleeve 3, and the temperature of the ring sleeve can be raised to 1500 within 20 minutes. ℃, and then indirectly preheat the riser sleeve 2. The thermocouple 5 is in contact with the inner wall of the riser sleeve 2, and the temperature signal measured by the thermocouple is transmitted to the multi-point temperature recorder 7, and the power output power of the induction heating riser device is adjusted by observing the indication information on the temperature recorder 7, Then adjust the preheating temperature of the ring sleeve 3 and the riser sleeve 2. The preheating temperature of the riser sleeve is set to 1500°C, and when the temperature is reached, it is kept warm and waits for casting.
钢水浇注时保持感应加热冒口装置的感应线圈不断电。随着浇注的进行，金属液会逐渐充满冒口，此时会造成感应加热冒口装置的有用电源功率变大，导致石墨圆环套温度快速升高，为了维持石墨圆环套的温度，此时要降低感应加热冒口装置的电源功率，使石墨圆环套维持在1500℃左右，方法仍然是通过无纸多点温度记录仪7上显示的信息来调节感应加热冒口装置的电源功率。 Keep the induction coil of the induction heating riser device uninterrupted when the molten steel is poured. As the pouring proceeds, the molten metal will gradually fill the riser. At this time, the useful power of the induction heating riser device will increase, resulting in a rapid rise in the temperature of the graphite ring sleeve. In order to maintain the temperature of the graphite ring sleeve, this It is necessary to reduce the power of the induction heating riser device to keep the graphite ring sleeve at about 1500°C. The method is still to adjust the power of the induction heating riser device through the information displayed on the paperless multi-point temperature recorder 7 .
在平板铸件凝固过程中也需要保持感应加热冒口装置的感应线圈不断电。通过计算铸件的凝固时间来决定感应加热时间的长短，当铸件完全凝固后切断感应加热冒口装置的电源，感应线圈停止加热。在本实施例中，平板铸件的凝固时间约为5min，所以在浇注完毕后再过约8min即关闭感应加热冒口装置的电源。 It is also necessary to keep the induction coil of the induction heating riser device uninterrupted during the solidification process of the flat casting. The length of the induction heating time is determined by calculating the solidification time of the casting. When the casting is completely solidified, the power supply of the induction heating riser device is cut off, and the induction coil stops heating. In this embodiment, the solidification time of the flat casting is about 5 minutes, so the power supply of the induction heating riser device is turned off after about 8 minutes after pouring.
切断感应加热线圈的电源后，仍需继续通冷却水以保护感应加热冒口装置。待铸件完全冷却到室温后，关闭循环冷却水，将感应加热冒口装置从上砂型中移出。然后打箱将平板铸件取出，进行试验效果分析。 After cutting off the power supply of the induction heating coil, it is still necessary to continue to pass the cooling water to protect the induction heating riser device. After the casting is completely cooled to room temperature, the circulating cooling water is turned off, and the induction heating riser device is removed from the upper sand mold. Then take out the flat casting from the box and analyze the test effect.
在切除平板铸件的浇冒口后，将平板铸件从正中间剖开，以观察分析平板铸件的缩孔缩松缺陷产生情况，试验结果如图4c所示。为了验证感应加热冒口的实施效果，还进行了对比试验。 After cutting off the riser of the flat casting, cut the flat casting from the middle to observe and analyze the shrinkage cavity and shrinkage defects of the flat casting. The test results are shown in Figure 4c. In order to verify the implementation effect of the induction heating riser, a comparative experiment was also carried out.
对比试验以相同平板铸件作为模型，分别采用Φ100mm和Φ60mm的陶瓷管冒口进行试验，冒口壁厚均为7mm，高度均为150mm。但在冒口外均未放置感应加热冒口装置。其试验结果分别如图4a和图4b所示。其中，Φ100mm陶瓷管冒口的试验是按照铸造工艺设计基本原理（依据《铸造手册》）来进行的，即采用普通冒口铸造，尺寸为400mm×160mm×40mm的平板铸件需要?100mm×150mm这么大的冒口。 In the comparative test, the same flat casting was used as the model, and ceramic pipe risers of Φ 100mm and Φ 60mm were used for the test respectively. The wall thickness of the risers was 7mm and the height was 150mm. But no induction heating riser device is placed outside the riser. The test results are shown in Figure 4a and Figure 4b, respectively. Among them, the test of the Φ 100mm ceramic pipe riser is carried out according to the basic principle of casting process design (according to the "Casting Manual"), that is, the flat casting with a size of 400mm×160mm×40mm needs ? 100mm×150mm Such a big riser.
从图4的试验结果可以看出，直径为Φ100mm的冒口得到的铸件质量完好，冒口根部也不存在任何缺陷；而直径为Φ60mm的未放置感应加热装置的冒口得到的铸件内部存在缩孔缩松缺陷，尤其是冒口根部存在明显缺陷；但是直径仍为Φ60mm的冒口，在放置感应加热装置后得到的铸件内部质量完好，冒口根部也无明显缺陷。 From the test results in Figure 4, it can be seen that the quality of the casting obtained by the riser with a diameter of Φ 100mm is intact, and there is no defect at the root of the riser; while the inside of the casting obtained by a riser with a diameter of Φ 60mm without induction heating device There are shrinkage cavity and shrinkage defects, especially obvious defects at the root of the riser; but the riser with a diameter of Φ 60mm, the internal quality of the casting obtained after placing the induction heating device is intact, and there is no obvious defect at the root of the riser.
通过对比试验发现感应加热冒口内更多的金属液能够补缩到铸件中去，使得到的铸件质量完好，从而大大缩小了冒口的尺寸，提高了冒口的补缩效率，显著提高了铸件的工艺出口率，感应加热冒口取得了良好效果。 Through comparative tests, it is found that more molten metal in the induction heating riser can be fed into the casting, so that the quality of the obtained casting is intact, thereby greatly reducing the size of the riser, improving the feeding efficiency of the riser, and significantly improving the quality of the casting. The export rate of the process is high, and the induction heating riser has achieved good results.
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