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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- General Induction Heating (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a casting riser induction heating device. The casting riser induction heating device comprises a riser sleeve; an annular sleeve prepared of graphite, steel, or other conductive materials; an induction coil; a thermoelectric couple; water cooled cables; a temperature recorder; and an induction heating power supply cabinet. Compared with conventional insulated risers and exothermic risers, the casting riser induction heating device possesses following advantages: riser setting time prolonging effect is more excellent than that of the conventional insulated risers and exothermic risers; real-time control on the temperature of molten metal in risers can be realized; recycling of induction heating risers can be realized; production cost is reduced; no environmental pollution is caused in using process; and environmental requirements are satisfied preferably.
Description
Technical Field
The invention relates to the machinery manufacturing industry, in particular to a riser induction heating method and a riser induction heating process device which are suitable for casting production in the casting field. The method is particularly suitable for risers of large-scale steel castings.
Background
In the production process of castings, a certain number of risers with certain sizes are generally arranged to supplement molten metal required by the solidification and shrinkage of the castings, so that the defects of shrinkage cavity and shrinkage porosity of the castings are avoided, and the castings with good internal quality are ensured to be obtained. The volume and the quantity of the feeder heads are generally determined by the structural shape and the volume of the casting, the total quantity of the supplemented molten liquid in the feeder heads generally accounts for 30-60% of the weight of the casting, the actual supplementary consumption of the molten liquid only accounts for about 10%, and the residual quantity of the supplemented molten liquid reaches about 90%. In addition, the riser needs to be cut and separated from the casting to be used as a scrap return material to be melted again, so that a large amount of energy is wasted, and the production cost of the casting is increased. For large propellers produced in China at present, in order to realize feeding, the size of a riser is large, the riser accounts for 22% -30% of the weight of a casting, raw materials are wasted, and the process export rate is low; and the riser is large, the cutting is difficult, and the reutilization is also difficult.
In order to improve the feeding efficiency of risers and the casting process yield, the common riser technology is developed to be applied to various special riser technologies such as an insulating riser, an exothermic riser, a heating riser, a pressurizing riser and the like at present, and the insulating riser and the exothermic riser are adopted in the conventional casting production method. The insulating feeder head and the heating feeder head are convenient to use, the feeding efficiency of the feeder head is improved to a certain extent, but for large castings, the solidification time of the casting is longer, so that the solidification time of molten metal in the feeder head is required to be longer, the effects of the insulating feeder head and the heating feeder head are not obvious, and the feeding efficiency of the feeder head is still lower.
The casting production is also carried out by a method of heating a riser in the current industrial production. The heating riser is further divided into a resistance heating riser, an electric arc heating riser, an electroslag heating riser and the like. In the prior art, the feeder head is heated and insulated by an electric arc, plasma or chemical heating method to compensate the heat loss of the feeder head and improve the feeding capacity of the feeder head, but the heat input by the prior art is mainly concentrated near a heating body, so that the problems of small heating area, low heat efficiency, molten steel pollution and the like exist. In recent years, induction heating risers have appeared, and the molten metal in the riser is heated mainly by using the induction heating principle, so that the feeding efficiency of the riser is improved.
Chinese patent CN102350485A discloses a device and a process for medium-frequency electric heating billet casting shrinkage hole, which are used for billet casting shrinkage. This patent is at steel mould upper portion assembly pouring rising head, and the rising head is suppressed with the mixed bubble flower alkali of quartz sand, has induction heating coil at the rising head overcoat, is connected with the intermediate frequency induction heating switch board. And (3) electrifying and heating the induction coil in time after the molten steel is fully cast, and then gradually reducing the current to ensure that the temperature of the molten steel in the riser is reduced at the speed of 100-120 ℃ per minute until the molten steel is completely solidified. The invention effectively reduces the cooling speed of the riser and greatly improves the product percent of pass. However, the invention is only suitable for steel ingot production, and the molten steel is directly poured into a steel mold cavity from a riser, and the electric heating is carried out only after the molten steel is fully poured. In addition, the magnetic lines of force emitted in this patent inductively heat the iron mold when passing through the iron mold, reducing the cooling capacity of the iron mold.
The Chinese patent CN103212675A discloses an induction heating and electromagnetic stirring device for a steel ingot feeder head, which is used for heating, heat preservation and electromagnetic stirring of the feeder head of a ferrous and nonferrous metal cast ingot. The multi-group induction coils are vertically arranged outside a riser heat-insulating sleeve of a steel ingot and are connected with a three-phase power frequency power supply cabinet through water-cooling cables. After the power supply is switched on, molten steel in the riser is inductively heated, so that the heat loss of the molten metal in the riser in the steel ingot solidification process is compensated, the solidification process of the riser is delayed, the feeding capacity of the riser is improved, a magnetic field is formed around the riser, an electromagnetic stirring effect is generated on the metal melt under the action of the magnetic field, the gas and the impurities in the metal melt are favorably removed, and the quality of the steel ingot is improved. The invention is also only suitable for steel ingot production, and the electric heating is started after the molten steel is poured from the top of the feeder head.
Chinese utility model patent CN202316980U discloses a casting rising head induction heating device, this patent series capacitor and at least a pair induction coil in inverter output circuit, every pair induction coil corresponds the cover and establishes on a rising head cup outer wall to can use than the less model rising head cup that normal rising head will be little, can reduce the total amount of molten metal and the surplus of metal in the rising head like this, molten metal utilization ratio can reach more than 95% in the rising head, the waste and the saving electric energy of the heat energy that significantly reduces. In the patent, after the molten metal is poured, the induction heating power supply is started to perform induction heating on the molten metal in the riser cup.
Therefore, the existing method and device for induction heating the riser start the induction heating power supply after the molten metal is poured, so that the molten metal in the riser is subjected to induction heating and heat preservation by utilizing the induction heating principle. And because the riser material is non-conductive material, if the molten metal is not filled in the riser, the riser can not be inductively heated even if the induction heating power supply is started before pouring. In fact, in the casting production process, when molten metal is poured, the molten metal with high temperature meets the low-temperature riser cup, and a solid metal shell layer is formed near the outer wall of the riser cup under the chilling action of the molten metal, so that the feeding efficiency of the molten metal in the riser is directly reduced, and meanwhile, the solidified shell layer can block the downward flow of the molten metal to influence the feeding effect. In addition, when the molten metal is poured, a large amount of heat is also dissipated in the process of filling the molten metal in the riser, so that the temperature of the molten metal in the riser is reduced quickly, and particularly, a long pouring time is often needed in large casting production. These all greatly reduce the feeding efficiency of the feeder.
Disclosure of Invention
The purpose of the invention is as follows: the invention provides an induction heating device and an induction heating method for a casting riser, and aims to overcome the defect that the feeding efficiency of the prior riser technology is still low.
The technical scheme is as follows:
the utility model provides a casting rising head induction heating device which characterized in that: the device comprises a riser sleeve, a graphite sleeve, a steel sleeve or a circular sleeve made of other conductive materials, an induction coil, a thermocouple, a water-cooling cable, a temperature recorder and an induction heating power supply box; the circular ring sleeve is arranged on the periphery of the riser sleeve, the induction coil is arranged on the periphery of the circular ring sleeve, two ends of the induction coil are connected with the induction heating power supply box through water-cooling cables, the temperature recorder is connected with the thermocouple, and the thermocouple is in contact with the inner wall of the riser sleeve.
And heat insulating material is arranged between the induction coil and the circular ring sleeve.
The casting riser induction heating method implemented by the casting riser induction heating device is characterized by comprising the following steps of: according to the method, the graphite sleeve, the steel sleeve or the annular sleeve made of other conductive materials is placed outside the riser sleeve, the induction coil is placed outside the annular sleeve, the conductive material annular sleeve outside the riser sleeve is heated through the induction coil, and then molten metal in the riser sleeve and the riser is heated, so that the temperature difference between the molten metal in the riser and the riser sleeve is reduced, the heat loss of the molten metal in the riser is reduced, and the effect of delaying the solidification of the molten metal in the riser is achieved.
Before the molten metal is poured, the annular sleeve is heated by using the induction heating coil, and then the temperature of the empty riser sleeve is raised by using the heat transfer principle, so that the temperature difference between the molten metal in the riser and the riser sleeve can be reduced when the molten metal enters the riser after the molten metal is poured, the effect of delaying the solidification of the molten metal in the riser is achieved, and the feeding efficiency of the casting riser and the process exit rate of the casting are improved.
The feeder heads with different sizes can adopt the ring sleeves with different specifications and the induction coils corresponding to the ring sleeves, or only adopt one larger induction coil, and then the requirements of the feeder heads with different sizes in actual production are met by changing the structural size of the ring sleeve.
The induction heating power box adopts an IGBT power supply, the cooling mode can be water cooling or air cooling, or the power box adopts silicon controlled rectifier for adjustment, the silicon controlled rectifier power supply adopts the water cooling mode, and the power of the induction coil is changed by adjusting the output power of the power supply, so that the preheating temperature of the ring sleeve and the temperature of the molten metal in the riser after pouring are controlled.
The thermocouple contacts with the inner wall of the circular sleeve, a temperature signal measured by the thermocouple is transmitted to the multipoint temperature recorder, the output power of the power supply is adjusted by observing the indication information on the temperature recorder, and then the temperature of the circular sleeve is adjusted.
The other conductive materials adopted by the ring sleeve are graphite, steel, iron and copper aluminum, the graphite material is selected as the ring sleeve for the production of steel castings, the other conductive materials are selected for the production of low-melting-point nonferrous alloy material castings, and the melting point of the material of the ring sleeve is higher than the temperature of poured metal liquid.
The method utilizes the induction heating coil to heat the circular ring sleeve to realize the preheating effect of the riser sleeve, and utilizes the induction heating coil to directly heat the molten metal in the riser sleeve after the molten metal is poured into the riser sleeve, so that the molten metal in the riser can play a feeding role to the maximum extent, and the shrinkage defect of a casting is avoided.
Heat insulating material is arranged between the induction coil and the circular ring sleeve; the power supply frequency adopts intermediate frequency.
The advantages and effects are as follows: the invention provides an induction heating riser method, which adopts medium-frequency induction heating, not only heats a riser sleeve before pouring, but also heats a riser and molten metal in the riser all the time in the pouring process and after pouring is finished, thereby greatly reducing the heat loss of the molten metal in the riser and obviously improving the feeding efficiency of the riser. The casting riser device comprises 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.
The casting riser induction heating method provided by the invention utilizes an induction heating principle, the heating process is carried out before pouring, the chilling effect of the riser sleeve on the molten metal entering the riser is reduced, and after the molten metal is poured into the riser, the riser sleeve and the molten metal in the riser are simultaneously heated, so that the solidification time of the molten metal in the riser can be greatly prolonged.
The casting riser induction heating method can adopt ring sleeves with different specifications and induction coils corresponding to the ring sleeves aiming at risers with different sizes. In order to improve the applicability of the casting riser induction heating device, only one larger induction coil can be adopted, and then the requirement of risers with different sizes in actual production can be met by changing the structural size of the annular sleeve.
According to the casting riser induction heating method, the power box adopts an IGBT power supply, and the cooling mode can be water cooling or air cooling. The power box can also be regulated by adopting a silicon controlled rectifier, and the silicon controlled rectifier power supply adopts a water cooling mode. The power of the induction coil is changed by adjusting the output power of the power supply, so that the preheating temperature of the circular ring sleeve and the riser sleeve and the temperature of molten metal in the riser after pouring are controlled.
According to the casting riser induction heating method, the power frequency adopts the intermediate frequency. Because the electromagnetic force borne by the molten metal is inversely proportional to the square root of the power supply frequency, the electromagnetic stirring force of the medium-frequency power supply is much smaller than that of the power-frequency power supply. The medium-frequency power supply has better effect on removing impurities and uniform chemical components of molten metal in the riser and uniform temperature. The better electromagnetic stirring effect of intermediate frequency induction heating is also favorable to the come-up of molten metal gas and inclusion in the rising head, also is favorable to alleviateing the oxidation of high temperature liquid metal moreover to can improve the quality of molten metal in the rising head, and then can reduce the gas pocket in the foundry goods and mix with class defect.
According to the casting riser induction heating method, the thermocouple is in contact with the inner wall of the riser sleeve, a temperature signal measured by the thermocouple is transmitted to the multipoint temperature recorder, the output power of the power supply is adjusted by observing indication information on the temperature recorder, and then the temperature of the circular ring sleeve and the temperature of the riser sleeve are adjusted.
According to the induction heating method for the casting riser, the annular sleeve can be made of other conductive materials, such as graphite, steel, iron, copper, aluminum and other materials. For the production of steel castings, graphite materials are selected as the ring sleeves. For the production of low melting point non-ferrous alloy castings, other electrically conductive materials may be selected. The melting point of the material of the ring sleeve is higher than the temperature of the poured metal liquid.
According to the casting riser induction heating device, the induction heating coil is used for heating the circular ring sleeve to achieve the preheating effect of the riser sleeve, and the induction heating coil is used for directly heating the molten metal in the riser sleeve after the molten metal is poured into the riser sleeve, so that the molten metal in the riser can play a feeding role to the greatest extent, and the casting is prevented from generating shrinkage defects.
The invention has the following specific beneficial effects: the invention adopts an induction heating mode, combines indirect heating and direct heating, namely, the riser sleeve is indirectly heated in advance, the chilling effect of the riser sleeve on the molten metal entering the riser is reduced, and the molten metal entering the riser in the casting process is directly inductively heated, so that the solidification time of the molten metal in the riser is greatly prolonged, the feeding effect of the molten metal in the riser is fully exerted, the feeding efficiency of the molten metal in the riser is obviously improved, the riser size of a casting is greatly reduced, the generation of the shrinkage cavity and shrinkage porosity defect in the casting is reduced and even avoided, and finally the improvement of the internal quality of the casting and the improvement of the process outlet rate of the casting are realized. The invention adopts induction heating, has simple and reliable equipment composition, easy realization, large heating area, high heating speed and high heating efficiency, can be suitable for the casting production of various metal castings with different weights and sizes, and is particularly suitable for the production of medium and large castings. Compared with the existing heat-insulating riser and heating riser, the invention has the following advantages: (1) the effect of prolonging the riser solidification time is more remarkable than that of a heat-insulating riser and a heating riser; (2) the temperature of molten metal in the riser can be controlled in real time; (3) the induction heating riser can be recycled, and the production cost is relatively low; (4) the environment pollution can not be caused in the using process, and the environment-friendly requirement is better met. Compared with the existing resistance heating riser, electric arc heating riser and electroslag heating riser, the invention has the advantages that: (1) the heating efficiency is higher; (2) the energy-saving and emission-reducing effects are better; (3) in the casting process, induction heating can not cause pollution to the metal liquid in the riser, so that the metal liquid in the riser is relatively pure, and the defects of impurities and the like in the casting can be reduced.
Description of the drawings:
fig. 1 is a schematic view of an induction heating riser apparatus.
Fig. 2 is a top view of an induction heating riser section.
Fig. 3 shows a rod-shaped casting mold used in the example.
FIG. 4 is a comparison of the actual feeding effect of the feeder in the example, wherein FIG. 4a shows the diameter of the feederΦA 100mm conventional riser, FIG. 4b is a diameter ofΦ60mm conventional risers, FIG. 4c diameterΦAn induction heating riser of 60 mm;
in the above drawings, the components are: 1. molten metal in the riser; 2. a riser sleeve; 3. a circular ring sleeve; 4. an induction coil; 5. a thermocouple; 6. a water-cooled cable; 7. a multipoint temperature recorder; 8. sand molding; 9. an induction heating power supply box; 10. a pouring cup; 11. and a magnetic yoke.
The specific implementation mode is as follows:the invention is further illustrated below with reference to examples and experimental methods:
the invention relates to an induction heating device for a casting riser, which comprises a riser sleeve 2, a graphite sleeve, a steel sleeve or a circular sleeve 3 made of other conductive materials, an induction coil 4, a thermocouple 5, a water-cooling cable 6, a temperature recorder 7 and an induction heating power supply box 9, wherein the graphite sleeve is arranged on the riser sleeve; the circular ring sleeve 3 is arranged on the periphery of the riser sleeve 2, the induction coil 4 is arranged on the periphery of the circular ring sleeve 3, two ends of the induction coil 4 are connected with the induction heating power supply box 9 through the water-cooled cable 6, the temperature recorder 7 is connected with the thermocouple 5, and the thermocouple 5 is in contact with the inner wall of the riser sleeve 2.
The casting riser induction heating method implemented by the casting riser induction heating device comprises the steps of placing a graphite sleeve, a steel sleeve or a ring sleeve 3 made of other conductive materials outside a riser sleeve 2, placing an induction coil 4 outside the ring sleeve, heating the conductive material ring sleeve outside the riser sleeve through the induction coil, further heating the riser sleeve and molten metal 1 in a riser, reducing the temperature difference between the molten metal in the riser and the riser sleeve, reducing the heat loss of the molten metal in the riser, and achieving the effect of delaying the solidification of the molten metal in the riser.
Before the molten metal is poured, the annular sleeve 3 is heated by the induction heating coil 4, and then the empty riser sleeve 2 is heated by the heat transfer principle, so that the temperature difference between the molten metal in the riser and the riser sleeve can be reduced when the molten metal enters the riser after the molten metal is poured, the effect of delaying the solidification of the molten metal in the riser is achieved, and the feeding efficiency of the casting riser and the process exit rate of the casting are improved.
This application utilizes induction heating principle, and the heating process goes on before the pouring, has reduced the chilling effect of riser cover to the molten metal that gets into in the riser to back in the molten metal pouring gets into the riser, the molten metal heats in riser cover and the riser simultaneously, thereby can prolong the setting time of molten metal in the riser greatly.
Aiming at risers with different sizes, the ring sleeves 3 with different specifications and the induction coils 4 corresponding to the ring sleeves can be adopted, or only one larger induction coil is adopted, and then the requirements of risers with different sizes in actual production are met by changing the structural size of the ring sleeve 3.
The induction heating power box 9 adopts an IGBT power supply, the cooling mode can be water cooling or air cooling, or the power box 9 adopts silicon controlled rectifier for adjustment, the silicon controlled rectifier power supply adopts the water cooling mode, and the power of the induction coil 4 is changed by adjusting the output power of the power supply, so that the preheating temperature of the ring sleeve 3 and the temperature of the molten metal in the riser after pouring are controlled.
Thermocouple 5 contacts with 3 inner walls of ring cover, and the temperature signal who measures by the thermocouple transmits for multiple spot temperature recorder 7, adjusts power output through observing the indicating information on temperature recorder 7, and then adjusts the temperature of ring cover 3.
Other conductive materials adopted by the ring sleeve 3 are graphite, steel, iron and copper aluminum, for the production of steel castings, graphite materials are selected as the ring sleeve, and for the production of low-melting-point nonferrous alloy material castings, other conductive materials can be selected. The melting point of the material of the ring sleeve 3 is higher than the temperature of the poured metal liquid.
Other conductive materials, such as graphite, steel, iron, copper, aluminum, and other materials, can also be used for the annular sleeve 3.
According to the method, the induction heating coil 4 is used for heating the circular ring sleeve 3 to achieve the preheating effect of the riser sleeve 2, and the induction heating coil 4 is used for directly heating the molten metal in the riser sleeve 2 after the molten metal is poured into the riser sleeve, so that the molten metal in a riser can play a feeding role to the greatest extent, and the casting is prevented from generating shrinkage defects.
Heat insulation material is arranged between the induction coil 4 and the circular ring sleeve 3; the power supply frequency adopts intermediate frequency.
Fig. 1 is a schematic diagram of the induction heating riser apparatus of the present invention. Wherein the induction coil has an inner diameter ofΦ255mm, the copper pipe with the square cross section is adopted for manufacturing, the size of the square cross section is 23mm multiplied by 25mm, and cooling water is introduced into the middle of the square cross section. The induction coil is coiled into a spiral shape by a pure copper pipe with a square section, and an insulating mica tape is wound on the outer surface of the induction coil. The induction coil yoke is used outside. The height of the induction heater consisting of an induction coil was 160 mm. The ring sleeve 3 is made of graphite and has an inner diameter ofΦ85mm, 20mm wall thickness and 160mm height. The riser sleeve is made of ceramic and has an inner diameter ofΦ60mm, 7mm wall thickness and 150mm height. The power supply adopts an IGBT power supply, the maximum power is 100kW, and the power is adjustable. The sectional area of the water-cooled cable is 300mm2The maximum carrying current reaches 2400A. Asbestos, a heat insulating material, is placed between the induction coil 4 and the toroidal sleeve 3. The induction coil 4, the circular ring sleeve 3 and asbestos between the induction coil and the circular ring sleeve are all arranged on a ceramic plate base.
A simple plate-like casting was used as an example model, and its dimensions were 400 mm. times.160 mm. times.40 mm. The sizes of the upper and lower sand boxes are 700mm multiplied by 200 mm. An open gating system is used.
The operation process of the embodiment is as follows: first, the model is formed. The molding is carried out by adopting ester hardening self-hardening sodium silicate sand. Wherein the lower mould is only a plain sand block and only supports the upper mould. The cope molding requires a pattern. The die comprises a sprue, a cross gate, an ingate and a plate casting die, and also comprises a die for forming a space for placing an induction heating riser. The pattern is provided with draft angle for drawing. Before modeling, the mold parting agent is coated. Firstly, placing the sprue, the cross gate, the ingate and the plate-shaped casting pattern in a sand box, and then filling sand and compacting. And when the molding sand is compacted to a certain thickness, putting the molding sand into a space for forming the induction heating riser, continuously filling the molding sand, compacting the molding sand, and scraping the molding sand. And (3) after waiting for a period of time, starting stripping, stripping the sprue pattern and the induction heating riser space by using the pattern, turning the sand mold, and stripping the horizontal sprue, the ingate and the plate casting pattern, so that the upper mold is manufactured. After the upper sand mould and the lower sand mould are hardened and compacted, the mould is closed, and after the mould is closed, the induction heating riser device is placed into a cylindrical space which is formed in the upper mould in advance. Then the ceramic riser bush is directly put into the circular ring bush 3. If the gap between the riser bush and the ring bush is large, dry sand can be filled in.
After the molding, the alloy material is melted. In the examples, ZG35 material with a large shrinkage rate was used as the material of the plate-like casting. Smelting is carried out by adopting a 50kg electromagnetic induction furnace. When the alloy smelting temperature reaches 1650 ℃, tapping molten iron is deoxidized, slagging off and the like, and finally, the molten iron is poured into a pouring cup at about 1560 ℃.
This application is in the alloy smelting operation, and the power of beginning switch on induction heating rising head device 30 minutes before the casting, induction coil circular telegram carries out induction heating to ring cover 3, and ring cover temperature can promote to more than 1500 ℃ within 20 minutes, and then carries out indirect preheating to rising head cover 2. The thermocouple 5 contacts with the inner wall of the riser bush 2, a temperature signal measured by the thermocouple is transmitted to the multipoint temperature recorder 7, the power output power of the induction heating riser device is adjusted by observing the indication information on the temperature recorder 7, and then the preheating temperature of the circular ring bush 3 and the riser bush 2 is adjusted. The preheating temperature of the riser bush is set to be 1500 ℃, and when the temperature is reached, heat preservation is carried out to wait for casting.
And keeping the power of an induction coil of the induction heating riser device uninterrupted when the molten steel is poured. Along with the pouring, the metal liquid can gradually fill the riser, so that the useful power supply power of the induction heating riser device is increased, the temperature of the graphite ring sleeve is rapidly increased, in order to maintain the temperature of the graphite ring sleeve, the power supply power of the induction heating riser device is reduced, the temperature of the graphite ring sleeve is maintained at about 1500 ℃, and the method still adjusts the power supply power of the induction heating riser device through the information displayed on the paperless multipoint temperature recorder 7.
It is also desirable to keep the induction coil of the induction heating riser apparatus powered off during solidification of the slab. The length of the induction heating time is determined by calculating the solidification time of the casting, and 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 slab casting is about 5min, so that the power supply of the induction heating riser device is turned off after about 8min after the completion of pouring.
After the power supply of the induction heating coil is cut off, cooling water still needs to be continuously introduced to protect the induction heating riser device. And after the casting is completely cooled to the room temperature, closing the circulating cooling water, and removing the induction heating riser device from the upper sand mold. And then boxing and taking out the flat plate casting for test effect analysis.
After the casting head of the slab casting was cut off, the slab casting was sectioned from the middle to observe and analyze the occurrence of shrinkage cavity and shrinkage porosity defects of the slab casting, and the test results are shown in fig. 4 c. In order to verify the effectiveness of the induction heating risers, comparative tests were also performed.
The comparative test uses the same slab casting as a model and respectively adoptsΦ100mm andΦthe test is carried out on 60mm ceramic tube risers, the wall thickness of each riser is 7mm, and the height of each riser is 150 mm. But no induction heating riser device is arranged outside the riser. The test results are shown in fig. 4a and 4b, respectively. Wherein,Φthe test of the feeder of the 100mm ceramic tube was carried out according to the basic principle of casting process design (according to the casting handbook), i.e. casting with a plain feeder, a slab casting with dimensions of 400mm x 160mm x 40mmNeed of a pieceϕ100mm 150mm large feeder.
As can be seen from the test results of FIG. 4, the diameter isΦThe casting obtained by the feeder head with the diameter of 100mm has good quality, and the root of the feeder head does not have any defect; and a diameter ofΦThe method comprises the following steps of (1) causing shrinkage cavity and shrinkage porosity defects to exist in a casting obtained by a 60mm riser without an induction heating device, and particularly causing the root of the riser to have obvious defects; but still have a diameter ofΦThe casting with the 60mm riser is good in internal quality after the induction heating device is placed, and the root of the riser has no obvious defect.
The comparative test shows that more molten metal in the induction heating riser can be fed into the casting, so that the obtained casting is good in quality, the size of the riser is greatly reduced, the feeding efficiency of the riser is improved, the process outlet rate of the casting is obviously improved, and the induction heating riser has a good effect.
Claims (10)
1. The utility model provides a casting rising head induction heating device which characterized in that: the device 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-cooling cable (6), a temperature recorder (7) and an induction heating power supply box (9); the round ring sleeve (3) is arranged on the periphery of the riser sleeve (2), the induction coil (4) is arranged on the periphery of the round ring sleeve (3), two ends of the induction coil (4) are connected with the induction heating power supply box (9) through the water-cooling cable (6), the temperature recorder (7) is connected with the thermocouple (5), and the thermocouple (5) is in contact with the inner wall of the riser sleeve (2).
2. The casting riser induction heating apparatus of claim 1, wherein: and a heat insulation material is arranged between the induction coil (4) and the circular ring sleeve (3).
3. A casting riser induction heating method performed by the casting riser induction heating apparatus according to claim 1, characterized by comprising: according to the method, the graphite sleeve, the steel sleeve or the annular sleeve (3) made of other conductive materials is placed outside the riser sleeve (2), the induction coil (4) is placed outside the annular sleeve, the conductive material annular sleeve outside the riser sleeve is heated through the induction coil, and then the riser sleeve and the molten metal (1) in the riser are heated, so that the temperature difference between the molten metal in the riser and the riser sleeve is reduced, the loss of the heat of the molten metal in the riser is reduced, and the effect of delaying the solidification of the molten metal in the riser is achieved.
4. The method of induction heating of the casting riser of claim 3, wherein: before the molten metal is poured, the annular sleeve (3) is heated by the induction heating coil (4), and then the temperature of the empty riser sleeve (2) is raised by utilizing the heat transfer principle, so that the temperature difference between the molten metal in the riser and the riser sleeve can be reduced when the molten metal enters the riser after the molten metal is poured, the effect of delaying the solidification of the molten metal in the riser is achieved, and the feeding efficiency of the casting riser and the process exit rate of the casting are improved.
5. The method of induction heating of the casting riser of claim 3, wherein: aiming at risers with different sizes, the circular sleeve (3) with different specifications and the induction coil (4) corresponding to the circular sleeve can be adopted, or only one larger induction coil is adopted, and then the requirements of risers with different sizes in actual production are met by changing the structural size of the circular sleeve (3).
6. The method of induction heating of the casting riser of claim 3, wherein: the induction heating power box (9) adopts an IGBT power supply, the cooling mode can be water cooling or air cooling, or the power box (9) adopts silicon controlled rectifier for adjustment, the silicon controlled rectifier power supply adopts a water cooling mode, and the power of the induction coil (4) is changed by adjusting the output power of the power supply, so that the preheating temperature of the circular sleeve (3) and the temperature of the molten metal in the riser after pouring are controlled.
7. The method of induction heating of the casting riser of claim 3, wherein: thermocouple (5) and ring cover (3) inner wall contact, and the temperature signal who measures by the thermocouple transmits for multiple spot temperature recorder (7), adjusts power output through observing the indicating information on temperature recorder (7), and then adjusts the temperature of ring cover (3).
8. The method of induction heating a foundry riser as set forth in claim 2, wherein: other conductive materials adopted by the ring sleeve (3) are graphite, steel, iron and copper activated aluminum, for the production of steel castings, graphite materials are selected as the ring sleeve, for the production of low-melting-point nonferrous alloy material castings, other conductive materials are selected, and the melting point of the material of the ring sleeve (3) is higher than the temperature of poured metal liquid.
9. The method of induction heating of the casting riser of claim 3, wherein: according to the method, the induction heating coil (4) is used for heating the circular ring sleeve (3) to achieve the preheating effect of the riser sleeve (2), and the induction heating coil (4) is used for directly heating the molten metal in the riser sleeve (2) after the molten metal is poured into the riser sleeve, so that the molten metal in a riser can play a feeding role to the greatest extent, and the casting is prevented from generating shrinkage defects.
10. The method of induction heating of the casting riser of claim 3, wherein: heat insulation materials are placed between the induction coil (4) and the circular ring sleeve (3); the power supply frequency adopts intermediate frequency.
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| CN106734933A (en) * | 2016-12-31 | 2017-05-31 | 邓锦志 | One kind casting heating rising head |
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| CN110791750A (en) * | 2019-10-15 | 2020-02-14 | 中北大学 | Method for improving bonding strength of aluminum-steel bimetal solid-liquid composite casting interface |
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