CN105382206A - Casting mold and forming method for box body of gearbox - Google Patents
Casting mold and forming method for box body of gearbox Download PDFInfo
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- CN105382206A CN105382206A CN201510916548.5A CN201510916548A CN105382206A CN 105382206 A CN105382206 A CN 105382206A CN 201510916548 A CN201510916548 A CN 201510916548A CN 105382206 A CN105382206 A CN 105382206A
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- precoated sand
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- lump
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- 238000005266 casting Methods 0.000 title claims abstract description 119
- 238000000034 method Methods 0.000 title claims abstract description 37
- 239000004576 sand Substances 0.000 claims abstract description 202
- 229920005989 resin Polymers 0.000 claims abstract description 79
- 239000011347 resin Substances 0.000 claims abstract description 79
- 244000035744 Hura crepitans Species 0.000 claims abstract description 29
- 238000000465 moulding Methods 0.000 claims abstract description 25
- 239000007788 liquid Substances 0.000 claims abstract description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical group O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 225
- 238000007493 shaping process Methods 0.000 claims description 29
- 239000011248 coating agent Substances 0.000 claims description 15
- 238000000576 coating method Methods 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 15
- 238000003618 dip coating Methods 0.000 claims description 14
- 229920003986 novolac Polymers 0.000 claims description 14
- 230000003746 surface roughness Effects 0.000 claims description 11
- 229910045601 alloy Inorganic materials 0.000 claims description 10
- 239000000956 alloy Substances 0.000 claims description 10
- 238000002844 melting Methods 0.000 claims description 10
- 230000008018 melting Effects 0.000 claims description 10
- 238000007711 solidification Methods 0.000 claims description 10
- 230000008023 solidification Effects 0.000 claims description 10
- 239000006004 Quartz sand Substances 0.000 claims description 9
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 claims description 8
- 239000008116 calcium stearate Substances 0.000 claims description 8
- 235000013539 calcium stearate Nutrition 0.000 claims description 8
- 235000010299 hexamethylene tetramine Nutrition 0.000 claims description 8
- VKYKSIONXSXAKP-UHFFFAOYSA-N hexamethylenetetramine Chemical compound C1N(C2)CN3CN1CN2C3 VKYKSIONXSXAKP-UHFFFAOYSA-N 0.000 claims description 8
- 229960004011 methenamine Drugs 0.000 claims description 8
- 239000007921 spray Substances 0.000 claims description 6
- 208000034189 Sclerosis Diseases 0.000 claims description 5
- 238000007872 degassing Methods 0.000 claims description 5
- 238000007670 refining Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 abstract description 10
- 239000002184 metal Substances 0.000 abstract description 10
- 230000015572 biosynthetic process Effects 0.000 abstract description 6
- 230000007547 defect Effects 0.000 abstract description 6
- 238000005245 sintering Methods 0.000 abstract description 5
- 206010039509 Scab Diseases 0.000 description 13
- 230000001680 brushing effect Effects 0.000 description 10
- 238000010586 diagram Methods 0.000 description 9
- 239000003973 paint Substances 0.000 description 6
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 6
- 230000005484 gravity Effects 0.000 description 4
- 239000000377 silicon dioxide Substances 0.000 description 4
- 239000004411 aluminium Substances 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000010923 batch production Methods 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000007596 consolidation process Methods 0.000 description 3
- 238000009749 continuous casting Methods 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 239000003110 molding sand Substances 0.000 description 3
- 238000010422 painting Methods 0.000 description 3
- 101100384819 Caenorhabditis elegans cope-1 gene Proteins 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000005429 filling process Methods 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000004382 potting Methods 0.000 description 2
- 238000007528 sand casting Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 229910000521 B alloy Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 230000003031 feeding effect Effects 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000007591 painting process Methods 0.000 description 1
- 238000010120 permanent mold casting Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention provides a casting mold and forming method for a box body of a gearbox and belongs to the technical field of liquid formation of metal. The forming method comprises the following steps that precoated sand is used for core shooting, so that precoated sand blocks are manufactured, then an outer precoated sand mold layer is formed by splicing the precoated sand blocks, and the outer precoated sand mold layer and a sand core are used for forming a casting cavity of the box body of the gearbox; and finally the box body of the gearbox is manufactured through the casting mold in a low-pressure casting way. According to the specific structure of the casting mold, the sand core is located in the center of the casting mold; the casting cavity is formed in the outer layer of the sand core and mainly formed by the sand core and the outer precoated sand mold layer; an outer resin sand mold layer is arranged on the outer layer of the outer precoated sand mold layer, and the outer precoated sand mold layer and a sand box are connected through the outer resin sand mold layer, so that the casting mold is formed. According to the casting mold and forming method for the box body of the gearbox, the cavity which is formed by the precoated sand and used for large complicated castings is used for low-pressure casting for the first time, the precoated sand blocks are subjected to core shooting under pressure, high-temperature sintering formation is conducted, filling is compact, and the situations that sand filling is incompact and sand adhesion defects are caused due to human factors during resin sand molding are avoided.
Description
Technical field
The present invention relates to a kind of casting mold and forming method thereof of gear-box, be specifically related to a kind of gear case body casting mold and forming method thereof, belong to liquid metal field shaping technique.
Background technology
Existing gear-box molding mode is mainly sand casting and permanent mold casting.Sand casting die cavity generally adopts phenolic sand molding, after phenolic sand molding there is cross-linking reaction and harden in resin under the catalytic action of curing agent, the resin sand grains of sand after sclerosis and between the grains of sand hole larger, simultaneously because the refractoriness of resin sand is lower, when casting, die cavity directly contacts aluminium liquid with aluminium liquid and enters grains of sand gap, top layer and very easily produce scab, affects the quality of foundry goods.In order to improve die cavity refractoriness, avoid scab, just must on die cavity brush one coating; In the process of brushing, just inevitably form brush mark, affect the presentation quality of foundry goods.In addition, phenolic sand molding needs tamp or shake ram-jolt a little on bumper by hand, and the quality of die cavity depends on the degree of workman comparatively greatly, for intricate casting, if the problems such as the tight just easy generation back-up sand of plug is unreal, cause later stage foundry goods to produce the quality problems such as scab, misrun.In addition, the presentation quality of foundry goods and batch production outward appearance uniformity poor.
When gear-box die cavity is metal mold, effectively can prevent the quality problems of foundry goods scab, surface quality of continuous castings is good.But metal type dies heat conduction is fast, and in order to improve the heat-insulating property of mould, be convenient to foundry goods molding, metal type dies also needs spray paint on die cavity before casting simultaneously; In order to improve the coating quality of coating, during spray paint, mould must be heated to about 200 DEG C, and during spray paint, mould installs at casting platform, and temperature is higher, and operation is very inconvenient.Because metal type dies does not possess gas permeability, exhaust must be set when mould is offered, defects such as arranging more difficult, easy generation is felt suffocated, pore is vented for large-scaled complex castings.Metal die does not possess deformability simultaneously, and foundry goods easily produces casting stress in process of setting, if casting stress effectively can not be removed and be present in cast-internal, under the operating mode of complexity, foundry goods just easily cracks, and finally causes the generation of accident.
Although apply the existing existence of die cavity of precoated sand mould casting in prior art, it is applied in gravitational casting aspect mostly, or is only precoated sand core shooting is formed simple loam core be applied to Castingother.Wherein, precoated sand is used for gravitational casting, shaping foundry goods clear-cut, simple to operate; The pressure that gravitational casting molten metal bears in die cavity is less, and the gap that molten metal is not easy through between the grains of sand enters layer of sand, not easily produces scab; And precoated sand gravitational casting is without the need to swabbing.
And for large complicated gear housing shell moulded casting, be not suitable for adopting the casting of gravity precoated sand, if adopt the casting of gravity precoated sand, the speed that aluminium liquid enters die cavity is affected by gravity, unadjustable, easily produce at cavity filling process and splash and volume gas, splashing and volume gas just cause foundry goods to produce the defect such as cold shut and pore.Meanwhile, foundry goods solidifies under gravity, and the pressure be subject to is less, is unfavorable for feeding, and foundry goods easily produces the defect such as shrinkage porosite, shrinkage cavity.For large complicated gear housing foundry goods, by cavity filling process is steady, molded tissue is finer and closely woven, the better low pressure casting of feeding effect realizes; Low pressure casting solidifies under stress, and must carry out brushing to prevent scab to die cavity, existing mode painting efficiency is lower, easily produces brush mark after brushing, affects the surface quality of foundry goods.
For ensureing the dimensional accuracy after casting pouring and surface roughness, improve quality and the yield rate of foundry goods, not only casting mold need have certain intensity, also need to ensure the dimensional accuracy after casting pouring and surface roughness by certain technological measure, improve quality and the yield rate of foundry goods, conventional process is all difficult to meet the demands.
Summary of the invention
For the shortcoming that prior art exists, the object of the present invention is to provide a kind of gear case body casting mold and forming method thereof, casting mold die cavity is made up of the outer mold layer of core, chill and precoated sand sand lump, foundry goods die cavity core shooting high temperature sintering is shaping under stress, fill consolidation, machine molding, avoid the defects such as the back-up sand scab that is unreal and that cause because back-up sand is unreal that phenolic sand molding process causes because of human factor, shaping foundry goods clear-cut, during batch production, outward appearance uniformity is good.Precoated sand die cavity, in conjunction with the mode of dip-coating, avoids brush mark and produces, improve brushing quality, improve painting efficiency simultaneously.This casting mold is used for shaping EMU gear-box in conjunction with low-pressure casting method by the present invention, and shaping gear-box is inner and presentation quality is good, and production efficiency is high.
The technical solution adopted for the present invention to solve the technical problems is:
A forming method for gear case body casting mold, step is as follows:
1) Design and manufacture of mould: design and manufacture precoated sand core shooting sand lump, core, the mould of chill and cast model, precoated sand locating piece model, the running gate system model with mould core print, and according to the requirement of casting mold somatotype, the above-mentioned cast model with mould core print, precoated sand locating piece model and running gate system model are fixed on template;
2) chill and core is made: adopt chill and core mold pour into a mould chill respectively and make core;
3) precoated sand core shooting manufactures precoated sand sand lump: the mould above-mentioned chill made being placed in precoated sand core shooting sand lump, and precoated sand under high pressure sprays and forms precoated sand sand lump;
4) moulding:
The precoated sand sand lump first polylith being coated coating is embedded on the cast model with mould core print, and precoated sand sand lump is spliced to form the outer mold layer of precoated sand sand lump, and the shape of the outer shape of mold layer of precoated sand sand lump and the cast model of described gear case body matches; The outside of the outer mold layer of precoated sand sand lump is provided with bulge-structure, and described bulge-structure is used for the overall demoulding outer for precoated sand sand lump mold layer and the outer mold layer of resin sand being fixedly convenient to the later stage;
Then on template, overlap cope, fill up resin sand between sandbox and the outer mold layer of precoated sand sand lump, resin sand sclerosis forms the outer mold layer of resin sand, and the outer mold layer of resin sand covers the outer mold layer of precoated sand completely and sandbox and the outer mold layer of precoated sand sand lump connected together; Namely the upper half mould of foundry goods die cavity or lower half mould is formed after molding;
5) core under: by step 2) core made puts into the lower half mould of described foundry goods die cavity;
6) mould assembling: by the lower half mould of the described foundry goods die cavity after lower core and upper half mould mould assembling, the casting mold of formative gear box body;
7) alloy melting: alloy carry out melting and carry out going bad, refining and degassing processing;
8) low-pressure casting: adopt the mode of low pressure casting to cast to described casting mold, casting cycle comprise rise liquid, fill type, crust, pressurize and stress-relief process;
9) unpack and clear up: unpacking and sand removal process after casting solidification, obtain gear case body foundry goods, surface roughness≤20 μm of described foundry goods.
Further, described step 3) in, the composition of precoated sand comprises the 70-140 order quartz sand of 60-80% and the 50-100 order quartz sand (percentage by weight) of 20-40%; Described precoated sand also comprises novolac resin, methenamine and calcium stearate; The content of novolac resin accounts for the 2-3% (percentage by weight) of quartz sand total amount; The content of methenamine accounts for the 10-15% (percentage by weight) of novolac resin, and the content of calcium stearate accounts for the 10-12% of novolac resin (percentage by weight).During core shooting, the temperature of the mould of precoated sand core shooting sand lump is 180 ~ 250 DEG C; Thickness >=the 10mm of the thinnest part of described precoated sand sand lump.
Surface roughness≤12 μm of described foundry goods.
Further, described step 4) in, only adopt the mode of dip-coating to coat coating to precoated sand sand lump and light a fire and dryout, the Baume degrees of coating is 22-24; Described bulge-structure is bevelling shape or dove tail shape; The gap that adjacent described precoated sand sand lump forms foundry goods die cavity side is set to 0, and pattern draft is set to 5-8 degree.
Described core adopt resin sand or precoated sand shaping; Described chill can be arranged in core or be positioned at the intersection of the outer mold layer of precoated sand sand lump and the outer mold layer of resin sand.
A kind of gear case body casting mold, be made up of core, die cavity, chill, the outer mold layer of precoated sand, the outer mold layer of resin sand and sandbox, die cavity comprises foundry goods die cavity and running gate system cavity, and running gate system cavity communicates with foundry goods die cavity; The structure of casting mold is specific as follows: the center of casting mold is core, and the skin of core is foundry goods die cavity, and foundry goods die cavity is by core, chill, precoated sand sand lump external mold formable layer, and chill is placed in the outer mold layer of precoated sand; The skin of the outer mold layer of precoated sand sand lump is the outer mold layer of resin sand, and the outer mold layer of resin sand covers the outer mold layer of precoated sand completely and fills up outside precoated sand sand lump between mold layer and sandbox, thus outer for precoated sand sand lump mold layer and sandbox is linked together, and forms casting mold;
The outer mold layer of described precoated sand sand lump is spliced by polylith precoated sand sand lump, and the shape of the outer shape of mold layer of precoated sand sand lump and the cast model of gear case body matches; The outside of the outer mold layer of precoated sand sand lump is provided with bulge-structure, for outer for precoated sand sand lump mold layer and the outer mold layer of resin sand being fixedly convenient to the overall demoulding in later stage.
Further, the thickness >=10mm of the thinnest part of described precoated sand sand lump.
Further, described bulge-structure is bevelling shape or dove tail shape; The gap that adjacent described precoated sand sand lump forms foundry goods die cavity side is set to 0, and pattern draft is set to 5-8 degree.
Further, described core adopt resin sand or precoated sand shaping; Described chill also can be arranged in core or be positioned at the intersection of the outer mold layer of precoated sand sand lump and the outer mold layer of resin sand.
The present invention has following beneficial effect:
(1) the present invention is used for low pressure casting by with the die cavity of the shaping large-scaled complex castings of precoated sand first, this casting mold die cavity is made up of the outer mold layer of core, chill and precoated sand sand lump, and precoated sand sand lump core shooting high temperature sintering is shaping under stress, fill consolidation, machine molding, avoid the defects such as the back-up sand scab that is unreal and that cause because back-up sand is unreal that phenolic sand molding process causes because of human factor, shaping foundry goods clear-cut, during batch production, outward appearance uniformity is good.
Compared with the die cavity that the present invention and phenolic sand molding are formed, the shaping grains of sand of precoated sand are tiny, mainly due to the forming under the pressure at machine, consolidation is filled on the surface of die cavity, gap between the grains of sand and the grains of sand is less, and the surface roughness shaping by precoated sand are little, and surface quality is good.
(2) outside of the outer mold layer of precoated sand sand lump is provided with bulge-structure, and the design of this bulge-structure can ensure that the outer mold layer of resin sand and the outer mold layer of precoated sand combine good; Simultaneously, can also utilize in the outer mold layer solidification process of resin sand to produce and shrink this feature of precoated sand sanding block grip, further the outer mold layer of precoated sand be fixed and well connected, being conducive to the demoulding that the outer mold layer of resin sand after the outer mold layer of precoated sand in subsequent process and solidification is overall.
(3) because low pressure casting completes cast under stress, sealing and safety-type must ensure; If directly die cavity shaping for precoated sand core shooting is used for low pressure casting, die cavity, sealing between whole running gate system and molten metal body of heater just cannot be realized.Precoated sand sand lump is embedded in inside sandbox by the present invention, and whole casting cycle running gate system and die cavity can effectively be sealed, and simple to operate, casting process is safe and reliable.
(4), during the moulding brushing of large-scaled complex castings resin sand low pressure, the mode of the manual brushing of Multipurpose brush is coated, and human factor is comparatively large on brushing impact, easily forms the phenomenons such as brush mark, sagging, leakage brush, affects the surface quality of foundry goods; And for the die cavity of complexity, painting process is very consuming time, the efficiency that impact is produced.If adopt the mode of dip-coating or flow coat, due to the related sandbox of die cavity, whole casting mold is too large, cannot operate, and the quality of dip-coating is also difficult to ensure.If adopt bulk container to carry out dip-coating, also can coat without the need to the place leaching of swabbing behind to sandbox, high to place, equipment requirement, paint waste is serious, to whole sandbox brushing, also affects the quality of foundry goods.
Large-scaled complex castings of the present invention due to the precoated sand sand lump of foundry goods be pre-buried being spliced to form, sand lump is less, can the mode of dip-coating be adopted to carry out paint to precoated sand sand lump before moulding, carry out moulding again, eliminate and use hairbrush brushing after dip-coating.The mold cavity surface of dip-coating is even, can not produce the factor that brush mark etc. affects surface quality of continuous castings.The painting efficiency of dip-coating is simultaneously high, and originally brushing die cavity probably needs 1 hour, and adopts dip-coating only to need 6 minutes, substantially increases the production efficiency of heavy castings.
(5) consider and splice the surface quality that base seam can affect foundry goods between precoated sand sand lump, the present invention is when Design of Dies, the gap that adjacent precoated sand sand lump forms foundry goods die cavity side is set to 0, and pattern draft is set to 5-8 degree: 0 gap decreases the impact of splicing base seam to greatest extent; The large pattern draft of 5-8 degree is conducive to resin sand and is filled between the gap of precoated sand sand lump, ensure that resin sand is combined with the close and firm of overlay film sand lump.
(6) cost due to resin sand is low relative to precoated sand, the present invention only foundry goods cavity portion adopt precoated sand shaping, adopt resin sand to fill between sandbox and precoated sand sand lump; Wherein, foundry goods cavity portion adopts precoated sand shaping, ensure that the Forming Quality of die cavity, and adopts resin sand shaping between sandbox and precoated sand sand lump, provide cost savings.
(7) the present invention adopts precoated sand shaping due to die cavity completely, and because the collapsibility of precoated sand is better than resin sand, the difficulty of sand removal of unpacking reduces, and decreases the labour intensity of sand removal.In addition, resin sand due to sand removal more difficult, low pressure casting gear-box easily produces scab again, causes because of the damage that sand removal produces on cast(ing) surface, and precoated sand due to sand removal easy, avoid the damage that sand removal produces, improve the surface quality of foundry goods.
(8) the present invention's whole foundry goods die cavity and skin adopt molding sand shaping, compare metal-mold low-pressure casting good permeability, are convenient to arrange exhaust.Simultaneously owing to being that molding sand is shaping, be convenient to arrange chill, easily regulate the thermograde of whole casting mold, ensure the quality of foundry goods.Because molding sand has good deformability, and metal-mold low-pressure casting does not possess deformability, and therefore the present invention compares metal-mold low-pressure casting and is not easy formation casting stress, and the serviceability of foundry goods is good.
Accompanying drawing explanation
Fig. 1 is the schematic diagram of gear case body foundry goods of the present invention;
Fig. 2 is schematic diagram cast model and sandbox are placed on template;
Precoated sand sand lump and chill are placed in the schematic diagram on the cast model of band mould core print by Fig. 3;
Fig. 4 is potting resin sand on Fig. 3 basis, takes out after resin sand solidification from model, and a certain cross section simplified schematic diagram after lower core;
Fig. 5 is potting resin sand on Fig. 3 basis, takes out after resin sand solidification from model, and another cross section simplified schematic diagram after lower core;
Fig. 6 is the sectional view along B-B line in Fig. 5;
Fig. 7 (a) and (b) are the schematic diagrames of bulge-structure;
To be the present invention be respectively reduces base and seam in the schematic diagram of the adjacent precoated sand sand lump splicing of meter and conventional design and easily occur the schematic diagram that the adjacent precoated sand sand lump that base stitch splices for Fig. 8 (a) and (b);
Fig. 9 is the pressure curve schematic diagram of low pressure casting;
Wherein, 1-sandbox, 2-template, 3-is with the cast model of mould core print, 4-running gate system model, 5-precoated sand locating piece model, 6-mould core print, 7-precoated sand sand lump (7a-first precoated sand sand lump, 7b-second precoated sand sand lump), 8-chill, 9-resin sand, 10-foundry goods die cavity, 11-core, 12-running gate system cavity, 13-bulge-structure (13a-dove tail shape, 13b-bevelling shape), 14-pattern draft.
Detailed description of the invention
The gear case body casting mold of the present embodiment forms primarily of core 11, die cavity, chill 8, the outer mold layer of precoated sand, the outer mold layer of resin sand and sandbox 1; This die cavity comprises foundry goods die cavity 10 and running gate system cavity 12, and running gate system cavity 12 communicates with foundry goods die cavity 10, for the cast in later stage.
The structure of casting mold is specific as follows: the center of casting mold is core 11, and the skin of core 11 is foundry goods die cavities 10, and foundry goods die cavity 10 is shaping by the outer mold layer 7 of core 11, chill 8 and precoated sand sand lump, and chill 8 is placed in the precoated sand sand lump 7 of the outer mold layer of precoated sand 7; The skin of the outer mold layer of precoated sand sand lump is the outer mold layer of resin sand, and the outer mold layer of resin sand covers the outer mold layer of precoated sand completely, and fills up in the middle of the outer mold layer of precoated sand sand lump and sandbox 1, thus outer for precoated sand sand lump mold layer and sandbox 1 is linked together, and forms casting mold.The outer mold layer of precoated sand sand lump can be spliced by polylith precoated sand sand lump 7, and the shape of the outer shape of mold layer of precoated sand sand lump and the cast model of gear case body matches; The outside of the outer mold layer of precoated sand sand lump is provided with bulge-structure, for outer for precoated sand sand lump mold layer and the outer mold layer of resin sand being fixedly convenient to the overall demoulding in later stage.In addition, chill 8 also can be placed in core 11, and chill 8 also can be placed in the intersection of the outer mold layer of precoated sand and the outer mold layer of resin sand.
The concrete steps of the forming method of the gear case body casting mold of the present embodiment are as follows:
(1) complete casting Technology Design according to the structure of foundry goods (i.e. gear case body), determine the casting process scheme of foundry goods.In order to ensure surface quality of continuous castings, improve the production efficiency of foundry goods, foundry goods is when technological design, and foundry goods die cavity 10 adopts precoated sand core shooting shaping, core 11 adopt resin sand 9 or precoated sand shaping, pouring type is low pressure casting; Wherein, the structure of gear case body as shown in Figure 1.
(2) design and manufacture of mould: design and manufacture the mould of precoated sand core shooting sand lump 7, chill 8 and core 11, the cast model 3 being with mould core print, running gate system model 4 and precoated sand locating piece model 5; The cast model 3 of above-mentioned band mould core print, running gate system model 4 and precoated sand locating piece model 5 etc. are fixed on template 2 for the formation of the mould of casting mold; Precoated sand locating piece model 5 is mainly used in locating precoated sand sand lump 7 in modeling process, prevents precoated sand sand lump 7 from moving, as shown in Figure 2.
(3) making of chill 8 and core 11: adopt chill mould and core mold pour into a mould chill 8 and make core 11 respectively, successful for above-mentioned cast chill 8 can be placed in core mold to make core 11, core 11 can adopt resin sand 9 or precoated sand shaping.
(4) precoated sand core shooting manufactures precoated sand sand lump 7: the mould successful for above-mentioned cast chill 8 being placed in precoated sand core shooting sand lump, utilizes this mould core shooting to manufacture precoated sand sand lump 7 (machine under high pressure sprays and forms precoated sand sand lump 7); During core shooting, the temperature of the mould of precoated sand core shooting sand lump controls at 180 ~ 250 DEG C;
Wherein, for ensureing intensity and the surface quality of precoated sand, the composition of precoated sand is the 70-140 order quartz sand of 60-80% (percentage by weight) and the 50-100 order quartz sand of 20-40%, precoated sand, in preparation process, also needs to mix novolac resin, methenamine and calcium stearate; The content of novolac resin accounts for the 2-3% (percentage by weight) of quartz sand total amount; The content of methenamine accounts for the 10-15% (percentage by weight) of novolac resin, and the content of calcium stearate accounts for the 10-12% of novolac resin (percentage by weight).
(5) coat: only precoated sand sand lump 7 dip-coating paint is dryouied; The Baume degrees of coating is 22-24.
(6) moulding: by means of the precoated sand locating piece model 5 that template 2 is arranged, on the cast model 3 that the precoated sand sand lump 7 respectively polylith being coated coating is embedded in band mould core print (as shown in Figure 3), multiple precoated sand sand lump 7 is spliced to form the outer mold layer of precoated sand sand lump, the shape of the outer mold layer of precoated sand sand lump and the shape of gear case body casing (being namely with the cast model 3 of mould core print) substantially identical.
Contact surface between precoated sand sand lump 7 and resin sand 9 is provided with bulge-structure 13, bulge-structure 13 can be rendered as dove tail shape 13a, oblique angle shape 13b with negative taper, or other and can cover outer for resin sand mold layer the outer mold layer of precoated sand and carry out better fixing mode (as shown in Figure 7).For some precoated sand sand lumps 7 or the outer mold layer of whole precoated sand sand lump, the bulge-structure 13 that its direction that locally outer mold layer is perpendicular in withdrawing pattern direction with resin sand is formed, can be called grab; Concerning the outer mold layer of resin sand, this bulge-structure is actual is a cavity, and namely the cavity of the outer mold layer of resin sand and the grab of the outer mold layer of precoated sand agree with mutually, are conducive to the overall demoulding of the outer mold layer of resin sand after precoated sand sand lump 7 and solidification.
Preferably, the gap that adjacent precoated sand sand lump 7 forms foundry goods die cavity 10 side is set to 0, a side clearance as shown in Figure 8 near the cast model 3 of band mould core print is 0, and pattern draft 14 is set to the impact that 5 ~ 8 degree: 0 gap decreases splicing base seam to greatest extent; The large pattern draft 14 of 5-8 degree is conducive to resin sand 9 and is filled between the gap of precoated sand sand lump 7, as shown in Fig. 8 (a); But contrary setting is as shown in Fig. 8 (b), shaping foundry goods die cavity 10 can form gap, and casting cycle molten metal can enter gap, forms base seam comparatively large, finally can affect the surface quality of foundry goods.
The sandbox 1 that can be used for low pressure casting is overlapped again on template 2, full resin sand 9 is filled between sandbox 1 and precoated sand sand lump 7, the outer mold layer of resin sand is formed after resin sand 9 hardens, resin sand external mold is placed in the middle of the outer mold layer of precoated sand sand lump and sandbox 1, the outer mold layer of resin sand covers the outer mold layer of precoated sand completely and sandbox 1 and precoated sand sand lump 7 is connected together, molding after resin sand 9 hardens (removing template 2), namely forms the upper half mould of foundry goods die cavity 10 or lower half mould; Namely the step of overall modelling that can be used for low pressure casting is completed.
Wherein, chill 8 also can be positioned on the interface of the outer mold layer of precoated sand sand lump and the outer mold layer of resin sand.
(7) core under: the lower half mould core 11 made being put into foundry goods die cavity 10, as Figure 4-Figure 6.
(8) mould assembling: upper half mould and lower half mould mould assembling are formed casting mold.
(9) alloy melting: alloy carry out melting and carry out going bad, refining and degassing processing.
(10) low-pressure casting: adopt the mode of low pressure casting, cast by running gate system cavity 4 pairs of gear-boxes, casting cycle divides to comprise and rises liquid-fill type-crust-pressurize-boosting-stress-relief process, as shown in Figure 9.
(11) unpack and clear up: after casting solidification, unpack and carry out sand removal process, the surface roughness Ra≤20um of foundry goods, preferably, surface roughness Ra≤15 μm of foundry goods.
Below in conjunction with embodiment, the present invention is further illustrated.
Embodiment 1:
1) mould design and manufacture: design and manufacture the moulds such as precoated sand core shooting sand lump 7, chill 8, core 11;
2) making of chill 8 and core 11: adopt chill die casting chill 8; Successful for above-mentioned cast chill 8 is placed in core mold and makes core 11, the core 11 of the present embodiment adopts precoated sand shaping;
3) manufacture of precoated sand core shooting is for assembling and the precoated sand sand lump 7 of formative gear box body: mixed by the 50-100 order silica sand of the 70-140 order silica sand of 30kg and 20kg, then the calcium stearate adding the novolac resin of 1kg, the methenamine of 0.1kg and 0.1kg mixes formation precoated sand;
Successful for above-mentioned cast chill 8 is placed in the mould of precoated sand core shooting sand lump 7, carry out penetrating sand when mold temperature is heated to 200 DEG C, precoated sand is sintering, sclerosis under the effect of resin and curing agent, form precoated sand sand lump 7, the thickness of precoated sand sand lump 7 is 10mm, and precoated sand sand lump 7 is provided with bulge-structure 13 in dove tail shape 13a (as Suo Shi Fig. 7 (a));
4) coat: adopt dip coating manner to coat to precoated sand sand lump 7, the Baume degrees of coating is 22;
5) moulding: the cast model 3 precoated sand sand lump 7 of first-class coating being embedded in band mould core print is spliced into gear case body casing; On template 2, overlap cope 1 again, fill up resin sand 9 between the inside casing of sandbox 1 and precoated sand sand lump 7, sandbox 1 and precoated sand sand lump 7 connect together after hardening by resin sand 9; Molding after resin sand 9 hardens (removing template 2), namely forms the upper half mould of foundry goods die cavity 10 or lower half mould;
6) core under: the lower half mould core 11 made being put into foundry goods die cavity 10;
7) mould assembling: above-mentioned upper half mould and lower half mould are carried out mould assembling and form casting mold;
8) alloy melting: alloy carries out melting and rotten, refining and degassing processing;
9) low-pressure casting: adopt the mode of low pressure casting to cast to gear-box casting mold, the temperature of casting is 680 DEG C ~ 720 DEG C, casting cycle specifically comprises and rises liquid (time is 6s, pressure is 0.32Mpa)-(time is 25s to fill type, pressure is 0.49Mpa)-(time is 2s to crust, pressure is 0.49Mpa)-(time is 2s in boosting, pressure is 0.80Mpa) (time is 500s in-pressurize, pressure is 0.80Mpa)-stress-relief process (time is 1s, and pressure is 0Mpa);
10) unpack and clear up: after casting solidification, unpack and carry out sand removal process, surface roughness Ra is≤13 μm.
Embodiment 2:
1) mould design and manufacture: design and manufacture the moulds such as precoated sand core shooting sand lump 7, chill 8, core 11;
2) making of chill 8 and core 11: adopt chill mould and core mold pour into a mould chill 8 and make core 11 respectively, the core 11 of the present embodiment adopts resin sand 9 shaping;
3) precoated sand core shooting manufactures precoated sand sand lump 7: by 40kg70-140 order silica sand, the mixing of 10kg50-100 order silica sand, add 1.5kg novolac resin, 0.225kg methenamine and 0.18kg calcium stearate and mix formation precoated sand.Successful for above-mentioned cast chill 8 is placed in the mould of precoated sand core shooting sand lump 7, carry out penetrating sand when mold temperature is heated to 250 DEG C, precoated sand is sintering, sclerosis under the effect of resin and curing agent, form precoated sand sand lump 7, the thickness of precoated sand sand lump 7 is 25mm, precoated sand sand lump 7 is provided with bulge-structure 13 and presents bevelling shape 13b (as Suo Shi Fig. 7 (b)), is taken up when being convenient to molding by resin sand 9;
4) coat: adopt dip coating manner to coat to precoated sand sand lump 7, the Baume degrees of coating is 24;
5) moulding: the cast model 3 precoated sand sand lump 7 of first-class for polylith coating being embedded in band mould core print is spliced into gear case body, cope 1 is overlapped again on template 2, fill up resin sand 9 between sandbox 1 and precoated sand sand lump 7, sandbox 1 and precoated sand sand lump 7 connect together after hardening by resin sand 9; Molding after resin sand 9 hardens, namely forms the upper half mould of foundry goods die cavity 10 or lower half mould;
6) core under: the lower half mould core 1 made being put into foundry goods die cavity 10;
7) mould assembling: above-mentioned upper half mould and lower half mould are carried out mould assembling and form casting mold;
8) alloy melting: alloy carries out melting, adds that appropriate Al-Ti-B alloy carries out going bad, refining and degassing processing;
9) low-pressure casting: adopt the mode of low pressure casting to cast to gear-box, cast temperature is 680 DEG C ~ 720 DEG C, casting cycle divides to comprise and rises liquid (time is 6s, pressure is 0.25Mpa)-(time is 50s to fill type, pressure is 0.56Mpa)-(time is 2s to crust, pressure is 0.56Mpa)-(time is 2s in boosting, pressure is 0.80Mpa) (time is 800s in-pressurize, pressure is 0.80Mpa)-stress-relief process (time is 1s, and pressure is 0Mpa);
10) unpack and clear up: after casting solidification, unpack and carry out sand removal process, surface roughness Ra is≤12 μm.
Claims (10)
1. a forming method for gear case body casting mold, is characterized in that, described method step is as follows:
1) Design and manufacture of mould: design and manufacture precoated sand core shooting sand lump, core, the mould of chill and cast model, precoated sand locating piece model, the running gate system model with mould core print, and according to the requirement of casting mold somatotype, the above-mentioned cast model with mould core print, precoated sand locating piece model and running gate system model are fixed on template;
2) chill and core is made: adopt chill and core mold pour into a mould chill respectively and make core;
3) precoated sand core shooting manufactures precoated sand sand lump: the mould above-mentioned chill made being placed in precoated sand core shooting sand lump, and precoated sand under high pressure sprays and forms precoated sand sand lump;
4) moulding:
The precoated sand sand lump first polylith being coated coating is embedded on the cast model with mould core print, and precoated sand sand lump is spliced to form the outer mold layer of precoated sand sand lump, and the shape of the outer shape of mold layer of precoated sand sand lump and the cast model of described gear case body matches; The outside of the outer mold layer of precoated sand sand lump is provided with bulge-structure, and described bulge-structure is used for the overall demoulding outer for precoated sand sand lump mold layer and the outer mold layer of resin sand being fixedly convenient to the later stage;
Then on template, overlap cope, fill up resin sand between sandbox and the outer mold layer of precoated sand sand lump, resin sand sclerosis forms the outer mold layer of resin sand, and the outer mold layer of resin sand covers the outer mold layer of precoated sand completely and sandbox and the outer mold layer of precoated sand sand lump connected together; Namely the upper half mould of foundry goods die cavity or lower half mould is formed after molding;
5) core under: by step 2) core made puts into the lower half mould of described foundry goods die cavity;
6) mould assembling: by the lower half mould of the described foundry goods die cavity after lower core and upper half mould mould assembling, the casting mold of formative gear box body;
7) alloy melting: alloy carry out melting and carry out going bad, refining and degassing processing;
8) low-pressure casting: adopt the mode of low pressure casting to cast to described casting mold, casting cycle comprise rise liquid, fill type, crust, pressurize and stress-relief process;
9) unpack and clear up: unpacking and sand removal process after casting solidification, obtain gear case body foundry goods, surface roughness≤20 μm of described foundry goods.
2. the forming method of a kind of gear case body casting mold according to claim 1, described step 3) in, the composition of precoated sand comprises the 70-140 order quartz sand of 60-80% and the 50-100 order quartz sand (percentage by weight) of 20-40%; Described precoated sand also comprises novolac resin, methenamine and calcium stearate; The content of novolac resin accounts for the 2-3% (percentage by weight) of quartz sand total amount; The content of methenamine accounts for the 10-15% (percentage by weight) of novolac resin, and the content of calcium stearate accounts for the 10-12% of novolac resin (percentage by weight).
3. the forming method of a kind of gear case body casting mold according to claim 1, is characterized in that, described step 3) in, during core shooting, the temperature of the mould of precoated sand core shooting sand lump is 180 ~ 250 DEG C; Thickness >=the 10mm of the thinnest part of described precoated sand sand lump.
4., according to the forming method of one of any described a kind of gear case body casting mold of claim 1-3, it is characterized in that, surface roughness≤12 μm of described foundry goods.
5., according to the forming method of one of any described a kind of gear case body casting mold of claim 1-3, it is characterized in that, described step 4) in, only adopt the mode of dip-coating to coat coating to precoated sand sand lump and igniting is dryouied, the Baume degrees of coating is 22-24; Described bulge-structure is bevelling shape or dove tail shape; The gap that adjacent described precoated sand sand lump forms foundry goods die cavity side is set to 0, and pattern draft is set to 5-8 degree.
6., according to the forming method of one of any described a kind of gear case body casting mold of claim 1-3, it is characterized in that, described core adopt resin sand or precoated sand shaping; Described chill can be arranged in core or be positioned at the intersection of the outer mold layer of precoated sand sand lump and the outer mold layer of resin sand.
7. a gear case body casting mold, is characterized in that, described casting mold is made up of core, die cavity, chill, the outer mold layer of precoated sand, the outer mold layer of resin sand and sandbox, and die cavity comprises foundry goods die cavity and running gate system cavity, and running gate system cavity communicates with foundry goods die cavity; The structure of casting mold is specific as follows: the center of casting mold is core, and the skin of core is foundry goods die cavity, and foundry goods die cavity is by core, chill, precoated sand sand lump external mold formable layer, and chill is placed in the outer mold layer of precoated sand; The skin of the outer mold layer of precoated sand sand lump is the outer mold layer of resin sand, and the outer mold layer of resin sand covers the outer mold layer of precoated sand completely and fills up outside precoated sand sand lump between mold layer and sandbox, thus outer for precoated sand sand lump mold layer and sandbox is linked together, and forms casting mold;
The outer mold layer of described precoated sand sand lump is spliced by polylith precoated sand sand lump, and the shape of the outer shape of mold layer of precoated sand sand lump and the cast model of gear case body matches; The outside of the outer mold layer of precoated sand sand lump is provided with bulge-structure, for outer for precoated sand sand lump mold layer and the outer mold layer of resin sand being fixedly convenient to the overall demoulding in later stage.
8. casting mold according to claim 7, is characterized in that, the thickness >=10mm of the thinnest part of described precoated sand sand lump.
9. the casting mold according to claim 7 or 8, is characterized in that, described bulge-structure is bevelling shape or dove tail shape; The gap that adjacent described precoated sand sand lump forms foundry goods die cavity side is set to 0, and pattern draft is set to 5-8 degree.
10. the casting mold according to claim 7 or 8, is characterized in that, described core adopt resin sand or precoated sand shaping; Described chill also can be arranged in core or be positioned at the intersection of the outer mold layer of precoated sand sand lump and the outer mold layer of resin sand.
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| CN111974969A (en) * | 2020-07-22 | 2020-11-24 | 江苏宏德特种部件股份有限公司 | Casting process of aluminum alloy gear box for high-speed rail |
| CN112605338A (en) * | 2020-11-20 | 2021-04-06 | 江苏朗锐茂达铸造有限公司 | Method for producing mounting seat steel casting based on precoated sand shell mold process |
| CN113070453A (en) * | 2021-03-10 | 2021-07-06 | 慈溪汇丽机电股份有限公司 | Casting method of gear box casting |
| CN113070453B (en) * | 2021-03-10 | 2022-08-23 | 慈溪汇丽机电股份有限公司 | Casting method of gear box casting |
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| CN114260426B (en) * | 2021-12-24 | 2023-11-14 | 阜新力达钢铁铸造有限公司 | Edge-opening nut mold, special sand core for edge-opening nut and casting method of special sand core |
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| CN114799049B (en) * | 2022-03-30 | 2024-02-09 | 西安航天发动机有限公司 | Processing die and method for sand core for variable-section blade casting of aerospace liquid engine |
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