Warm airtight formwork precision stainless steel casting method in one
Technical field
The present invention relates to a kind of stainless casting method, be specifically related to warm airtight formwork precision stainless steel casting method in one.
Background technology
The weak corrosive mediums such as the resistance to air of stainless steel, steam, water or the steel grade with rustless property are called stainless steel.Because stainless steel not easily produces burn into corrosion or wearing and tearing, it is one of material that in metal material for building, intensity is the highest, and it can make structure member for good and all keep the integrality of engineering design.
At present, some problems of ubiquity in stainless casting technique, as: consume energy high, the power consumption of stainless steel material smelting furnace and molten steel power consumption, stainless steel material will reach 1600 DEG C just can be molten into liquid state.In addition, when in roasting mold shell stove burner hearth, temperature reaches 1050 DEG C to 1250 DEG C, just can pour into a mould, and after burner hearth Temperature fall, just can will pour into a mould from being newly heated to 1050 DEG C, in view of this this power consumption is larger.
In the wax-pattern assembly generally used, casting wax mould use level and the arrangement mode evacuated, the design of central aperture, the design concept of wax-pattern assembly is in order to by thermal balance, facilitates discharged air, reduces the flow distance of molten steel.But because traditional arrangement mode is all adopt horizontally, molten steel trickling lacks pressure, and local in the corner of casting wax mould, often because molten steel cannot be poured into a mould full, and form waste product, percent defective usually reaches about 11%.Horizontally be unfavorable for the discharge of air in casting wax mould simultaneously, usually cause air venting not thorough, and the temperature of formwork is higher, the crystallization water that high temperature can decompose die casing material generates oxygen, oxidation reaction is there is with the surface of molten steel, make cast(ing) surface produce age spot, serious generation honeycomb, has a strong impact on the quality of product.
In addition, in stainless steel is produced, because the requirement of formwork to refractory material is higher, the cost which results in raw materials for production is high, high in order to meet framework calcinatory fire box temperature, the technological requirement of formwork good permeability, the refractory material that formwork uses requires can be high temperature resistant, good permeability, current normally used material is zircon sand (powder), but its price comparison is expensive.Expensive raw material substantially increases the cost of foundry goods, reduces the interests of businessman.
And foundry's indoor temperature is mainly subject to the joint effect of smelting furnace and framework calcinatory, and framework calcinatory body of heater is large, and in operating process, the exposed time is long, it is the main source of workshop high temperature, the temperature of workshop is too high, and the labour intensity of workman is larger, inefficiency.
Summary of the invention
The shortcoming existed in prior art, the invention provides one and can reduce energy consumption, boost productivity and product quality, saves the middle temperature airtight formwork precision stainless steel casting method of formwork refractory material cost.
The technical solution adopted in the present invention is:
Warm airtight formwork precision stainless steel casting method in one, comprises the following steps:
(1) formwork is made;
(2) roasting mold shell, pour steel in the formwork after roasting;
(3), after the middle moulding by casting of step (2), foundry goods stainless steel product is cooled to obtain.
Further, make formwork in step (1) and comprise the following steps,
(1) foundry goods die and die head die is made;
(2) in foundry goods die and die head die, penetrate wax obtain casting wax mould and die head wax-pattern respectively;
(3) casting wax mould is welded on die head wax-pattern and forms wax sample assembly;
(4) wax sample assembly is carried out bag slurry, obtain wax sample assembly mould;
(5) the wax sample assembly mould after bag slurry is dewaxed, obtain formwork.
Further, in step (2) when the roaster fire box temperature of roasting mold shell reaches 600-800 DEG C, pour steel in formwork.The minimum critical-temperature of cast of common process roasting mold shell is 1050 DEG C, and the pouring temperature used in method of the present invention is 600-800 DEG C, when roaster fire box temperature reaches 600-800 DEG C, formwork is come out of the stove and pours into a mould, in this process, roaster burner hearth can be lowered the temperature automatically, when then next group formwork being entered stove, then be heated to 600-800 DEG C, this reduces the temperature of roasting mold shell on the whole, effectively to carry out energy-conservation, and do not affect the quality of foundry goods.
Further, in step (3), casting wax mould is welded perpendicular to die head wax-pattern.Common casting wax mould uses horizontal mode, and owing to will stay exhaust clearance between adjacent casting wax mould formwork, arranges more loose.Method of the present invention is that formwork housing is air-locked, overlap exhaust clearance can not be stayed between casting wax mould formwork, adopt the arrangement mode that casting wax mould is vertical, make to arrange between casting wax mould compact, relative to common horizontal mode, the wax-pattern assembly of same volume, can increase by the casting wax mould of 25%.Namely be when formwork roasting, the power consumption that same roaster is identical can increase by 25% and for the foundry goods type storehouse of cast, greatly can enhance productivity, and saves formwork roasting energy consumption 25%.The foundry goods that foundry goods type storehouse is formed in formwork is product, and remaining is then die head, and cast product molten steel used accounts for the percentage of the total amount of whole formwork pour steel, is namely ratio defective product, is water rate in industry.Common horizontal mode, arrange more loose, the ratio shared by die head is higher, reduces ratio defective product.
Further, wrap slurry described in step (4) to comprise the following steps: white fused alumina and quartz sand composite material powder are added Ludox furnishing and starches even showering on wax sample assembly as starch adhesive, evenly sprinkling one deck white fused alumina and quartz sand composite material sand, as floor sand, form ground floor bag slurry again; After the drying of ground floor bag slurry, will not carry out sand powder and add Ludox furnishing and starch even showering on ground floor bag slurry, more evenly spray one deck and do not carry out sand and form second layer bag slurry; After the drying of second layer bag slurry, will not carry out sand powder and add Ludox furnishing and starch even showering on second layer bag slurry, more evenly spray one deck formwork reclaiming material sand and form third layer bag slurry; After the drying of third layer bag slurry, will not carry out sand powder and add Ludox furnishing and starch even showering on third layer bag slurry, more evenly spray one deck formwork reclaiming material sand and form the 4th layer of bag slurry; Until the 4th layer bag slurry drying after, will not come sand powder add Ludox furnishing starch even showering the 4th layer bag slurry on, realize starching the bag of wax sample assembly.By starching the bag of wax sample assembly, requiring that formwork will reach certain intensity and bearing capacity, producing wax sample assembly mould.Common process is when carrying out wax sample assembly bag slurry, higher to the requirement of bag pulp material, need bag pulp material energy high temperature resistant and good permeability, what the starch adhesive of ground floor and floor sand adopted respectively is zircon flour and zircon sand, and the price comparison of zirconium English (powder) sand is expensive.And method of the present invention, what the starch adhesive of ground floor and floor sand adopted respectively is white fused alumina and quartz sand composite material powder and white fused alumina and quartz sand composite material sand, the price of white fused alumina and quartz sand composite material is well below the price of zirconium English (powder) sand, though the refractory temperature of white fused alumina and quartz sand composite material does not have the refractory temperature of zirconium English (powder) sand high, but in method of the present invention, its formwork sintering temperature reduces, so do not affect its result of use.Formwork of the present invention is air-locked simultaneously, and white fused alumina and quartz sand composite material just in time can reach requirement.Directly will not carry out the showering of sand powder slurry on the 4th layer of bag slurry, and no longer spray floor sand, do like this and the floor sand of final layer can be bonded together, prevent its drop.As than more preferably scheme, the ratio of white fused alumina and quartz sand is 80:20 ~ 60:40.
After foundry goods formwork after moulding by casting cools naturally, machinery is used to shake broken foundry goods formwork, isolate stainless cast steel part and formwork waste material, and then cast product and foundry goods die head are separated, foundry goods die head and underproof cast product then melt down again, the waste recovery processing of formwork is used as the floor sand of the 3rd, the 4th layer of bag slurry, not only cost-saving but also environmental protection.
Further, described die head wax-pattern is provided with skeleton, described casting wax mould is fixed on the both sides of skeleton with the axis of skeleton for symmetry axis symmetry, has angle between the described casting wax mould being symmetricly set on skeleton both sides.
Further, the length direction along described skeleton is provided with some groups of symmetrically arranged described casting wax moulds, and the angle between the some groups of described casting wax moulds being symmetricly set on skeleton both sides is all identical.
Further, the quantity of described skeleton is some layers, and some described skeletons are positioned on same vertical plane, and from top to bottom be arranged in parallel.
Further, the angle between the described casting wax mould being fixed on skeleton described in upper strata is larger than the angle between the described casting wax mould being fixed on skeleton described in lower floor.Namely the described casting wax mould on lower floor's skeleton embeds in the described casting wax mould on layer skeleton fixed thereon.
Further, the top of described casting wax mould is connected with die head skeleton, and the top of described casting wax mould is provided with sprue gate, and during cast, molten steel from top to bottom.The sprue gate of the casting wax mould of the horizontal mode of common process is arranged on the centre of casting wax mould, the trickling of such molten steel lacks pressure, to such an extent as to the place that molten steel is local or more sharp-pointed in corner, all cannot pour into a mould full, and sprue gate is arranged on the top of casting wax mould, casting wax mould is again arranged vertically, like this due to Action of Gravity Field, add the trickling pressure of molten steel, be conducive to by the air row in formwork thoroughly, prevent it because the air venting in formwork is not thorough and molten steel surface generation oxidation reaction, form cast(ing) surface age spot, even produce honeycomb, affect the quality of product.The molten steel that is conducive to arranged vertically fills each bit position in foundry goods type storehouse fast simultaneously, contributes to the raising of the qualification rate of cast product.
Beneficial effect of the present invention is: the power consumption saving formwork roasting, and it is 1050 DEG C that the formwork of conventional cast technique pours into a mould minimum critical-temperature, and method formwork pouring temperature of the present invention is 600-800 DEG C, and this saves the energy to a great extent.
Casting wax mould in present invention process wax-pattern assembly adopts compact mode arranged vertically, and the casting wax mould in common process wax-pattern assembly adopts loose horizontal mode.Common process needs the exhaust considering formwork housing, will leave the gap of exhaust between casting wax mould formwork, and therefore its arrangement mode is more loose dredges.And present invention process need not consider the exhaust of formwork, arrange compacter between casting wax mould, can arrange the casting wax mould of 25% more in the wax-pattern assembly of same volume, the power consumption that is same roaster is same can increase by the foundry goods type storehouse of 25%.Effectively save the energy of formwork roasting, enhanced productivity.Simultaneously because common loose arrangement causes die head proportion larger.The compact arrangement die head accounting example of present invention process reduces, and ratio defective product improves 7%.Such production efficiency improves significantly, and energy-saving effect is obvious, greatly reduces production cost.
In addition the horizontal and sprue gate middle opening mode of common process, when pouring into a mould, MOLTEN STEEL FLOW lacks pressure,, more sharp-pointed place local in corner often cannot be poured into a mould full due to molten steel and be formed waste product, this reduces the qualification rate of product to a great extent, improves the cost of product.Adopt mode arranged vertically need not consider the exhausting problem of formwork housing, molten steel fills type storehouse fast due to Action of Gravity Field, while making in type storehouse air directly discharge from sprue gate, molten steel can arrive each position in foundry goods type storehouse fast, and product percent of pass improves obviously.When simultaneously common process adopts horizontal mode, because air venting in formwork is thorough, with molten steel surface generation oxidation reaction, form cast(ing) surface age spot, serious meeting produces honeycomb at cast(ing) surface, have impact on the quality of product.And the present invention is when adopting vertical arrangement, then can avoid the generation of these problems, cast product density is high, and fineness is good, and product quality is excellent, and CSAT is high.
Because roasting mold shell carries out under the high temperature conditions, higher to the requirement of formwork refractory material, the refractory material that formwork uses requires high temperature resistant, the good permeability of energy, so normally used wax sample assembly bag pulp material, ground floor bag slurry adopts zircon flour and zircon sand respectively, and its price all costly, certainly too increase production cost.Because formwork sintering temperature being dropped to 600-800 DEG C by common 1050 DEG C in method of the present invention, when carrying out wax sample assembly bag slurry, ground floor uses white fused alumina and quartz sand composite material powder and white fused alumina and quartz sand composite material sand respectively, and the price of white fused alumina and quartz sand composite material is only the half of zircon sand material price.The floor sand of its 3rd, the 4th layer bag slurry then uses the reworked material reclaiming the processing of formwork waste material.The material used can meet the high temperature resistant requirement of formwork, reaches intensity and support force that formwork possesses.Also meet the air-locked object of formwork of the present invention simultaneously.Which decrease production cost, improve the interests of businessman.
In addition, the temperature in cast product workshop is mainly subject to the joint effect of smelting furnace and framework calcinatory, and the body of heater of framework calcinatory is larger, in operating process, the exposed time is long, this is the main heating source causing workshop high temperature, and temperature height in workshop increases the labour intensity of workpeople, reduce the productivity ratio of work.And method of the present invention, the temperature of roaster drops to 600-800 DEG C from 1050 DEG C, effectively reduces the temperature in workshop, improves work situation, improves the job enthusiasm of workman, and then improves labor productivity.
Accompanying drawing explanation
Fig. 1 is the structural representation of the die head wax-pattern of cast stainless steel of the present invention;
Fig. 2 is the survey view of the wax sample assembly of cast stainless steel of the present invention;
Fig. 3 is the structural representation of cast stainless steel wax sample assembly of the present invention.
In figure: 1, die head wax-pattern; 2, skeleton; 3, casting wax mould; 4, sprue gate.
Detailed description of the invention
Below in conjunction with embodiment, the invention will be further described.
Warm airtight formwork precision stainless steel casting method in one, comprises the following steps:
Foundry goods die and die head die is made according to foundry goods sample, by heating, the paraffin after dissolving is noted in foundry goods die and die head die, namely saidly in industry penetrate wax, obtain casting wax mould 3 and die head wax-pattern 1 respectively, use the method adding thermal weld that casting wax mould 3 and die head wax-pattern 1 are welded together, this process is called group mould in industry, connects rear formation wax sample assembly.
When casting wax mould 3 is welded on die head wax-pattern 1, employing be mode arranged vertically, weld by the skeleton 2 of casting wax mould 3 perpendicular to die head wax-pattern 1.Common casting wax mould 3 uses horizontal mode, arranges more loose.Present invention process adopts the vertical arrangement mode of casting wax mould 3, and make to arrange between casting wax mould 3 compact, relative to common horizontal mode, the wax-pattern assembly of same volume, can increase by the casting wax mould 3 of 25%.Namely be when formwork roasting, the power consumption that same roaster is identical can increase by 25% and for the foundry goods type storehouse of cast, greatly can save formwork roasting energy consumption, enhance productivity.The foundry goods that foundry goods type storehouse is formed in formwork is product, and remaining is then die head, and cast product molten steel used accounts for the percentage of the total amount of whole formwork pour steel, is namely ratio defective product, is water rate in industry.Common horizontal mode, arrange more loose, the ratio shared by die head is higher, reduces ratio defective product.Arrange compact between casting wax mould 3 of the present invention, die head reduces relatively, contributes to the raising of ratio defective product.
As shown in Figures 2 and 3: the concrete fixed form of casting wax mould 3 and die head wax-pattern 1 is: on described die head wax-pattern 1, be provided with skeleton 2, described casting wax mould 3 is fixed on skeleton 2 both sides with skeleton 2 for symmetry axis symmetry, has angle between the described casting wax mould 3 being symmetricly set on skeleton 2 both sides.Because the shape of casting wax mould 3 is curved, so can angle be formed between the described casting wax mould 3 being symmetricly set on skeleton 2 both sides.Length direction along described skeleton 2 is provided with some groups of symmetrically arranged described casting wax moulds 3, and the angle between the some groups of described casting wax moulds 3 being symmetricly set on skeleton 2 both sides is all identical.
As shown in Figure 1, as more preferred embodiment, the quantity of described skeleton 2 is four layers.Four layers of described skeleton 2 are positioned on same vertical plane, from top to bottom be arranged in parallel.Angle between the described casting wax mould 3 being fixed on skeleton 2 described in upper strata is greater than the angle between the described casting wax mould 3 being fixed on skeleton 2 described in lower floor.The described casting wax mould 3 be fixed on lower floor's skeleton 2 embeds in the described casting wax mould 3 on layer skeleton 2 fixed thereon.
In order to increase the trickling pressure of molten steel, the top of described casting wax mould 3 is provided with sprue gate 4.The sprue gate 4 of the casting wax mould 3 of horizontal mode is arranged on the centre of casting wax mould 3, the trickling of such molten steel lacks pressure, to such an extent as to the place that molten steel is local or more sharp-pointed in corner, all cannot pour into a mould full, and sprue gate 4 is arranged on the top of casting wax mould 3, casting wax mould 3 is again arranged vertically, which increase the trickling pressure of molten steel, be conducive to by the air row in formwork type storehouse thoroughly, prevent it because the air venting in formwork type storehouse is not thorough and molten steel surface generation oxidation reaction, form cast(ing) surface age spot, even produce honeycomb, affect the quality of product.
After wax sample assembly completes, need to carry out bag slurry to wax sample assembly, method of the present invention uses white fused alumina and quartz sand composite material powder to add Ludox furnishing and starches even showering on wax sample assembly as starch adhesive, evenly sprinkling one deck white fused alumina and quartz sand composite material sand, as floor sand, form ground floor bag slurry again; After the drying of ground floor bag slurry, will not carry out sand powder and add Ludox furnishing and starch even showering on ground floor bag slurry, more evenly spray one deck and do not carry out sand and form second layer bag slurry; After the drying of second layer bag slurry, will not carry out sand powder and add Ludox furnishing and starch even showering on second layer bag slurry, more evenly spray one deck formwork reclaiming material sand and form third layer bag slurry; After the drying of third layer bag slurry, will not carry out sand powder and add Ludox furnishing and starch even showering on third layer bag slurry, more evenly spray one deck formwork reclaiming material sand and form the 4th layer of bag slurry; Until the 4th layer bag slurry drying after, will not come sand powder add Ludox furnishing starch even showering the 4th layer bag slurry on, by starching the bag of wax sample assembly, making formwork will reach certain intensity and bearing capacity, producing wax sample assembly mould.Because formwork will reach certain intensity and bearing capacity, so when carrying out bag slurry to wax sample assembly, higher to the requirement of bag pulp material, common needs bag pulp material energy high temperature resistant and good permeability, ground floor wax sample assembly bag slurry adopt be respectively zircon flour slurry and zircon sand, and the price comparison of zirconium English (powder) sand is expensive, and method of the present invention, what ground floor bag slurry adopted is that white fused alumina and quartz sand composite material powder are starched and sand respectively, the price of white fused alumina and quartz sand composite material is well below the price of zirconium English (powder) sand, though the refractory temperature of white fused alumina and quartz sand composite material does not have the refractory temperature of zirconium English (powder) sand high, but in method of the present invention, its formwork sintering temperature reduces, so do not affect its result of use.And the air-locked technological requirement of applicable formwork of the present invention.When carrying out the 3rd, the 4th layer of bag slurry, its floor sand then uses the reworked material reclaiming the processing of formwork waste material.Directly will not carry out the showering of sand powder slurry on the 4th layer of bag slurry, and no longer spray floor sand, do like this and the floor sand that the 4th layer is sprayed can be bonded together, prevent its drop.
Wax sample assembly bag starches all processes all at 25 DEG C of freeze-day with constant temperature, after the drying of wax sample assembly mould, by the method for temperature-pressure, is dissolved by the paraffin in wax sample assembly mould and gets rid of outside wax sample assembly mould, be called dewaxing, obtain formwork after dewaxing in industry.
Put into by formwork in framework calcinatory burner hearth, when putting into, formwork wants proper alignment, and interval appropriateness is with handled easily.After formwork is put well, to heat roasting, when roaster fire box temperature reaches 600-800 DEG C, formwork is come out of the stove and carries out pour steel, in this process, roaster burner hearth can be lowered the temperature automatically, when then next group formwork being entered stove, then is heated to 600-800 DEG C, in prior art roaster fire box temperature need reach more than 1050 DEG C, the present invention reduces roasting mold shell temperature on the whole, has effectively saved the energy, and does not affect the quality of foundry goods.In addition, the temperature in cast product workshop is mainly subject to the joint effect of smelting furnace and framework calcinatory, and the body of heater of framework calcinatory is larger, in operating process, the exposed time is long, this is the main heating source causing workshop high temperature, and temperature height in workshop increases the labour intensity of workpeople, reduce the productivity ratio of work.And method of the present invention, the temperature of roaster drops to 600-800 DEG C from 1050 DEG C, like this next group formwork is put into roaster burner hearth when heating, the temperature of roaster burner hearth be elevated to 600-800 DEG C just passable, and common need to be elevated to 1050 DEG C, effectively reduce the temperature in workshop like this, improve work situation, improve the job enthusiasm of workman, and then improve productivity ratio.
After foundry goods formwork after moulding by casting cools naturally, machinery is used to shake broken foundry goods formwork, isolate stainless cast steel part and formwork waste material, and then cast product and foundry goods die head are separated, foundry goods die head and underproof cast product then melt down again, and after the processing of formwork waste recovery, recycle the floor sand of the 3rd, the 4th layer in wax part assembly bag slurry, namely environmental protection in turn saves raw material.
The present invention is not limited to above-mentioned preferred forms; anyone can draw other various forms of products under enlightenment of the present invention; though but any change is done in its details, every have identical with the application or akin technical scheme, all drops within protection scope of the present invention.