CN105772635A - Cylinder sleeve producing method - Google Patents
Cylinder sleeve producing method Download PDFInfo
- Publication number
- CN105772635A CN105772635A CN201610143799.9A CN201610143799A CN105772635A CN 105772635 A CN105772635 A CN 105772635A CN 201610143799 A CN201610143799 A CN 201610143799A CN 105772635 A CN105772635 A CN 105772635A
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- CN
- China
- Prior art keywords
- casting
- cylinder jacket
- cylinder sleeve
- endoporus
- casting sandbox
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
-
- 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
Abstract
Provided is a cylinder sleeve producing method which can reduce raw materials consumption, subsequent machining workload and manufacturing cost. The method comprises the following steps: 1) molding by a lost foam; 2) pouring and cooling to form a casting blank of a cylinder sleeve; 3) roughly machining the casting blank of the cylinder sleeve; 4) heat-treating; 5) machining platform cross hatches. Compared with traditional common sand mold casting processes, the lost foam casting process adopted in the invention not only has the similar inheritance in alloy solidification characteristics, also has the complementarity in molding process. Obviously, the lost foam casting process has the advantages of improving the quality of the cylinder sleeve product and the stability of the inner structure greatly, reducing the raw materials consumption of the casting and the total energy sources needed in metal smelting, saving energy, reducing emission, benefiting environment protection and reducing the subsequent machining workload and manufacturing cost at the same time.
Description
Technical field
The present invention relates to class of metal materials, particularly to the production method of a kind of cylinder liner of supercharger engine.
Background technology
In the prior art, air cylinder sleeve of engine adopts boron cast iron, boron casting in bronze ferrum, chromium molybdenum copper cast iron, High phosphorus alloys cast iron, high-phosphorous iron, high-load chrome molybdenum nihard, chromium molybdenum copper boron alloy cast iron etc. to manufacture.Conventional casting methods generally adopts sand casting, and during production, the casting mold forming the external surface shape of product and the core forming interior surface shape are separately operations.Wherein moulding external mold includes again three parts: product design mold cavity forming mould, two rising head shaping moulds and running gate system shaping mould.During moulding, now three is placed on moulding board according to its relative position relation and carries out moulding.During delivery, first two rising heads and sprue are taken out from the back of cope, then external mold by product model and related cross gate model thereof take out from the front of sandbox, thus forming the upper impression of casting mold;And core molding can take various ways: clay core, oil core or resin sand core.Due to traditional sand casting, the operation of its technique own is numerous and diverse on the one hand, and the casting technical ability dependency of practitioner is relatively big, and labor intensity is big, it is serious that sand processes dust pollution, practitioner's occupational hazards is relatively big, which results in castability and is difficult to stable, and practitioner troop is also unstable；On the other hand, ordinary sand casting casting dimension accuracy out is low, so machine-finish allowance is also just bigger than normal, normally all between 5～6mm.Being limited to the dual restriction of common sand mold formative technology and box space size, the product yield of each moulding cast is very low, is only 60%.Energy total amount needed for this raw materials consumption not only adding foundry goods itself and smelting metal, also increases workload and the manufacturing cost of subsequent mechanical processing simultaneously.
At present, tradition sand mould casting method can not meet the requirement of modernization green manufacturing, and the method considerably increases the energy total amount needed for the raw materials consumption of foundry goods itself and smelting metal, also increases workload and manufacturing cost that subsequent mechanical is processed simultaneously.
Summary of the invention
The present invention is directed to problem above, it is provided that a kind of reduction raw materials consumption, reduce the workload of subsequent mechanical processing and the production method of the cylinder jacket of manufacturing cost.
The technical scheme is that and comprise the following steps:
1) lost foam modeling, adopts polystyrene foam plastics foaming in cylinder jacket mould, forms the evaporative pattern identical with cylinder jacket shape, and evaporative pattern is stained with the running channel and cast gate that adopt polystyrene foam plastics foaming；
At evaporative pattern surface coating paint layer and dry, imbedded in the dry sand in casting sandbox；
2) cylinder cover casting strand, uses low-sulfur hematite iron to pour into a mould, and condensation forms blank, sulfur S < 0.02%, phosphorus P < 0.03%, manganese Mn < 0.31% in described low-sulfur hematite iron；
3) cylinder jacket strand is carried out roughing；
4) heat treatment, under the protection of controllable gas, carries out in 320～385 DEG C of salt bath furnaces, and the heat treated time is 1～3.5 hour, and controllable gas is made up of percent by volume respectively carbon monoxide 16%, hydrogen 44% and nitrogen 40%；
5) platform reticulate pattern processing, within the scope of 4mm, groove >=6 of groove depth >=4 μm of cross hatch, profile degree of skewness-0.9～-2.8.
Described dope layer has internal layer and outer layer, is provided with magnetic powder in the dope layer of outer layer, and the surrounding of described casting sandbox has endoporus, and the endoporus of described casting sandbox removably connects and is provided with Magnet.
Being provided with magnetic powder in the dry sand of described casting sandbox, described magnetic powder is positioned at the surrounding of described evaporative pattern, and the surrounding of described casting sandbox has endoporus, and the endoporus of described casting sandbox removably connects and is provided with Magnet.
The present invention is at work, evaporative pattern adopts polystyrene foam plastics foaming to carry out the assembling of model cluster after coating coating drying, it is placed in casting sandbox, last in casting sandbox, realize disposal pouring shape, namely cylinder jacket product bubbles model along with the cast of molten metal bath combustion gasification.
In casting process, along with the pyrolysis temperature of polystyrene foam plastics is more high, its gas forming amount is more big, can pass through to arrange magnetic powder in outer layer coating layer, be adsorbed by Magnet, form exhaust passage, improve the breathability of dope layer, convenient discharge, improve the surface quality of cylinder jacket；
Maybe can pass through to arrange magnetic powder in the dry sand of evaporative pattern surrounding, be adsorbed by Magnet, form the exhaust passage of dry sand so that gas is discharged then through the exhaust passage of dry sand from dope layer, improve the surface quality of cylinder jacket.
Cylinder cover casting strand, according to designing requirement formula, uses low-sulfur hematite iron to pour into a mould, the sulfur S < 0.02% in low-sulfur hematite iron, phosphorus P < 0.03%, manganese Mn < 0.31%.
Heat treatment is under the protection of controllable gas, carries out in 320～385 DEG C of salt bath furnaces, and the heat treated time is 1～3.5 hour, improves quality and the stability of cylinder jacket.
Plateau honing cross hatches processing is within the scope of 4mm, groove >=6 of groove depth >=4 μm of cross hatch, profile degree of skewness SK-0.9～-2.8.Platform reticulate pattern is exactly bright and clean have narrow and deep groove uniformly over the surface smooth, good its platform roughness of platform reticulate pattern is very low, it is generally < 0.2 μm and groove is narrow and deep, its great advantage is that oil storage capacity is strong, and surface abrasion resistance substantially reduces initial stage running-in time simultaneously, such as state's intrinsic motivation needs break-in several hours at least before dispatching from the factory, within tens hours, just reach requirement at most, and close to zero break-in when Foreign Engine dispatches from the factory, a few minutes just can reach requirement.
Between lost foam casting process and traditional ordinary sand casting technique in the present invention, both there is the inheritance that alloy graining characteristic aspect is close, there is again the complementarity in formative technology, obvious lost foam casting process has cylinder jacket product quality and internal structure stability obviously improves, reduce the energy total amount needed for the raw materials consumption of foundry goods itself and smelting metal, energy-saving and emission-reduction, are conducive to environmental protection；Also reduce workload and the manufacturing cost of subsequent mechanical processing simultaneously.
Accompanying drawing explanation
Fig. 1 is the structural representation of the first embodiment of the present invention,
Fig. 2 is the structural representation of the second embodiment of the present invention；
In figure, 1 is evaporative pattern, and 2 is dope layer, and 21 is internal layer, and 22 is outer layer, and 3 is casting sandbox, and 4 is dry sand, and 5 is magnetic powder, and 6 is Magnet；
In figure, the arrow of vertical direction represents the direction of action of Magnet；Horizontal direction represents the direction of action of magnetic powder.
Detailed description of the invention
The present invention as shown in Figure 1-2, comprises the following steps:
1) lost foam modeling, adopts polystyrene foam plastics foaming in cylinder jacket mould, forms the evaporative pattern 1 identical with cylinder jacket shape, and evaporative pattern is stained with the running channel and cast gate that adopt polystyrene foam plastics foaming；
At evaporative pattern surface coating paint layer and dry, imbedded in the dry sand 4 in casting sandbox 3；Dope layer or dry sand are mixed into magnetic powder, are adsorbed by the Magnet that removably connects in casting sandbox, form exhaust passage, improve exhaust efficiency and reliability；Magnet is placed along with the flow direction of runner so that the gas of generation is progressively discharged, and improves the quality of casting billet surface.
2) cylinder cover casting strand, uses low-sulfur hematite iron to pour into a mould, and condensation forms blank, sulfur S < 0.02%, phosphorus P < 0.03%, manganese Mn < 0.31% in described low-sulfur hematite iron；
3) cylinder jacket strand is carried out roughing；
4) heat treatment, under the protection of controllable gas, carries out in 320～385 DEG C of salt bath furnaces, and the heat treated time is 1～3.5 hour, and controllable gas is made up of percent by volume respectively carbon monoxide 16%, hydrogen 44% and nitrogen 40%；
5) platform reticulate pattern processing, within the scope of 4mm, groove >=6 of groove depth >=4 μm of cross hatch, profile degree of skewness-0.9～-2.8.
The first embodiment of the present invention, as it is shown in figure 1, described dope layer 2 has internal layer 21 and outer layer 22, is provided with magnetic powder 5 in the dope layer of outer layer, the surrounding of described casting sandbox has endoporus, and the endoporus of described casting sandbox removably connects and is provided with Magnet 6.
By arranging magnetic powder in outer layer coating layer, adsorbed by Magnet, form exhaust passage, improve the breathability of dope layer, convenient discharge, improve the surface quality of cylinder jacket；Owing to carrying out dope layer drying in solid-state, the sucking-off of magnetic powder on outer layer coating layer, do not affect the normal operation of dope layer.
The second embodiment of the present invention as in figure 2 it is shown, described casting sandbox dry sand in be provided with magnetic powder 5, described magnetic powder is positioned at the surrounding of described evaporative pattern, and the surrounding of described casting sandbox has endoporus, and the endoporus of described casting sandbox removably connects and is provided with Magnet 6.
By arranging magnetic powder in the dry sand of evaporative pattern surrounding, adsorbed by Magnet, form the exhaust passage of dry sand so that gas is discharged then through the exhaust passage of dry sand from dope layer, improve the surface quality of cylinder jacket；The sucking-off of the magnetic powder in dry sand so that suitable loose of dry sand around, forms exhaust passage, it is simple to the discharge of gas.
When cast, Magnet is put in the endoporus of casting sandbox surrounding one by one along with the flow direction of running channel, on the one hand, ensure the density in cast front casting sandbox；On the other hand, in casting process, gas produces gradually, by the progressively absorption of Magnet so that the gas of generation progressively filling exhaust passage is discharged, it is to avoid cylinder sleeve cast part surface is subject to the impact of gas, improves the quality of cylinder-barrel surface.
During work, dope layer and dry sand can be exhausted, but exhaust efficiency is low so that gas easily gathers, and reduce the reliability of aerofluxus, cause cc billet surface quality poor；By arranging exhaust passage, improve exhaust efficiency and reliability.
The production process of the present invention is:
One, production stage:
1, lost foam modeling: the bubbles model of evaporative pattern adopts expandable polystyrene foam plastics EPS.Make bubble and mould the white mould of gasification, composite pouring system, the white mould surface brush that gasifies, spray special high-temperature resistant coating and dry.Lost foam casting is cavityless casting, directly carrys out moulding with product bubbles model, it is not necessary to core.
2, being placed on shaking table by casting sandbox, insert bed load (dry sand) jolt ramming, strike off, be put on bed load by the gasified pattern of drying, fill up dry sand, micro-appropriate time that shakes strikes off case mouth.
3, after dry sand fastening molding, pouring into a mould, Bai Mo gasifies disappearance, and molten metal replaces its position.
4, mould turnover after foundry goods condenses, takes out foundry goods from loose dry sand, carries out subsequent cycle.
Two,Cylinder cover casting strand:
1, the conjunction of steel scrap carburetting is selectedGoldCast iron or high-purity magnesium iron pig iron are as the major metal material producing cylinder jacket, the strict addition controlling alloy element；Melt iron in middle frequency furnace, comes out of the stove for 1520～1580 DEG C.In casting process, model gasification needs to absorb heat, and the pouring temperature of evaporative pattern apparatus for casting should slightly above sand casting.
2、The addition (%) of alloy element, all the other are Fe:
| C | Si | Mn | P | S |
| 3.1-3.9 | 2.0-3.0 | < 0.31 | < 0.03 | < 0.02 |
3、Cylinder jacket strand is carried out roughing.
4, heat treatment:
Protect in the salt bath furnace of (being made up of percent by volume respectively carbon monoxide 16%, hydrogen 44% and nitrogen 40%) at controllable gas and carry out, heat treatment 320-385 DEG C, 1-3.5 hour.Control heat distortion amount within ± 0.2mm.
Sample after heat treatment, metallographic examination measure hardness.
5, plateau honing cross hatches processes:
Within the scope of 4mm, groove >=6 of groove depth >=4 μm of cross hatch, profile degree of skewness SK-0.9～-2.8.
6, check, go out the quality certification, packaging.
Two, product performance index:
Tested by bench test and circuit running assessment: the performance of the cylinder jacket adopting the inventive method to produce can reach the requirement of engine with supercharger.
1, cylinder jacket key dimension (mm):
| Internal diameter size | Outside dimension | Upper flange external diameter | Height overall |
| 228.6 | 296 | 310 | 580 |
2, service condition:
Geometrical compression ratio 15
Rotating speed (r/min) 1100
Mean piston speed (m/s) 9.8
Power (kw) 1800
Mean effective pressure (MPa) 1.61
Maximum explosive pressure (MPa) 13.5
3, chemical composition (%) after alloy element addition
| C | Si | Mn | P | S |
| 3.3 | 2.5 | 0.26 | 0.028 | 0.019 |
4, closeGoldCast iron metallographic structure
Pearlite 96-100%.
5, material mechanical performance: tensile strength >=300MPa
6, HB=207-285
Adopt cylinder jacket product quality that the inventive method formed and internal structure stability obviously to obtain raising, and reduce the energy total amount needed for the raw materials consumption of foundry goods itself and smelting metal, energy-saving and emission-reduction, be conducive to environmental protection；Also reduce workload and the manufacturing cost of subsequent mechanical processing simultaneously.
Lost foam casting process integrates the advantage of cavityless casting, V method casting technique, uses dry sand curable type, prototype former state；Casting dimension accuracy is high, uniformity；Do not play core, do not detain case, foundry goods non-trimming, burr；Surface flatness is close to hot investment casting, and internal structure is stable, gets rid of, reduces the casting flaw such as sand holes, gas sky.Whole production process environmental protection, it does not have pollute.In sum, lost foam casting meets the general trend of current foundry engieering development, has wide prospect.Compared with conventional casting technologies, the advantage of Technology of EPC tool being and not being rival.
Claims (3)
1. the production method of a cylinder jacket, it is characterised in that: comprise the following steps:
1) lost foam modeling, adopts polystyrene foam plastics foaming in cylinder jacket mould, forms the evaporative pattern identical with cylinder jacket shape, and evaporative pattern is stained with the running channel and cast gate that adopt polystyrene foam plastics foaming；
At evaporative pattern surface coating paint layer and dry, imbedded in the dry sand in casting sandbox；
2) cylinder cover casting strand, uses low-sulfur hematite iron to pour into a mould, and condensation forms blank, sulfur S < 0.02%, phosphorus P < 0.03%, manganese Mn < 0.31% in described low-sulfur hematite iron；
3) cylinder jacket strand is carried out roughing；
4) heat treatment, under the protection of controllable gas, carries out in 320～385 DEG C of salt bath furnaces, and the heat treated time is 1～3.5 hour, and controllable gas is made up of percent by volume respectively carbon monoxide 16%, hydrogen 44% and nitrogen 40%；
5) platform reticulate pattern processing, within the scope of 4mm, groove >=6 of groove depth >=4 μm of cross hatch, profile degree of skewness-0.9～-2.8.
2. the production method of a kind of cylinder jacket according to claim 1, it is characterized in that, described dope layer has internal layer and outer layer, is provided with magnetic powder in the dope layer of outer layer, the surrounding of described casting sandbox has endoporus, and the endoporus of described casting sandbox removably connects and is provided with Magnet.
3. the production method of a kind of cylinder jacket according to claim 1, it is characterized in that, being provided with magnetic powder in the dry sand of described casting sandbox, described magnetic powder is positioned at the surrounding of described evaporative pattern, the surrounding of described casting sandbox has endoporus, and the endoporus of described casting sandbox removably connects and is provided with Magnet.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201610143799.9A CN105772635B (en) | 2016-03-14 | 2016-03-14 | A kind of production method of cylinder jacket |
| CN201810308465.1A CN108273964B (en) | 2016-03-14 | 2016-03-14 | A kind of production method for the cylinder jacket improving surface quality |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201610143799.9A CN105772635B (en) | 2016-03-14 | 2016-03-14 | A kind of production method of cylinder jacket |
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| CN201810308465.1A Division CN108273964B (en) | 2016-03-14 | 2016-03-14 | A kind of production method for the cylinder jacket improving surface quality |
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| CN105772635A true CN105772635A (en) | 2016-07-20 |
| CN105772635B CN105772635B (en) | 2018-05-15 |
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| CN201610143799.9A Active CN105772635B (en) | 2016-03-14 | 2016-03-14 | A kind of production method of cylinder jacket |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107876697A (en) * | 2017-11-27 | 2018-04-06 | 安徽省岳西缸套有限公司 | The production technology of gold cylinder sleeve |
| CN107917010A (en) * | 2017-11-29 | 2018-04-17 | 常州中车柴油机零部件有限公司 | A kind of two-stroke diesel engine cylinder jacket and its processing method |
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| CN1333104A (en) * | 2000-07-12 | 2002-01-30 | 山东科技大学机械厂 | Method for producing cast iron cylinder jacket of diesel engine |
| JP4507209B2 (en) * | 2007-03-14 | 2010-07-21 | 新東工業株式会社 | Full mold casting method and mold used in the casting method |
| CN101698219A (en) * | 2009-10-23 | 2010-04-28 | 湖北省缸套厂 | Method for casting negative pressure solid cylinder sleeve |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107876697A (en) * | 2017-11-27 | 2018-04-06 | 安徽省岳西缸套有限公司 | The production technology of gold cylinder sleeve |
| CN107917010A (en) * | 2017-11-29 | 2018-04-17 | 常州中车柴油机零部件有限公司 | A kind of two-stroke diesel engine cylinder jacket and its processing method |
Also Published As
| Publication number | Publication date |
|---|---|
| CN108273964B (en) | 2019-07-26 |
| CN108273964A (en) | 2018-07-13 |
| CN105772635B (en) | 2018-05-15 |
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