CN107520944B - Ceramic body vacuum grouting process - Google Patents
Ceramic body vacuum grouting process Download PDFInfo
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- CN107520944B CN107520944B CN201710865932.6A CN201710865932A CN107520944B CN 107520944 B CN107520944 B CN 107520944B CN 201710865932 A CN201710865932 A CN 201710865932A CN 107520944 B CN107520944 B CN 107520944B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/265—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor pressure being applied on the slip in the filled mould or on the moulded article in the mould, e.g. pneumatically, by compressing slip in a closed mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/261—Moulds therefor
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- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
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- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Producing Shaped Articles From Materials (AREA)
Abstract
The invention discloses a ceramic body vacuum grouting process, which adopts vertical casting molding equipment, wherein a high-pressure microporous material mold is adopted as the mold, the process comprises the steps of mold closing, mold locking, filling, slurry feeding, mud discharging, consolidation, mold opening, mold separation, drying, blank discharging and the like, wherein the mold locking pressure is 45-50Mpa, and the slurry feeding step comprises two substeps of vacuum slurry feeding and pressurized slurry feeding. Compared with the low-pressure quick-drainage gypsum mould grouting process, the process has the advantages that the production efficiency is greatly improved, and the mould cost and the labor cost are reduced; compared with the high-pressure grouting process, the method can utilize common vertical casting equipment without high fixed asset investment.
Description
Technical Field
The invention relates to the field of ceramic manufacturing, in particular to a vacuum grouting process for a ceramic body.
Background
In the field of ceramic manufacture, the mainstream blank grouting process is a gypsum mold grouting process, and a low-pressure quick-drainage gypsum mold grouting process is developed on the basis of the gypsum mold grouting process, wherein 8-9 times of grouting are performed every day, the average service life is 150 times, and the line changing frequency reaches 1.5 times. Therefore, the process has the problems of high mold cost, high labor cost, high line changing labor intensity and the like. In order to overcome the problems, a high-pressure grouting process is developed, but the high-pressure grouting process generally has high requirements on equipment, large investment in fixed assets and the like.
Disclosure of Invention
The invention aims to overcome the defects or problems in the background art and provides a vacuum grouting process for a ceramic blank, which greatly improves the production efficiency and reduces the mould cost and the labor cost compared with the low-pressure quick-drainage gypsum mould grouting process; compared with the high-pressure grouting process, the method can utilize common vertical casting equipment without high fixed asset investment.
In order to achieve the purpose, the invention adopts the following technical scheme:
a ceramic body vacuum grouting process, the grouting equipment adopts the vertical casting molding equipment; the grouting mould adopts a high-pressure microporous material mould, and the strength of the high-pressure microporous material mould is 30-41N/mm2The partition ventilation capacity is more than 85L/min; under the process conditions, the ceramic body vacuum grouting process comprises the following steps of sequentially executing: step 1: closing the mold, and controlling a mold closing mechanism to drive the phenotype mold and the inner mold to approach each other; step 2: locking the mold, controlling a mold locking mechanism to lock the inner mold and the outer mold, wherein the mold locking pressure is 45-55 MPa; and step 3: filling, filling the slurryFilling into a mold cavity; step 4; slurry feeding, comprising the following sub-steps performed in sequence: step 4.1: feeding slurry in vacuum, keeping a cavity pressurizing channel closed, keeping a cavity grouting and mud discharging channel communicated with a high-level mud groove, controlling a mold drainage and exhaust channel to be communicated with a vacuum pump, and keeping the gauge pressure of the vacuum pump at 0.03-0.05Mpa for 10-12 minutes; step 4.2: pressurizing and feeding slurry, keeping a cavity pressurizing channel closed, controlling a cavity grouting and mud discharging channel to be communicated with a mud pump, keeping a mold drainage and exhaust channel to be communicated with a vacuum pump, and gradually adjusting the pressure of the mud pump to 0.17-0.23Mpa within 1 minute for 18-22 minutes; and 5: discharging the mud, and discharging the redundant mud out of the die cavity; step 6: consolidation, discharging water out of the blank in the cavity to increase the hardness of the blank; and 7: opening the mold, and controlling the mold locking mechanism to release the pressure; and 8: separating the molds, namely controlling a mold closing mechanism to drive a phenotype mold and a lining mold to separate from each other; and step 9: drying, and waiting for the blank to improve the hardness; step 10: and (5) blanking, and transferring the blank to a supporting plate.
Further, the step 1 is executed according to the following conditions: and (5) closing the mold, wherein the closing mechanism drives the inner mold to approach the watch-shaped mold.
Further, the step 3 is executed according to the following conditions: and filling, wherein the cavity pressurizing channel is controlled to be closed, the cavity grouting and mud discharging channel is controlled to be communicated with the high-level mud groove, the mold drainage and exhaust channel is opened, the high-level mud groove is used for grouting the mold cavity of the mold through the cavity grouting and mud discharging channel until the mold cavity is full, the grouting pressure is kept at 0.005-0.015MPa, and the duration time is 5-8 minutes.
Further, the step 5 is executed according to the following conditions: and (3) discharging mud, wherein a cavity pressurization channel is controlled to be communicated with compressed air, a cavity grouting mud discharge channel is controlled to be communicated with a mud return tank, a mold drainage and exhaust channel is controlled to be closed, the air pressure is slowly increased to 0.01-0.02Mpa, redundant mud is discharged, and the duration is 5-8 minutes.
Further, the step 6 is executed according to the following conditions: and (4) consolidating, keeping the cavity pressurizing channel communicated with compressed air, controlling the cavity grouting and mud discharging channel to be closed, controlling the mold drainage and exhaust channel to be opened, and increasing the pressure of the compressed air to 0.04-0.08MPa for 5-15 minutes.
Further, the step 7 is executed according to the following conditions: and opening the mold, controlling the closing of the pressurizing channel of the mold cavity, keeping the closing of the grouting and mud discharging channel of the mold cavity, controlling the closing of the water and air discharging channel of the mold, and releasing the pressure of the mold locking mechanism.
Further, the step 8 is executed according to the following conditions: and (3) parting the mold, keeping the pressurizing channel of the mold cavity closed, keeping the grouting and mud discharging channel of the mold cavity closed, controlling the drainage and exhaust channel of the inner mold to be communicated with compressed air, keeping the drainage and exhaust channel of the phenotypic mold closed, adjusting the air pressure of the compressed air to 0.1-0.2Mpa, and driving the inner mold to leave by the mold closing mechanism after the pressurization lasts for 6-8 seconds.
Further, the step 9 is executed according to the following conditions: and drying, namely keeping the pressurizing channel of the cavity closed, keeping the grouting and mud discharging channel of the cavity closed, controlling the drainage and exhaust channel of the inner mold closed, keeping the drainage and exhaust channel of the phenotypic mold closed, and drying the blank on the phenotypic mold for 5-10 minutes until the hardness reaches 65 HW.
Further, the step 10 is executed according to the following conditions: and (3) blanking, abutting the supporting plate against the blank body, keeping a cavity pressurization channel closed, keeping a cavity grouting mud discharge channel closed, keeping a cavity drainage and exhaust channel closed, controlling the cavity drainage and exhaust channel to be communicated with compressed air, adjusting the air pressure of the compressed air to 0.1-0.2Mpa, and after pressurization lasts for 6-8 seconds, supporting the blank body by the supporting plate.
As can be seen from the above description of the present invention, the present invention has the following advantages over the prior art:
1. the mold locking pressure in the invention is lower than the mold locking pressure in high-pressure grouting, so that the ordinary vertical casting grouting equipment can be put into production.
2. The mold locking pressure of the low-pressure quick-drainage gypsum mold grouting process is too low, so that the vacuum pumping cannot be realized; the high-pressure grouting process has high pressurization on the slurry in the cavity, and the slurry feeding in vacuum is not needed, so the invention can accelerate the slurry feeding speed by utilizing vacuum.
3. When the pressure is increased and the slurry is fed, the pressure of the slurry pump is kept between 0.17 and 0.25Mpa, so that the slurry cannot seep when the mold locking pressure is between 45 and 50 Mpa.
4. The high-level slurry tank is used for sizing, so that the sizing pressure is kept between 0.005 and 0.015Mpa, and no air bubble is generated during sizing.
5. When the mold is separated and the blank is discharged, the inner mold or the phenotypic mold is pressurized, so that a water film is formed between the mold and the blank before the mold is separated or the blank is discharged, and the separation of the inner mold is facilitated.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below. It is to be understood that the described embodiments are presently preferred embodiments of the invention and are not to be taken as an exclusion of other embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
In the claims and the specification of the present invention, unless otherwise specifically limited, the terms "first", "second", or "third", etc., are used for distinguishing between different objects and not for describing a particular order.
In the claims and specification of the present invention, the terms "including", "comprising" and "having", and variations thereof, are intended to be inclusive or non-exclusive.
The technical scheme of the invention is implemented under the condition that a high-pressure microporous material mould, generally a resin mould, is adopted. The mold is relatively low in requirements relative to molds used in high pressure grouting processes, and the requirements for the mold are shown in table one.
Table one: comparison of the molds
From the above table, the main difference between the high-pressure microporous material mold applied to the technical scheme and the mold for the high-pressure grouting process is that the ventilation quantity is improved, and the mold strength is reduced. This is achieved by adjusting the manufacturing process when the mold is manufactured. The above differences are also compatible with the grouting pressure.
The other condition that this technical scheme implemented is that slip casting equipment can adopt and founds the former, need not to drop into high-pressure slip casting equipment. In fact, the equipment is selected based on the mold clamping pressure, the higher the equipment requirements, and the greater the equipment investment.
The technical scheme comprises the following steps which are executed in sequence:
step 1: closing the mold, and controlling a mold closing mechanism to drive the phenotype mold and the inner mold to approach each other; preferably, the clamping mechanism drives the inner mold to close the watch-type mold.
Step 2: and locking the mold, wherein the mold locking mechanism is controlled to lock the inner mold and the outer mold, and the mold locking pressure is 45 MPa.
And step 3: filling, namely filling the slurry into a mold cavity; preferably, the filling is performed by: and controlling the cavity pressurization channel to be closed, controlling the cavity grouting and mud discharging channel to be communicated with the high-level mud groove, opening the mold drainage and exhaust channel, and starching the high-level mud groove to the mold cavity through the cavity grouting and mud discharging channel until the cavity is full, wherein the starching pressure is kept at 0.01MPa for 5 minutes.
And 4, step 4: slurry feeding, comprising the following sub-steps performed in sequence: step 4.1: feeding slurry in vacuum, keeping a cavity pressurization channel closed, keeping a cavity grouting and mud discharging channel communicated with a high-level mud groove, controlling a mold drainage and exhaust channel to be communicated with a vacuum pump, and keeping the gauge pressure of the vacuum pump at 0.04MPa for 10 minutes; step 4.2: and (3) pressurizing and feeding slurry, keeping a cavity pressurizing channel closed, controlling a cavity grouting and mud discharging channel to be communicated with a mud pump, keeping a mold drainage and exhaust channel to be communicated with a vacuum pump, and gradually adjusting the pressure of the mud pump to 0.2Mpa within 1 minute for 20 minutes.
And 5: discharging the mud, and discharging the redundant mud out of the die cavity; preferably, the sludge discharge is performed by: and controlling a cavity pressurizing channel to be communicated with compressed air, controlling a cavity grouting and mud discharging channel to be communicated with a mud returning tank, controlling a mould drainage and exhaust channel to be closed, slowly increasing the air pressure to 0.012Mpa, and discharging redundant mud for 5 minutes.
Step 6: consolidation, discharging water out of the blank in the cavity to increase the hardness of the blank; preferably, consolidation is performed by: and (3) keeping the cavity pressurizing channel communicated with compressed air, controlling the cavity grouting mud discharging channel to be closed, controlling the mold water discharging and air discharging channel to be opened, and increasing the pressure of the compressed air to 0.08MPa for 15 minutes.
And 7: opening the mold, and controlling the mold locking mechanism to release the pressure; preferably, the opening of the mold is performed by the following conditions: and controlling the closing of the cavity pressurizing channel, keeping the closing of the cavity grouting mud discharging channel, controlling the closing of the mold water discharging and air discharging channel, and releasing the pressure of the mold locking mechanism.
And 8: separating the molds, namely controlling a mold closing mechanism to drive a phenotype mold and a lining mold to separate from each other; preferably, the division into the modules is performed by: keeping the cavity pressurizing channel closed, keeping the cavity grouting mud discharging channel closed, controlling the inner die drainage and exhaust channel to be communicated with compressed air, keeping the phenotype die drainage and exhaust channel closed, adjusting the air pressure of the compressed air to 0.13Mpa, and after pressurizing lasts for 6 seconds, driving the inner die to leave by the die closing mechanism.
And step 9: drying, and waiting for the blank to improve the hardness; preferably, the drying is performed by: keeping the cavity pressurizing passage closed, keeping the cavity grouting mud discharging passage closed, controlling the water and air discharging passage of the inner mold to be closed, keeping the water and air discharging passage of the phenotypic mold to be closed, and drying the blank on the phenotypic mold for 5 minutes until the hardness reaches 65 HW.
Step 10: blanking, and transferring the blank body to a supporting plate; preferably, blanking is performed by: and abutting the supporting plate against the green body, keeping the cavity pressurization channel closed, keeping the cavity grouting and mud discharging channel closed, keeping the water and air discharging channel of the inner die closed, controlling the water and air discharging channel of the inner die to be communicated with compressed air, adjusting the air pressure of the compressed air to 0.13MPa, and after pressurization lasts for 6 seconds, bearing the green body by the supporting plate.
The arrangement and the function of the cavity pressurizing channel, the cavity grouting mud discharging channel and the mold drainage and exhaust channel are the same as those of a mold for a high-pressure grouting process, and the cavity pressurizing channel, the cavity grouting mud discharging channel and the mold drainage and exhaust channel are all in the prior art.
We further compare the parameters of the grouting process of the technical scheme with the parameters of the high-pressure grouting process and the ordinary low-pressure grouting process, see table two.
As can be seen from the above table, compared with the low-pressure quick-drainage gypsum mold grouting process, the technical scheme greatly improves the production efficiency in each step, and reduces the mold cost and the labor cost; compared with the high-pressure grouting process, the mold locking pressure is lower than that of high-pressure grouting, so that common vertical casting forming equipment can be utilized, and high fixed asset investment is not needed.
In addition, compared with other two processes, the mold locking pressure of the low-pressure quick-drainage gypsum mold grouting process is too low, so that the vacuum pumping cannot be realized; the high-pressure grouting process has high pressurization on the slurry in the cavity, and the slurry feeding in vacuum is not needed, so the invention can accelerate the slurry feeding speed by utilizing vacuum. When the pressure is increased and the slurry is fed, the pressure of the slurry pump is kept between 0.17 and 0.25Mpa, so that the slurry cannot seep when the mold locking pressure is between 45 and 50 Mpa.
The high-level slurry tank is used for sizing, so that the sizing pressure is kept between 0.005 and 0.015Mpa, and no air bubble is generated during sizing.
When the mold is separated and the blank is discharged, the inner mold or the phenotypic mold is pressurized, so that a water film is formed between the mold and the blank before the mold is separated or the blank is discharged, and the separation of the inner mold is facilitated.
Table two: comparison of Process parameters
The description of the above specification and examples is intended to be illustrative of the scope of the present invention and is not intended to be limiting. Modifications, equivalents and other improvements which may occur to those skilled in the art and which may be made to the embodiments of the invention or portions thereof through a reasonable analysis, inference or limited experimentation, in light of the common general knowledge, the common general knowledge in the art and/or the prior art, are intended to be within the scope of the invention.
Claims (9)
1. A ceramic body vacuum grouting process is characterized in that: the grouting equipment adopts vertical casting molding equipment; the grouting mould adopts a high-pressure microporous material mould, and the strength of the high-pressure microporous material mould is more than 30N/mm2The zonal ventilation is more than 85L/min；
Under the process conditions, the ceramic body vacuum grouting process comprises the following steps of sequentially executing:
step 1: closing the mold, and controlling a mold closing mechanism to drive the phenotype mold and the inner mold to approach each other;
step 2: locking the mold, controlling a mold locking mechanism to lock the inner mold and the outer mold, wherein the mold locking pressure is 45-50 MPa;
and step 3: filling, namely filling the slurry into a mold cavity;
step 4; slurry feeding, comprising the following sub-steps performed in sequence:
step 4.1: feeding slurry in vacuum, keeping a cavity pressurizing channel closed, keeping a cavity grouting and mud discharging channel communicated with a high-level mud groove, controlling a mold drainage and exhaust channel to be communicated with a vacuum pump, and keeping the gauge pressure of the vacuum pump at 0.03-0.05Mpa for 10-12 minutes;
step 4.2: pressurizing and feeding slurry, keeping a cavity pressurizing channel closed, controlling a cavity grouting and mud discharging channel to be communicated with a mud pump, keeping a mold drainage and exhaust channel to be communicated with a vacuum pump, and gradually adjusting the pressure of the mud pump to 0.17-0.25Mpa within 1 minute for 18-22 minutes;
and 5: discharging the mud, and discharging the redundant mud out of the die cavity;
step 6: consolidation, discharging water out of the blank in the cavity to increase the hardness of the blank;
and 7: opening the mold, and controlling the mold locking mechanism to release the pressure;
and 8: separating the molds, namely controlling a mold closing mechanism to drive a phenotype mold and a lining mold to separate from each other;
and step 9: drying, and waiting for the blank to improve the hardness;
step 10: and (5) blanking, and transferring the blank to a supporting plate.
2. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 1 is carried out under the following conditions: and (5) closing the mold, wherein the closing mechanism drives the inner mold to approach the watch-shaped mold.
3. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 3 is performed according to the following conditions: and filling, wherein the cavity pressurizing channel is controlled to be closed, the cavity grouting and mud discharging channel is controlled to be communicated with the high-level mud groove, the mold drainage and exhaust channel is opened, the high-level mud groove is used for grouting the mold cavity of the mold through the cavity grouting and mud discharging channel until the mold cavity is full, the grouting pressure is kept at 0.005-0.015MPa, and the duration time is 5-8 minutes.
4. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 5 is performed according to the following conditions: and (3) discharging mud, wherein a cavity pressurization channel is controlled to be communicated with compressed air, a cavity grouting mud discharge channel is controlled to be communicated with a mud return tank, a mold drainage and exhaust channel is controlled to be closed, the air pressure is slowly increased to 0.01-0.02Mpa, redundant mud is discharged, and the duration is 5-8 minutes.
5. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 6 is performed according to the following conditions: and (4) consolidating, keeping the cavity pressurizing channel communicated with compressed air, controlling the cavity grouting and mud discharging channel to be closed, controlling the mold drainage and exhaust channel to be opened, and increasing the pressure of the compressed air to 0.04-0.08MPa for 5-15 minutes.
6. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 7 is performed according to the following conditions: and opening the mold, controlling the closing of the pressurizing channel of the mold cavity, keeping the closing of the grouting and mud discharging channel of the mold cavity, controlling the closing of the water and air discharging channel of the mold, and releasing the pressure of the mold locking mechanism.
7. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 8 is performed according to the following conditions: and (3) parting the mold, keeping the pressurizing channel of the mold cavity closed, keeping the grouting and mud discharging channel of the mold cavity closed, controlling the drainage and exhaust channel of the inner mold to be communicated with compressed air, keeping the drainage and exhaust channel of the phenotypic mold closed, adjusting the air pressure of the compressed air to 0.1-0.2Mpa, and driving the inner mold to leave by the mold closing mechanism after the pressurization lasts for 6-8 seconds.
8. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 9 is performed according to the following conditions: and drying, namely keeping the pressurizing channel of the cavity closed, keeping the grouting and mud discharging channel of the cavity closed, controlling the drainage and exhaust channel of the inner mold closed, keeping the drainage and exhaust channel of the phenotypic mold closed, and drying the blank on the phenotypic mold for 5-10 minutes until the hardness reaches 65 HW.
9. The vacuum grouting process for ceramic body as claimed in claim 1, wherein the step 10 is performed according to the following conditions: and (3) blanking, abutting the supporting plate against the blank body, keeping a cavity pressurization channel closed, keeping a cavity grouting mud discharge channel closed, keeping a cavity drainage and exhaust channel closed, controlling the cavity drainage and exhaust channel to be communicated with compressed air, adjusting the air pressure of the compressed air to 0.1-0.2Mpa, and after pressurization lasts for 6-8 seconds, supporting the blank body by the supporting plate.
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| CN113815091A (en) * | 2021-07-30 | 2021-12-21 | 安徽省含山民生瓷业有限责任公司 | Grouting process |
| CN114434596B (en) * | 2021-12-22 | 2023-11-21 | 萍乡市慧成精密机电有限公司 | Manufacturing method of ceramic injection molding shifting fork |
| CN115490501A (en) * | 2022-10-11 | 2022-12-20 | 广西北流市新源瓷业有限责任公司 | High-pressure slip casting process for ceramic blank |
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