CN107900311B - Integral forming die for thin-wall cabin and forming method thereof - Google Patents
Integral forming die for thin-wall cabin and forming method thereof Download PDFInfo
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- CN107900311B CN107900311B CN201711105354.2A CN201711105354A CN107900311B CN 107900311 B CN107900311 B CN 107900311B CN 201711105354 A CN201711105354 A CN 201711105354A CN 107900311 B CN107900311 B CN 107900311B
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- 238000010438 heat treatment Methods 0.000 claims abstract description 8
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- 238000007789 sealing Methods 0.000 claims description 63
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- KRLDNBXEMNGJGG-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[AlH3].[Cu] KRLDNBXEMNGJGG-UHFFFAOYSA-N 0.000 description 3
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- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 description 2
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- GANNOFFDYMSBSZ-UHFFFAOYSA-N [AlH3].[Mg] Chemical class [AlH3].[Mg] GANNOFFDYMSBSZ-UHFFFAOYSA-N 0.000 description 1
- KMWBBMXGHHLDKL-UHFFFAOYSA-N [AlH3].[Si] Chemical class [AlH3].[Si] KMWBBMXGHHLDKL-UHFFFAOYSA-N 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 1
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/06—Vacuum casting, i.e. making use of vacuum to fill the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
- C22F1/057—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with copper as the next major constituent
Abstract
The invention discloses an integral forming die of a thin-wall cabin body and a forming method thereof, wherein the die comprises a cylindrical casting main body, a cover plate and a bottom box body, the casting main body comprises a casting outer die and a casting inner die with a hollow inside, a ring-shaped vertical cylinder is arranged on the inner wall of the casting outer die, and a core pipe is arranged on the central axis of the inside of the casting inner die. The method comprises the steps of raw material weighing, raw material smelting and casting, die assembly, vacuum pressure-regulating casting, casting cleaning, casting blank heat treatment, vibration aging and mechanical processing to obtain the aluminum alloy thin-wall cabin body. The invention not only can be used for manufacturing the thin-wall high-strength aluminum alloy missile cabin body, but also can be used for integrally forming other complex thin-wall aluminum alloy castings, and has good application and development prospects.
Description
Technical Field
The invention relates to the field of nonferrous metal precision forming, in particular to an integral forming die of a thin-wall cabin body and a forming method thereof.
Background
The cabin shell is a main bearing part in the missile structure, bears larger external load and is required to have higher specific strength (strength/density) and specific rigidity (rigidity/density). Therefore, the material of the cabin body is generally selected from high-strength wrought aluminum alloy or forged aluminum alloy. At present, domestic missile cabins are produced by adopting a riveting, welding and forging combined process method. The cabin body is connected with the end frame and is processed in a numerical control mode after forging aluminum die forging; the cabin body skin is welded into a cylinder shape after being spun and bent by adopting a deformed aluminum alloy and then welded into a whole with the end frame; the longitudinal and transverse reinforcing ribs of the inner cavity of the cabin body and various mounting bosses of the inner cavity are formed by cold pressing stainless steel plates or processed by deformed aluminum alloy, and then are riveted with the skin to form the complete cabin body. The missile hull manufactured by the method requires a large number of fixture clamps, and has the advantages of complex and complicated process, lower production efficiency, long manufacturing period and high production cost.
In advanced countries such as the advanced U.S. and russia in the fields of aviation, aerospace, navigation and the like, for the workpiece with complex shape and high processing difficulty such as a missile thin-wall cabin body, in order to reduce the cutting processing amount, reduce the cost, lighten the structure weight and increase the effective volume, precision casting forming is adopted, high-quality castings with high surface and internal quality and dimensional accuracy can be cast, and some blanks are even accurate to the extent that the blanks can be directly assembled without allowance.
According to the description of related data, the foreign missile cabin body is manufactured by adopting a high-strength aluminum alloy integral casting technology, such as an air-ground missile AGM-86B air-launched cruising missile developed by Boeing company for the United states air force, the missile length is 6.36m, the missile diameter is 693mm, the rest parts of the missile body except for the aileron surface are cast by adopting the aluminum alloy, and 4 cabin sections are all cast by adopting the high-strength aluminum alloy integral casting, so that the manufacturing cost is reduced by more than 30 percent. All-weather medium-range and medium-high-altitude ground-air missiles produced by Kangtla Wilson, switzerland have a warhead length of 420mm, and the missile shell body is integrally cast by high-strength aluminum alloy. The missile cabin aluminum alloy material has uniform casting structure, extremely fine grains and good processing performance, the tensile strength reaches 400MPa, the yield strength reaches 300MPa, and the elongation reaches 8%.
At present, only a few units in China adopt aluminum-silicon casting aluminum alloy or aluminum-magnesium alloy casting to produce a small-sized low-Mach flying cruise missile cabin body, the integral forming of a middle-large thin-wall missile cabin body in high Mach flying cannot be realized, and the main problems are as follows:
1) The cabin body material is aluminum-silicon series or aluminum-magnesium series casting alloy, the mechanical property of the material is low, the maximum tensile strength is only 300MPa, and the strength index is low.
2) At present, the minimum wall thickness of the casting is not less than 6mm, the integral forming of the thin-wall cabin body cannot be realized, and the wall thickness of the casting is increased to ensure the forming of the casting.
3) The thick-wall casting has low cooling speed, so that the grains are coarse, the performance of the casting is reduced, the tensile strength of a cabin sample is only about 200MPa, and the performance requirement of the thin-wall cabin cannot be met.
The application research of the domestic high-strength aluminum alloy casting technology is relatively late in start in developed countries such as Europe and America, the eighth of the last century, beijing aviation materials research institute develops aluminum-copper high-strength aluminum alloy ZL201A, the mechanical property of which reaches the mechanical property of a conventional aluminum alloy forging, and the strength of which is similar to that of an aluminum alloy with the KO-1 brand in the United states. However, the casting performance of ZL201A is poor, and many applications thereof are concentrated on small frame structural members, but they are not applied in the manufacture of medium-large thin-wall missile cabins for high mach flight. The missile cabin body is a thin-wall structural member, so that a great problem exists in the casting forming process of the missile cabin body, and at present, the technology for casting the thin-wall cabin section by aluminum-copper aluminum alloy is not mastered at home, and the following aspects are mainly presented:
1) The aluminum-copper alloy has poor fluidity and filling capability, and the casting forming integrity with the wall thickness of 3-5 mm is difficult to ensure by adopting common gravity casting low-pressure casting and other technological methods.
2) The solid-liquid phase solidification temperature range of the aluminum-copper aluminum alloy is wide, the casting performance is poor, the casting is easy to generate defects such as inter-crystal loosening and the like, and the deviation of the mechanical property of the casting is large.
3) The aluminum-copper aluminum alloy has serious hot cracking tendency, and the thin-wall structural member has common crack defects.
Disclosure of Invention
Aiming at the defects existing in the prior art, the invention provides a thin-wall cabin integral forming die and a forming method thereof.
In order to achieve the above purpose, the integral forming die for the thin-wall cabin body comprises a cylindrical casting main body, a cover plate at the top and a box body at the bottom, wherein the casting main body comprises a casting outer die and a casting inner die with a hollow inside, a ring-shaped vertical cylinder is arranged on the inner wall of the casting outer die, and a core pipe is arranged on the central axis of the inside of the casting inner die.
Further, the box includes the bottom plate and the base case of lower part on upper portion, the bottom plate middle part is provided with the positioning seat of undercut, in the apron was inserted on core pipe upper portion, its core pipe lower part was provided with core pipe locating head, core pipe locating head is the toper structure, and it inserts positioning seat internal fixation, still offered the ingate that links to each other with the upright section of thick bamboo on the bottom plate.
Still further, the bottom box comprises an inner core seat sand core and a cross runner sand core arranged outside the core seat sand core, the core seat sand core is in a round table shape, the thickness of the inner wall of the cross runner sand core is gradually increased, the cross runner sand core is communicated with the central opening of the bottom surface of the bottom box to form an integral channel, the core seat sand core and the cross runner sand core are matched to form a connecting channel, the upper part of the connecting channel is communicated with an inner runner, and the lower part of the connecting channel is communicated with the integral channel; and a plurality of hanging rings are arranged on the surface of the cover plate.
The invention also provides a device for integrally forming the thin-wall cabin body, which comprises a lower sealing tank and an upper sealing tank which are matched with each other, wherein a pouring platform for installing a die is arranged at the top of the lower sealing tank, a holding furnace is arranged in the lower sealing tank, a crucible is arranged in the holding furnace, a riser tube is inserted into the center of the crucible, the top end of the riser tube is inserted into the center of the pouring platform and is communicated with the die, the die comprises a cylindrical casting main body, a cover plate at the top and a box body at the bottom, the casting main body comprises a casting outer die and a casting inner die with hollow inside, a ring-shaped vertical cylinder is arranged in the casting inner die, a core pipe is arranged on the central axis in the casting inner die, a vent pipe is arranged on the pouring platform, and an upper vent pipe and a lower vent pipe are arranged on the vent pipe in parallel.
Further, the box includes the bottom plate and the base case of lower part on upper portion, the bottom plate middle part is provided with the positioning seat of undercut, in the apron was inserted on core pipe upper portion, its core pipe lower part was provided with core pipe locating head, core pipe locating head is the toper structure, and it inserts the positioning seat internal fixation, still set up the ingate that links to each other with the upright section of thick bamboo on the bottom plate, be provided with a plurality of rings on the apron surface.
Still further, including inside headstock psammitolite and the cross gate psammitolite of setting outside the headstock psammitolite in the base case, the headstock psammitolite is the round platform form, the thickness of cross gate psammitolite inner wall increases gradually, just cross gate psammitolite and base case bottom surface central opening intercommunication form whole passageway, the cooperation forms the connecting channel between headstock psammitolite and the cross gate psammitolite, connecting channel upper portion is linked together with the ingate, connecting channel lower part is linked together with whole passageway, whole passageway and riser tube intercommunication.
Still further, there are intercommunication valves on the breather pipe between said upper breather pipe and lower breather pipe, still there are upper vacuum pipeline valves and upper seal pot communicating valves on the upper breather pipe, still there are lower high-pressure pipeline valves and lower seal pot communicating valves on the lower breather pipe, still there are branch pipes between lower breather pipe and the upper breather pipe, one end of the said branch pipe is between upper vacuum pipeline valve and upper seal pot communicating valve, its another end is between lower high-pressure pipeline valve and lower seal pot communicating valve; the periphery of the joint of the lower sealing tank and the upper sealing tank is fixed through a locking ring, and a pressing iron is arranged on the casting mold cover plate.
The invention also provides a method for integrally forming the thin-wall cabin body by using the device, which comprises the following steps:
1) Preparing alloy material for casting cabin
Pure aluminum and an alloy are prepared according to the weight percentage of the chemical components of the cabin alloy, and the weight percentage of the chemical components of the alloy is as follows: cu:4.6 to 5.0 percent of Mn:0.8 to 1.0 percent of Ti:0.3 to 0.4 percent of Cd:0.15 to 0.25 percent of Zr:0.1 to 0.2 percent, V:0.1 to 0.2 percent, B:0.05 to 0.1 percent of Re:0.1 to 0.2 percent, the balance of Al and unavoidable impurities,
2) Alloy material for smelting cabin
Smelting the pure aluminum and the alloy in a crucible, firstly adding the pure aluminum into the crucible of a lower sealed tank, melting at the smelting temperature of 750-760 ℃, adding and stirring the alloy after about 90% of the melting, adding a covering agent, cooling to 720-730 ℃ after the alloy is completely melted, introducing pure argon or nitrogen for refining and degassing, refining for 10-15 min, and removing scum on the upper surface of the crucible to obtain pure aluminum liquid;
3) Mold assembly
4) Vacuum air-conditioning pressure casting
Placing the assembled mould into a trolley furnace, preheating and preserving heat for 1-2 h at the temperature of 50-120 ℃; placing the preheated die on a vacuum pressure-regulating casting pouring platform, aligning the channel port of the whole channel at the bottom of the die with the pipe orifice of a riser pipe, sealing an upper sealing tank and a lower sealing tank, compacting and locking, and pouring, wherein the concrete operation is as follows:
a. firstly, closing the lower high-pressure pipeline valve, simultaneously opening the lower sealing tank communication valve, the upper sealing tank communication valve, the intercommunication valve and the upper vacuum pipeline valve, starting the vacuum pump, synchronously vacuumizing the upper sealing tank and the lower sealing tank,
b. when the vacuum degree reaches-50 KPa, the lower sealing tank communicating valve and the communicating valve are closed, the upper tank is continuously vacuumized, at the moment, the aluminum water in the crucible in the heat preservation furnace enters the die cavity in the upper tank from the liquid lifting pipe,
c. when the vacuum degree reaches-70 KPa, closing the upper vacuum pipeline valve, and closing the vacuum pump; opening the lower high-pressure pipeline valve, the lower sealing tank communicating valve, the upper vacuum pipeline valve and the communicating valve, introducing high-pressure air into the lower vent pipe, synchronously pressurizing the upper sealing tank and the lower sealing tank,
d. when in pressurization, the pressure of the lower tank is kept to be larger than the pressure of the upper tank, the pressure difference between the upper tank and the lower tank is controlled to be not smaller than 25KPa, and the filling speed is about 1-1.5 KPa/s; due to the pressure difference, aluminum water in the crucible rises into the cavity of the mould along the liquid lifting pipe to finish the forming of the casting; simultaneously, solidifying and crusting is carried out for a short time under the pressure, and the crusting time is 3-5 s; then, quick pressurization is carried out, so that the density of the casting is improved; keeping the highest pressure unchanged, and keeping the pressure for 5-10 min;
e. finally, opening an intercommunication valve, and enabling the non-solidified aluminum water in the pouring system at the bottom of the die to flow back to the crucible along the liquid lifting pipe so as to finish casting pouring;
5) Casting cleaning
After the mould is unpacked, removing a pouring system, a riser and flash burrs on the surface of the casting, and then carrying out sand blasting on the whole casting to obtain a casting blank;
6) Heat treatment of cast blanks
Heating the casting blank to 540+/-5 ℃, carrying out solid solution heat preservation for 10-18 h at the temperature of 540+/-5 ℃, naturally cooling the casting blank to 155+/-5 ℃, and carrying out aging heat preservation for 4-8 h at the temperature of 155+/-5 ℃;
7) Vibration aging
Carrying out vibration aging treatment on the heat-treated casting blank; before the heat-treated casting blank is transferred to mechanical processing, vibration aging treatment is carried out, so that the internal stress of the casting is further released, and the casting is prevented from deforming.
8) Machining process
And (3) after vibration aging treatment, machining, namely machining the parts such as the upper end frame, the lower end frame, the steps, the mounting holes and the like, ensuring the dimensional accuracy, and finishing the qualified part, namely the aluminum alloy thin-wall cabin.
Preferably, in the step 3), the specific method for assembling the mold comprises:
a. firstly, assembling a box body: putting the core seat sand core, the cross runner sand core of the outer wall and the connecting channel into a bottom box, and covering a bottom plate to complete the assembly of the box body;
b. then putting the casting mould main body into a box body, inserting a core tube positioning head at the lower part of a core tube on the central axis of the inside of the casting mould into a positioning seat for positioning, and putting the core tube into the casting mould in advance so as to facilitate positioning, exhausting and hoisting of the main body sand core; and finally, covering the cover plate to complete the assembly of the die.
Preferably, in the step d) of the step 4), the supercharging pressure is 30-50 KPa, and the supercharging speed is 10-15 KPa/s.
The working principle of the forming device and the forming method is as follows:
1) The device is control equipment for regulating and controlling the gas pressure, the lower pressure chamber and the upper pressure chamber are mutually isolated, and the isolation of the two pressure chambers and the external gas pressure is realized. Wherein a crucible is arranged in the pressing chamber to contain molten metal, and a holding furnace is adopted to control the temperature of the molten metal under the control of a temperature control system.
The casting mould is installed in the upper pressure chamber, one end of the cavity is opened and communicated with the liquid lifting pipe, the molten metal liquid level is inserted, the two pressure chambers are simultaneously connected with the positive pressure control system and the negative pressure control system respectively through pipelines, and gas is led into or led out of each pressure chamber, so that the accurate control of the air pressure in the pressure chambers from negative pressure to positive pressure is realized.
2) The process principle of the pressure regulating casting technology is described as follows:
firstly, synchronously vacuumizing an upper pressing chamber and a lower pressing chamber to keep negative pressure on a cavity and molten metal; when the mold is filled, the gas communication valve between the upper pressing chamber and the lower pressing chamber is closed, the upper pressing chamber of the mold cavity is continuously vacuumized, a pressure difference with a large lower part is formed between the upper pressing chamber and the lower pressing chamber, molten metal in the crucible is pressed into the mold cavity in vacuum along the liquid lifting pipe, the two pressing chambers are pressurized at the same time after the mold filling is finished, the pressure difference between the upper pressing chamber and the lower pressing chamber is always kept constant, the positive pressure is kept for a period of time, the molten metal is solidified and formed under the pressure, the pressure can be removed after the molten metal in the mold cavity is completely solidified, and the unset molten metal in the liquid lifting pipe flows back into the crucible.
Compared to other types of countergravity casting, the regulated casting technique has 3 important features:
1. vacuum degassing
Before filling, the molten metal is firstly placed in a pressing chamber, the temperature of the molten metal is kept, the two pressing chambers are synchronously pumped during the period, negative pressure is kept for a period of time after the set vacuum degree is reached, in the process of keeping the negative pressure, gas dissolved in the molten metal in the smelting process is easy to separate out, and oxidation film is not easy to be formed on the liquid surface under the negative pressure condition, so that the purification and purification of the molten metal are facilitated.
2. Negative pressure filling type
After the synchronous negative pressure is maintained for a period of time (3-5 min), the upper pressure chamber is continuously vacuumized, so that a pressure difference is formed between the upper pressure chamber and the lower pressure chamber, and the molten metal is pressed into the casting mold cavity in the upper pressure chamber along the liquid lifting pipe. The casting mold has extremely low air displacement in the filling process of the molten metal, the requirement on air permeability of the casting mold is reduced, under the favorable condition provided by negative pressure filling, the filling mold can be more stably filled than other antigravity casting methods by optimizing a pressure control curve, and a stable filling mode provided by negative pressure filling can form a temperature field favorable for sequential solidification in a cavity. For example, if the metal liquid level can be pushed from bottom to top smoothly, the metal liquid is cooled continuously in the flowing process, and simultaneously, heat is released on the flowing path of the metal liquid, so that macroscopic temperature distribution with gradually reduced temperature from bottom to top is formed, and the chill is reasonably used at the local hot junction in a matching manner, so that the most favorable solidification mode of the casting can be realized, namely, the upper end of the casting is solidified first, and the solidification interface is pushed downwards gradually, and finally, the bottom of the cavity and the neck of the liquid lifting tube are reached. During this solidification process, the molten metal at the lower end of the lift tube can provide an effective feed for solidification shrinkage.
3. Positive pressure coagulation
The anti-gravity direction filling under the negative pressure condition is beneficial to realizing sequential solidification of castings from top to bottom, and the pressure difference between the upper pressing chamber and the lower pressing chamber is still ensured after the filling is finished, so that not only can the backflow of molten metal be effectively avoided, but also the driving force can be provided for the completion of feeding action of the molten metal, and when the solid-phase framework formed in the solidification process cannot bear the externally applied pressure, shrinkage porosity or shrinkage cavity formed in the solid-phase framework can be compacted and disappear, thereby remarkably improving the compactness of the castings and ensuring the improvement of the metallurgical quality and the mechanical property of the castings.
The invention has the beneficial effects that:
1) The thin-wall high-strength aluminum alloy cabin casting prepared by the method has the advantages that various performance indexes of the product are ensured, meanwhile, the compactness, the dimensional accuracy and the surface smoothness of the casting are high, and the overall performance of the cabin casting is improved.
2) The invention adopts the integral casting forming method, can be used for manufacturing the thin-wall cabin body with complex and ideal shape, can adjust the wall thickness change in a certain range, obtains ideal stress distribution, and improves the reliability and the safety of the thin-wall cabin body.
3) The invention improves the casting performance of the aluminum alloy material by adjusting the composition components of the cast aluminum alloy, effectively avoids the defects of hot cracking, shrinkage porosity and the like of the cabin casting, and is more suitable for integral casting forming of the thin-wall cabin.
4) The vacuum pressure-regulating casting forming method is good in applicability to the thin-wall cabin casting, not only can improve the fluidity and the mold filling capability of the aluminum liquid, but also can eliminate concentrated shrinkage porosity, so that the crystal grains of the casting are thinned, the density is improved, the structure and the performance are obviously improved, and the mechanical property of the casting is improved.
In conclusion, the integral forming method of the thin-wall aluminum alloy cabin casting not only can be used for manufacturing the thin-wall high-strength aluminum alloy missile cabin, but also can be used for integral forming of other complex thin-wall aluminum alloy castings, and has good application and development prospects.
Drawings
FIG. 1 is a schematic diagram of the integral forming die of the thin-wall cabin of the invention;
FIG. 2 is a schematic structural view of the integral forming device of the thin-walled cabin body of the invention;
FIG. 3 is a schematic view of the structure of a casting for preparing a cabin in example 3;
FIG. 4 is an expanded view of the interior of a casting for preparing a capsule of example 3;
in the figure, a casting main body 1, a casting outer mold 1.1, a casting inner core 1.2, a vertical cylinder 1.3, a core pipe 1.4, a core pipe positioning head 1.41, a cover plate 2, a cover plate lifting ring 2.1, a box body 3, a bottom plate 3.1, a positioning seat 3.11, an inner pouring channel 3.12, a bottom box 3.2, a core seat sand core 3.3, a cross pouring sand core 3.4, a connecting channel 3.5, an integral channel 3.6, a lower sealing tank 4, an upper sealing tank 5, a pouring platform 6, a heat preservation furnace 7, a crucible 7.1, a riser pipe 8, a vent pipe 9, an intercommunication valve 9.1, an upper vent pipe 10, an upper vacuum pipeline valve 10.1, an upper sealing tank communication valve 10.2, a lower vent pipe 11, a lower high-pressure pipeline valve 11.1, a lower sealing tank communication valve 11.2, a branch pipe 12, a pressure iron 13 and a locking ring 14.
Detailed Description
For a better explanation of the present invention, the main content of the present invention is further elucidated below in conjunction with the specific examples, but the content of the present invention is not limited to the following examples only.
Example 1
The integral forming die for the thin-wall cabin body shown in fig. 1 comprises a cylindrical casting main body 1, a cover plate 2 and a bottom box body 3, wherein the casting main body 1 comprises a casting outer die 1.1 and a casting inner die 1.2 with a hollow inside, a ring-shaped vertical cylinder 1.3 is arranged on the inner wall of the casting outer die 1.1, and a core tube 1.4 is arranged on the central axis inside the casting inner die 1.2. 2 hanging rings 2.1 are arranged on the surface of the cover plate 2.
The box 3 includes the bottom plate 3.1 on upper portion and the base case 3.2 of lower part, and bottom plate 3.1 middle part is provided with undercut positioning seat 3.11, and in the apron 2 was inserted on core tube 1.4 upper portion, its core tube 1.4 lower part was provided with core tube positioning head 1.41, and core tube positioning head 1.41 is the toper structure, and it inserts positioning seat 3.11 internal fixation, still offered on the bottom plate 3.1 and found the runner 3.12 that links to each other of section of thick bamboo 1.3. The bottom box 3.2 comprises an inner core seat sand core 3.3 and a cross runner sand core 3.4 arranged outside the core seat sand core 3.3, the core seat sand core 3.3 is in a round table shape, the thickness of the inner wall of the cross runner sand core 3.4 is gradually increased, the cross runner sand core 3.4 is communicated with the central opening of the bottom surface of the bottom box 3.2 to form an integral channel 3.6, the core seat sand core 3.3 and the cross runner sand core 3.4 are matched to form a connecting channel 3.5, the upper part of the connecting channel 3.5 is communicated with the inner runner 3.12, and the lower part of the connecting channel 3.5 is communicated with the integral channel 3.6;
example 2
The device for integrally forming the thin-wall cabin body as shown in figures 1-2 comprises a lower sealing tank 4 and an upper sealing tank 5 which are matched with each other, a pouring platform 6 for installing a die is arranged at the top of the lower sealing tank 4, a heat preservation furnace 7 is arranged in the lower sealing tank 4, a crucible 7.1 is arranged in the heat preservation furnace 7, a liquid lifting pipe 8 is inserted in the center of the crucible 7.1, the top end of the liquid lifting pipe 8 is inserted in the center of the pouring platform 6 and communicated with the die,
the mould includes cylindrical mould main part 1, apron 2 and the box 3 of bottom at top, and mould main part 1 includes mould external mold 1.1 and inside hollow mould centre form 1.2, is provided with annular upright section of thick bamboo 1.3 on the inside of mould centre form 1.2, is provided with core pipe 1.4 on the inside axis of mould centre form 1.2, is provided with 2 rings 2.1 on the apron 2 surface.
The box 3 includes the bottom plate 3.1 on upper portion and the base case 3.2 of lower part, and bottom plate 3.1 middle part is provided with undercut positioning seat 3.11, and in the apron 2 was inserted on core tube 1.4 upper portion, its core tube 1.4 lower part was provided with core tube positioning head 1.41, and core tube positioning head 1.41 is the toper structure, and it inserts positioning seat 3.11 internal fixation, still offered on the bottom plate 3.1 and found the runner 3.12 that links to each other of section of thick bamboo 1.3.
The bottom box 3.2 comprises an inner core seat sand core 3.3 and a cross runner sand core 3.4 arranged outside the core seat sand core 3.3, the core seat sand core 3.3 is in a round table shape, the thickness of the inner wall of the cross runner sand core 3.4 is gradually increased, the cross runner sand core 3.4 is communicated with the central opening of the bottom surface of the bottom box 3.2 to form an integral channel 3.6, the core seat sand core 3.3 and the cross runner sand core 3.4 are matched to form a connecting channel 3.5, the upper part of the connecting channel 3.5 is communicated with the inner runner 3.12, the lower part of the connecting channel 3.5 is communicated with the integral channel 3.6, and the integral channel 3.6 is communicated with a liquid lifting pipe 8;
the pouring platform is provided with a vent pipe 9, and an upper vent pipe 10 and a lower vent pipe 11 are arranged on the vent pipe 9 in parallel.
An intercommunicating valve 9.1 is arranged on the vent pipe 9 between the upper vent pipe 10 and the lower vent pipe 11, an upper vacuum pipeline valve 10.1 and an upper sealing tank communicating valve 10.2 are also arranged on the upper vent pipe 10, a lower high-pressure pipeline valve 11.1 and a lower sealing tank communicating valve 11.2 are also arranged on the lower vent pipe 11, a branch pipe 12 is also arranged between the upper vent pipe 10 and the lower vent pipe 11, one end of the branch pipe 12 is arranged between the upper vacuum pipeline valve 10.1 and the upper sealing tank communicating valve 10.2, and the other end is arranged between the lower high-pressure pipeline valve 11.1 and the lower sealing tank communicating valve 11.2; the periphery of the joint of the lower sealing tank 4 and the upper sealing tank 5 is fixed by a locking ring 14, and a pressing iron 13 is arranged on the casting cover plate 2.
Example 3
FIGS. 3-4 show a capsule casting, which is a cylindrical thin-wall casting; cabin size: the outline diameter phi is 1200mm, and the height is 1000mm; the inner surface of the casting is not processed, 16 vertical reinforcing ribs, 4 annular reinforcing ribs, 16 connecting bosses, 8 mounting brackets and the wall thickness of the casting is 3.5mm plus or minus 0.5mm.
The method for manufacturing the aluminum alloy casting of the instrument cabin body by using the device for integrally forming the thin-wall cabin body in the embodiment 2 comprises the following steps:
1) Preparing alloy material for casting cabin
Pure aluminum and an alloy are prepared according to the weight percentage of the chemical components of the cabin alloy, and the weight percentage of the chemical components of the alloy is as follows: cu:4.6 to 5.0 percent of Mn:0.8 to 1.0 percent of Ti:0.3 to 0.4 percent of Cd:0.15 to 0.25 percent of Zr:0.1 to 0.2 percent, V:0.1 to 0.2 percent, B:0.05 to 0.1 percent of Re:0.1 to 0.2 percent, the balance of Al and unavoidable impurities,
wherein the total amount of the materials is 100kg, the aluminum ingot adopts pure aluminum with purity not lower than 99.95%, and Cu, mn, ti, cd, V, zr, B and Re elements are added in the form of alloy (mass percent) AlCu50A, alMn10, alTi4B, alCd10, alZr4 and AlRe9 respectively;
2) Alloy material for smelting cabin
Smelting the pure aluminum and the alloy in a crucible 7.1, firstly adding the pure aluminum into the crucible 7.1 of a lower sealed tank, melting at 750-760 ℃, adding and stirring the alloy after about 90% of the melting, adding a covering agent (45% KCl+55% NaCl) into the alloy, cooling to 720-730 ℃ after the alloy is completely melted, introducing pure argon or nitrogen for refining and degassing, and removing scum on the upper surface of the crucible for 10-15 min to obtain pure aluminum liquid; and (3) after the aluminum liquid is treated, carrying out modification, refinement and refining effect analysis on the aluminum liquid by using a thermal analyzer. The chemical components detected by a spectrometer are shown in table 1, and the chemical components of the alloy meet the chemical component requirements of the cabin alloy.
Table 1 alloy compositions of instrument pod body
3) Mold assembly
a. First, the box 3 is assembled: putting the core seat sand core 3.3, the cross runner sand core 3.4 of the outer wall and the connecting channel 3.5 into a bottom box 3.2, and covering a bottom plate 3.1 to complete the assembly of the box body 3;
b. then the casting mould main body 1 is put into the box body 3, and the core pipe 1.4 is put into the casting mould 1.2 in advance through the insertion of the core pipe positioning head 1.41 at the lower part of the core pipe 1.4 on the central axis of the casting mould 1.2 into the positioning seat 3.11 for positioning, the air exhaust and the hoisting of the main sand core; finally, covering the cover plate 2 to complete the assembly of the die;
4) Vacuum air-conditioning pressure casting
Placing the assembled mould into a trolley furnace, preheating and preserving heat for 1-2 h at the temperature of 50-120 ℃; the preheated mould is placed on a vacuum pressure-regulating casting pouring platform 6, the channel opening of the integral channel 3.6 at the bottom of the mould is aligned with the pipe opening of a riser pipe 8, the upper sealing tank 4 and the lower sealing tank 5 are sealed, compacted and locked, and the concrete operation is as follows:
a. firstly, the lower high-pressure pipeline valve 11.1 is closed, simultaneously the lower sealing tank communication valve 11.2, the upper sealing tank communication valve 10.2, the intercommunication valve 9.1 and the upper vacuum pipeline valve 10.1 are opened, the vacuum pump is started, the upper sealing tank and the lower sealing tank are synchronously vacuumized,
b. when the vacuum degree reaches-50 KPa, the lower sealing tank communicating valve 11.2 and the communicating valve 9.1 are closed, the upper tank is continuously vacuumized, at the moment, aluminum water in the crucible 7.1 in the holding furnace 7 enters the die cavity in the upper tank from the riser tube 8,
c. when the vacuum degree reaches-70 KPa, closing the upper vacuum pipeline valve 10.1, and closing the vacuum pump; the lower high-pressure pipeline valve 11.1, the lower sealing tank communicating valve 11.2, the upper vacuum pipeline valve 10.2 and the communicating valve 9.1 are opened, the lower ventilating pipe 11 is filled with high-pressure air, the upper sealing tank and the lower sealing tank are synchronously pressurized,
d. when in pressurization, the pressure of the lower tank is kept to be larger than the pressure of the upper tank, the pressure difference between the upper tank and the lower tank is controlled to be not smaller than 25KPa, and the filling speed is about 1-1.5 KPa/s; due to the pressure difference, the molten aluminum in the crucible 7.1 rises into the cavity of the die along the liquid lifting pipe 8 to finish the forming of the casting; simultaneously, solidifying and crusting is carried out for a short time under the pressure, and the crusting time is 3-5 s; then, quick supercharging is carried out, the supercharging pressure is 30-50 KPa, and the supercharging speed is 10-15 KPa/s; the compactness of the casting is improved; keeping the highest pressure unchanged, and keeping the pressure for 5-10 min;
e. finally, opening an intercommunication valve 9.1, and enabling the unset aluminum water in the pouring system at the bottom of the die to flow back to the crucible 7.1 along the liquid lifting pipe 8 so as to finish casting pouring;
5) Casting cleaning
After the mould is unpacked, removing a pouring system, a riser and flash burrs on the surface of the casting, and then carrying out sand blasting on the whole casting to obtain a casting blank;
6) Heat treatment of cast blanks
Heating the casting blank to 540+/-5 ℃, carrying out solid solution heat preservation for 18 hours at the temperature of 540+/-5 ℃, naturally cooling the casting blank to 155+/-5 ℃, and carrying out aging heat preservation for 8 hours at the temperature of 155+/-5 ℃;
after heat treatment, 6 body samples are cut for mechanical property detection, the tensile strength of the samples reaches 436-466 MPa, and the elongation reaches 9.4-11.4%, and the details are shown in Table 2.
TABLE 2 mechanical Properties of the body
7) Vibration aging
Carrying out vibration aging treatment on the heat-treated casting blank for 60 min;
8) Machining process
And (3) after vibration aging treatment, machining, namely machining the parts such as the upper end frame, the lower end frame, the steps, the mounting holes and the like, ensuring the dimensional accuracy, and finishing the qualified part, namely the aluminum alloy thin-wall cabin.
Other parts not described in detail are prior art. Although the foregoing embodiments have been described in some, but not all, embodiments of the invention, it should be understood that other embodiments may be devised in accordance with the present embodiments without departing from the spirit and scope of the invention.
Claims (6)
1. The device comprises a lower sealing tank (4) and an upper sealing tank (5) which are matched with each other, a pouring platform (6) for installing a mould is arranged at the top of the lower sealing tank (4), a heat preservation furnace (7) is arranged in the lower sealing tank (4), a crucible (7.1) is arranged in the heat preservation furnace (7), a riser tube (8) is inserted into the center of the crucible (7.1), the top end of the riser tube (8) is inserted into the center of the pouring platform (6) and communicated with the mould, the mould comprises a cylindrical mould main body (1), a cover plate (2) at the top and a box body (3) at the bottom, the mould main body (1) comprises a mould outer mould (1.1) and a mould inner mould (1.2) with hollow inside, a ring-shaped vertical cylinder (1.3) is arranged in the mould outer mould (1.1), a core tube (1.4) is arranged on the central axis in the mould inner mould (1.2), a vent pipe (9) is arranged in parallel with the vent pipe (9), and the vent pipe (11) is arranged on the upper vent pipe (10); the method is characterized in that: the method comprises the following steps:
1) Preparing alloy material for casting cabin
Pure aluminum and an alloy are prepared according to the weight percentage of the chemical components of the cabin alloy, and the weight percentage of the chemical components of the alloy is as follows: cu:4.6 to 5.0 percent of Mn:0.8 to 1.0 percent of Ti:0.3 to 0.4 percent of Cd:0.15 to 0.25 percent of Zr:0.1 to 0.2 percent, V:0.1 to 0.2 percent, B:0.05 to 0.1 percent of Re:0.1 to 0.2 percent, the balance of Al and unavoidable impurities,
2) Alloy material for smelting cabin
Smelting the pure aluminum and the alloy in a crucible (7.1), firstly adding the pure aluminum into the crucible (7.1) of a lower sealed tank, melting at the smelting temperature of 750-760 ℃, adding and stirring the alloy after about 90% of the melting, adding a covering agent, cooling to 720-730 ℃ after the alloy is completely melted, introducing pure argon or nitrogen for refining and degassing for 10-15 min, and removing scum on the upper surface of the crucible to obtain pure aluminum liquid;
3) Mold assembly
4) Vacuum air-conditioning pressure casting
Placing the assembled mould into a trolley furnace, preheating and preserving heat for 1-2 h at the temperature of 50-120 ℃; placing the preheated die on a pouring platform (6) for vacuum pressure-regulating casting, aligning the channel opening of an integral channel (3.6) at the bottom of the die with the pipe opening of a lift pipe (8), sealing an upper sealing tank (5) and a lower sealing tank (4), compacting and locking, and pouring, wherein the concrete operation is as follows:
a. firstly, the lower high-pressure pipeline valve (11.1) is closed, simultaneously the lower sealing tank communication valve (11.2), the upper sealing tank communication valve (10.2), the intercommunication valve (9.1) and the upper vacuum pipeline valve (10.1) are opened, the vacuum pump is started, the upper sealing tank and the lower sealing tank are synchronously vacuumized,
b. when the vacuum degree reaches-50 KPa, the lower sealing tank communicating valve (11.2) and the communicating valve (9.1) are closed, the upper tank is continuously vacuumized, at the moment, aluminum water in a crucible (7.1) in the holding furnace (7) enters a die cavity in the upper tank from the riser tube (8),
c. when the vacuum degree reaches-70 KPa, closing the upper vacuum pipeline valve (10.1), and closing the vacuum pump and the communicating valve (9.1); a lower high-pressure pipeline valve (11.1), a lower sealing tank communicating valve (11.2) and an upper sealing tank communicating valve (10.2) are opened, high-pressure air is introduced into a lower vent pipe (11), the upper sealing tank and the lower sealing tank are synchronously pressurized,
d. when in pressurization, the pressure of the lower tank is kept to be larger than the pressure of the upper tank, and the pressure difference between the upper tank and the lower tank is controlled to be not smaller than 25KPa, and the filling speed is 1-1.5 KPa/s; the aluminum water in the crucible (7.1) rises into the cavity of the mould along the liquid lifting pipe (8) to finish the forming of the casting; simultaneously, solidifying and crusting is carried out for a short time under the pressure, and the crusting time is 3-5 s; followed by rapid pressurization; keeping the highest pressure unchanged, and keeping the pressure for 5-10 min;
e. finally, an intercommunicating valve (9.1) is opened, and the unset aluminum water in the pouring system at the bottom of the mould flows back to the crucible (7.1) along a liquid lifting pipe (8) to finish casting pouring;
5) Casting cleaning
After the mould is unpacked, removing a pouring system, a riser and flash burrs on the surface of the casting, and then carrying out sand blasting on the whole casting to obtain a casting blank;
6) Heat treatment of cast blanks
Heating the casting blank to 540+/-5 ℃, carrying out solid solution heat preservation for 10-18 h at the temperature of 540+/-5 ℃, naturally cooling the casting blank to 155+/-5 ℃, and carrying out aging heat preservation for 4-8 h at the temperature of 155+/-5 ℃;
7) Vibration aging
Carrying out vibration aging treatment on the heat-treated casting blank;
8) Machining process
And (3) after vibration aging treatment, machining, namely machining upper and lower end frames, steps and mounting hole parts, and ensuring the dimensional accuracy, namely finishing qualified parts, namely the aluminum alloy thin-wall cabin body.
2. The thin-walled capsule of claim 1, wherein: in the step (3), the specific method for assembling the die comprises the following steps:
a. firstly, assembling a box body (3): putting the core seat sand core (3.3), the cross runner sand core (3.4) of the outer wall and the connecting channel (3.5) into a bottom box (3.2), and covering a bottom plate (3.1) to complete the assembly of the box body (3);
b. then the casting mould main body (1) is put into a box body (3), a core pipe (1.4) is put into the casting mould (1.2) in advance through inserting a core pipe positioning head (1.41) at the lower part of a core pipe positioning head (1.4) on the central axis of the inside of the casting mould (1.2) into a positioning seat (3.11) for positioning, exhausting and hoisting the main sand core; and finally, covering the cover plate (2) to complete the assembly of the die.
3. The thin-walled capsule of claim 1, wherein: in the step d) of the step 4), the supercharging pressure is 30-50 KPa, and the supercharging speed is 10-15 KPa/s.
4. The thin-walled capsule of claim 1, wherein: the box (3) comprises a bottom plate (3.1) on the upper portion and a bottom box (3.2) on the lower portion, a positioning seat (3.11) recessed downwards is arranged in the middle of the bottom plate (3.1), a core pipe (1.4) is inserted into a cover plate (2), a core pipe positioning head (1.41) is arranged on the lower portion of the core pipe (1.4), the core pipe positioning head (1.41) is of a conical structure and is inserted into the positioning seat (3.11) for internal fixation, an inner runner (3.12) connected with a vertical cylinder (1.3) is further arranged on the bottom plate (3.1), and a plurality of hanging rings (2.1) are arranged on the surface of the cover plate (2).
5. The thin-walled capsule of claim 4, wherein: the utility model discloses a liquid lift pipe, including base case (3.2) in including inside core headstock psammitolite (3.3) and setting up at outside runner psammitolite (3.4) of core headstock psammitolite (3.3), core headstock psammitolite (3.3) are round platform form, the thickness of runner psammitolite (3.4) inner wall increases gradually, just runner psammitolite (3.4) and base case (3.2) bottom surface central opening intercommunication forms whole passageway (3.6), cooperation forms connecting channel (3.5) between core headstock psammitolite (3.3) and runner psammitolite (3.4), connecting channel (3.5) upper portion is linked together with ingate (3.12), connecting channel (3.5) lower part is linked together with whole passageway (3.6), whole passageway (3.6) are linked together with lift pipe (8).
6. The thin-walled capsule of claim 1, wherein: an intercommunication valve (9.1) is arranged on the vent pipe (9) between the upper vent pipe (10) and the lower vent pipe (11), an upper vacuum pipeline valve (10.1) and an upper sealing tank communication valve (10.2) are further arranged on the upper vent pipe (10), a lower high-pressure pipeline valve (11.1) and a lower sealing tank communication valve (11.2) are further arranged on the lower vent pipe (11), a branch pipe (12) is further arranged between the upper vent pipe (10) and the lower vent pipe (11), one end of the branch pipe (12) is arranged between the upper vacuum pipeline valve (10.1) and the upper sealing tank communication valve (10.2), and the other end of the branch pipe is arranged between the lower high-pressure pipeline valve (11.1) and the lower sealing tank communication valve (11.2); the periphery of the joint of the lower sealing tank (4) and the upper sealing tank (5) is fixed through a locking ring (14), and a pressing iron (13) is arranged on the casting cover plate (2).
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