CN109175306B - Casting mold and casting process of gearbox body - Google Patents
Casting mold and casting process of gearbox body Download PDFInfo
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- CN109175306B CN109175306B CN201811217857.3A CN201811217857A CN109175306B CN 109175306 B CN109175306 B CN 109175306B CN 201811217857 A CN201811217857 A CN 201811217857A CN 109175306 B CN109175306 B CN 109175306B
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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
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- 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
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
Abstract
The invention discloses a casting mold and a casting process of a gearbox body, relates to the technical field of aluminum alloy casting, and aims to solve the problem that transition parts are easy to shrink and even shrink due to large wall thickness difference in the existing gearbox body casting process. The casting mould comprises an upper mould, a lower mould and a casting cavity formed by matching the upper mould and the lower mould, wherein a static insert matched with the appearance of the gearbox body is arranged on the inner side of the upper mould, and a pouring gate water inlet is formed in the lower mould; the low-pressure casting process is adopted, and the process steps comprise: batching, alloy smelting, transferring alloy solution into a low-pressure casting machine, preparing a die, die casting, opening the die and taking a workpiece and the like. By implementing the technical scheme, the fluidity of the aluminum alloy solution in the casting cavity can be fully improved, the problems of easy shrinkage porosity and shrinkage crack at the transition position due to large wall thickness difference of the gearbox body are avoided, the product percent of pass reaches more than 95.9 percent, the processing precision of casting products can be obviously improved, and the subsequent rough processing cost of the castings is reduced.
Description
Technical Field
The invention relates to the technical field of gearbox casting, in particular to a casting mold and a casting process for a gearbox body.
Background
The gearbox body is one of basic parts of a traveling vehicle, the gearbox body connects parts such as a shaft, a gear and the like in the gearbox into a whole, the supporting and connecting functions are realized in the whole transmission assembly, the parts and mechanisms are enabled to keep correct relative positions, so that various mechanisms and parts on the parts can work correctly and coordinately, the strength and the rigidity are sufficient, and the quality of the gearbox body directly influences the accuracy of the positions of the parts such as the shaft, the gear and the like, and further influences the service performance and the service life of the traveling vehicle transmission.
Chinese patent with publication number CN204194723U discloses a box mold of a gearbox shell, which comprises a movable half mold and a stationary half mold, wherein a movable male mold is arranged in the middle of the movable half mold, a core and a core pulling mechanism for a box bearing chamber are arranged on the upper end surface of the movable male mold, a movable insert for an inner cavity of a box body is arranged on the movable male mold, a pouring gate inlet is arranged on the upper end surface of the movable male mold, a mandril is arranged on the movable insert, a stationary insert for the shape of the box body is arranged on the stationary half mold, and a pouring gate opposite to the pouring gate inlet is arranged at the rear position of the. According to the technical scheme, the movable insert, the static insert and the core are adopted, so that the inner cavity and the appearance of the part are molded and cast at one time, the machining parts are reduced, and the production cost is reduced.
In view of the above research, a skilled person in the art finds that the length, width and height of the outline dimension of the mold of the LYP315.2 driving gearbox casing are 740mm, 560mm and 250mm respectively, the length, width and height of the blank are 600mm, 326mm and 120mm respectively, the thinnest part is 7.5mm, and the thickest part reaches 57.5 mm; because the equipment space limits the height of the pouring gate, even if improved methods such as adjusting the sectional area of a feeding system of a metal mold, additionally arranging a blind riser at the wall thickness part, combining with a heat-insulating coating for use in a partition mode and the like are adopted in the gravity casting process, the problems that the transition part is easy to shrink and even cracks due to the fact that the wall thickness of the product is changed rapidly, and further the product is leaked and scrapped cannot be solved.
In view of the above technical problems, it is necessary to improve and design a casting mold and a casting process for a transmission case by those skilled in the art to solve the problem that a transition part is easily shrunk and loosened, even shrunk and cracked due to a rapid change in the wall thickness of the product, thereby preventing the product from being leaked and scrapped.
Disclosure of Invention
The invention aims to solve the problem that a transition part is easy to shrink loose and even shrink crack due to large wall thickness difference in the casting process of the existing gearbox body, and the invention aims to provide a casting mold of the gearbox body, which can effectively solve the problems that the height of a pouring gate is not enough, and the temperature drop of an area in a cavity is large due to insufficient pressure provided by a feeding system, fully improve the fluidity of an aluminum alloy solution, and prevent the problem that products are leaked and scrapped due to easy shrinkage loose and crack at the transition part with rapidly changed wall thickness of the gearbox body.
The invention specifically adopts the following technical scheme for realizing the purpose:
a casting mold of a gearbox box body comprises an upper mold, a lower mold and a casting cavity formed by matching the upper mold and the lower mold, wherein an upper mold connecting plate is mounted at the upper end of the upper mold through a cushion block, an ejection mechanism is arranged between the upper mold connecting plate and the upper mold, a static insert matched with the shape of the gearbox box body is arranged on the inner side of the upper mold, a mold bottom plate is mounted at the bottom of the lower mold, and a pouring gate water inlet communicated with the casting cavity is formed in the mold bottom plate and the lower mold; the ejection mechanism comprises a thimble fixing plate and a plurality of thimbles uniformly arranged at the bottom of the thimble fixing plate, and a plurality of thimble through holes corresponding to the thimbles are arranged in the upper die; the diameters of the thimble through holes are all 11-13 mm;
the gearbox casing casting mould is a low-pressure casting mould modified from a gravity casting mould; reform transform into low pressure casting mould with current gravity casting mould, include the following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low pressure casting mould includes mould, lower mould and by last mould and the foundry goods die cavity that the lower mould cooperation constitutes, go up the mould upper end and install the mould connecting plate through the cushion, go up and be equipped with ejection mechanism between mould connecting plate and the last mould, just the inboard of going up the mould is equipped with the quiet mold insert with gearbox box appearance assorted, the mould bottom plate is installed to the lower mould bottom, the water inlet of watering with the foundry goods die cavity intercommunication is seted up to mould bottom plate and lower mould.
The working principle of the basic scheme of the invention is as follows: use above-mentioned mould casting gearbox box, this driving gearbox's casting width reaches 326mm, and the wall thickness difference is big, through the analysis: the height of the pouring gate is not enough, and the pressure provided by a feeding system is insufficient, so that the mold filling speed is slow, the temperature drop of the area in a casting cavity is large, and the defects of casting air holes, under-casting or unclear outline and the like are easily caused; this technical scheme adopts and to water the water inlet and locate foundry goods die cavity below middle part, and the alloy solution pours the water inlet and pours into the foundry goods die cavity into by watering, and the mode of adopting low pressure casting can effectively improve runner height inadequately, and the pressure that the feeding system provided is not enough and causes the big problem of the regional temperature drop in the die cavity, fully improves the aluminium alloy solution mobility, prevents that gearbox box wall thickness sharply changed's transition department from shrinkage porosity and shrinkage crack easily and leading to the condemned problem of product leakage.
The inner side of the upper die is provided with the static insert matched with the shape of the gearbox body, so that the inner cavity and the shape structure part of the gearbox casting can be effectively formed at one time, rough machining is reduced, the production cost is reduced, and the percent of pass of the gearbox casting is as high as 95.9%; in addition, the static insert structure is manufactured independently and then embedded in the mold, so that the machining precision of the integral mold structure of the gearbox body is high, the machining precision of a casting product can be effectively improved, and the machining quality of the gearbox product is further improved.
And a sleeve column structure is fixedly connected with the upper die connecting plate and the upper die, the thimble fixing plate is sleeved on the sleeve column and can slide up and down along the sleeve column, and the sleeve column can be used for supporting the stability of the connection of the upper die connecting plate and the upper die and can play a role in guiding the movement of the thimble fixing plate and the plurality of thimbles.
Preferably, evenly be equipped with many exhaust passage on the mould, many exhaust passage's diameter is 5 mm. The bottom area of the casting cavity is large, and the plurality of exhaust channels uniformly distributed on the upper die can uniformly exhaust gas in the casting cavity, so that different parts of a formed casting are fully formed, and the defects of casting air holes, under-casting or unclear outline and the like are avoided.
The casting process of the gearbox body comprises the following steps of: si: 6.5-7.5%, Mg: 0.3-0.4%, Ti: 0.1-0.2%, Cu: 2.1-3.5%, Mn: 0.2-0.5%, Fe is less than or equal to 0.75%, Ni is less than or equal to 0.35%, Zn is less than or equal to 0.1%, Pb is less than or equal to 0.2%, Sn is less than or equal to 0.1%, Cr is less than or equal to 0.2%, and the balance is Al and inevitable impurities, wherein the casting process comprises the following process steps:
step (a): batching, wherein corresponding simple substance raw materials and Al are selected for batching according to the components;
step (b): smelting an alloy, namely baking an aluminum melting furnace, putting the metal alloy prepared in the step (a) into the aluminum melting furnace for smelting at 780-790 ℃, and performing refining, deoxidation and slagging-off processes to prepare an alloy solution;
step (c): reform transform the mould, reform transform into low pressure casting mould with current gravity casting mould, include following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low-pressure casting die comprises an upper die, a lower die and a casting cavity formed by matching the upper die and the lower die, wherein an upper die connecting plate is mounted at the upper end of the upper die through a cushion block, an ejection mechanism is arranged between the upper die connecting plate and the upper die, a static insert matched with the appearance of a gearbox body is arranged on the inner side of the upper die, a die bottom plate is mounted at the bottom of the lower die, and a pouring gate water inlet communicated with the casting cavity is formed in the die bottom plate and the lower die;
step (d): preparing a mold, after assembling and debugging the low-pressure casting mold, preheating the mold to 250-270 ℃, and uniformly spraying a release agent in a casting cavity;
a step (e): transferring the alloy solution smelted in the aluminum melting furnace in the step (b) into a heat preservation furnace of a low-pressure casting machine, and introducing 99.999% high-purity nitrogen to be used as purified alloy solution for treatment, wherein the time for purifying the alloy solution is 15-20 min;
step (f): die casting, namely die casting the gearbox body by adopting a low-pressure casting mode, wherein the die casting process comprises the processes of liquid rising and filling, pressure maintaining and crystallization, pressure relief and cooling;
step (g): and (f) opening the mold after the box body casting is solidified and cooled in the step (f), and obtaining the automobile tail gas treatment box body casting.
Preferably, the alloy solution purified in the step (e) is kept at 680-700 ℃ for die casting.
Preferably, the die-casting process parameters in the step (f) are as follows: the liquid lifting pressure is 160-180 Mpa, the liquid lifting time is 15-17 s, and the pressure is kept for 2-3 s and then the pressure is increased; the pressure in the pressurization stage reaches 780-800 Mpa, and the pressurization time is 10-12 s; then stamping the blank to 950-980 MPa for 2-3 s, maintaining the pressure at 1100-1120 MPa for 300-320 s, and then slowly releasing the pressure and cooling.
Preferably, the weight of the alloy solution fed into the holding furnace of the low-pressure casting machine in the step (e) is 450 Kg.
Preferably, the mode of spraying the release agent in the casting cavity in the step (d) is as follows: and spraying by the spray gun nozzle at a distance of 230-250 mm from the surface of the mold shell. The coating spraying is too close and easy to accumulate, the coating spraying is too far and easy to bond and not firm, the spraying distance influences the quality of the coating, so that the rate of certified products of castings is influenced, multiple experiments show that the distance between the spray gun nozzle and the spraying surface of the mold shell is 230-250 mm, the spraying is uniform, and the surface of the coating of the mold shell is smooth.
Preferably, the spraying thickness of the release agent in the step (d) is 26-32 μm.
As described above, the beneficial effects of the present invention over the prior art are as follows:
1. the casting mold of the gearbox body is changed from a gravity casting mold into a low-pressure casting mold, a casting system of the gravity casting mold is welded on the basis of the original mold, a pouring channel water inlet communicated with a casting cavity is formed in the lower mold, the improved casting mold is provided with a connecting part of a low-pressure casting machine, the improved low-pressure casting mode can effectively solve the problem that products are leaked and scrapped due to shrinkage porosity and shrinkage cracks at a transition part with rapidly changed thickness in the casting process of the gearbox wall, the scheme can effectively utilize the original gravity casting mold, and can obviously improve the economic benefit of enterprises.
2. According to the invention, the water inlet of the pouring gate is arranged in the middle part below the casting cavity, and the alloy solution is injected into the casting cavity from the water inlet of the pouring gate, so that the problem of large temperature drop of the area in the cavity due to insufficient gate height and insufficient pressure provided by a feeding system can be effectively solved by an improved low-pressure casting mode, the flowability of the aluminum alloy solution is fully improved aiming at the problem of large wall thickness difference of a gearbox body, and the problem of product leakage scrapping caused by easy shrinkage porosity and shrinkage crack at a sharp transition part of the wall thickness is prevented; the arrangement of the static insert can improve the processing precision of the integral structure of the die, the improved low-pressure casting die combined casting process enables the qualification rate of box castings to reach 95.9%, the processing precision of casting products can be obviously improved, and the subsequent rough processing cost of the castings is reduced.
3. On the basis of the prior art, the components of the aluminum alloy are adjusted, the content of other alloy elements is adjusted, the tensile strength of the prepared gearbox casing casting is improved by more than 25% compared with the existing die casting, the aluminum alloy crystal structure is refined, the sufficient strength and rigidity are achieved, the use requirement of a travelling crane structural part with higher strength requirement can be met, the use performance of the travelling crane transmission is improved, and the service life is prolonged.
4. According to the invention, die-casting process parameters are improved, and the structural arrangement of the casting die is combined, so that pressurization can be effectively ensured after pressure maintaining is carried out in a liquid lifting stage, thus being beneficial to fully discharging gas in a cavity, being beneficial to pressurization, being beneficial to controlling the mold filling speed in the pressurization stage and improving the stability of mold filling flow; then, after pressurization is completed, pressure maintaining is carried out at 1100-1120 Mpa, the casting is crystallized under the pressure by fully utilizing the crystallization opportunity, the strength of the designed aluminum alloy is fully exerted, and the mold filling parameters are adjusted in stages, so that the box casting has better bonding performance, the large temperature drop of the area in the casting cavity is prevented, and the hot junction of the casting product is thinned; the parameter setting of the die-casting process can fully adjust the diffusivity of the aluminum alloy solution in the casting cavity, keep the aluminum alloy solution in different areas to have good associativity, and effectively solve the phenomenon that the transition part is easy to shrink and loosen and even shrink crack due to the rapid change of the wall thickness of the casting of the gearbox body; the casting product has good sealing performance, so that the casting product has high qualification rate.
Drawings
FIG. 1 is a perspective view of a casting mold for a transmission housing of the present invention;
FIG. 2 is an elevational, cross-sectional view of a casting mold for a transmission housing of the present invention;
fig. 3 is a top sectional view of a casting mold for a transmission case of the present invention.
Detailed Description
The following is further detailed by way of specific embodiments:
reference numerals in the drawings of the specification include: 1-upper die, 2-lower die, 3-casting cavity, 4-cushion block, 5-upper die connecting plate, 6-sleeve column, 7-static insert, 8-thimble fixing plate, 9-thimble through hole, 10-exhaust channel, 11-pouring gate water inlet, 12-die bottom plate and 13-thimble hole.
Example 1
Referring to fig. 1, 2 and 3, the embodiment provides a casting mold for a gearbox casing, which includes an upper mold 1, a lower mold 2 and a casting cavity 3 formed by the upper mold 1 and the lower mold 2 in a matching manner, an upper mold connecting plate 5 is installed at the upper end of the upper mold 1 through a cushion block 4, an ejection mechanism is arranged between the upper mold connecting plate 5 and the upper mold 1, the ejection mechanism includes a thimble fixing plate 8 and a plurality of thimbles uniformly installed on the thimble fixing plate 8, the plurality of thimbles are detachably connected with the thimble fixing plate 8 through threads, and the thimble fixing plate 8 is provided with a threaded hole for mounting the thi; ejector pin through holes 9 corresponding to a plurality of ejector pins are arranged in the upper die 1, the diameters of the ejector pin through holes 9 are 11-13 mm, and the diameters of the ejector pin through holes 9 are preferably 12 mm; and at last mould connecting plate 5 with go up mould 1 fixedly connected with cover post 6 structure, 8 covers of thimble fixed plate are established on cover post 6 and can be followed cover post 6 and slided from top to bottom, cover post 6 not only can be used to support the stability of going up mould connecting plate 5 and last mould 1 and be connected, also can play the guide effect to the removal of thimble fixed plate 8 and a plurality of thimble.
The inner side of the upper die 1 is provided with the static insert 7 matched with the appearance of the gearbox body, and the structure of the static insert 7 is manufactured independently and then embedded in the die, so that the machining precision of the integral die structure of the gearbox body is high, the machining precision of a casting product can be effectively improved, and the machining quality of the gearbox product is improved; and the static insert 7 is arranged and matched with the shape of the gearbox body, so that the inner cavity and the shape structure part of the gearbox casting can be effectively formed at one time, rough machining is reduced, the production cost is reduced, and the percent of pass of the gearbox casting is as high as 95.9%.
A plurality of exhaust passages 10 communicated with the casting cavity 3 are uniformly arranged on the upper die 1, and the diameter of each exhaust passage 10 is 5 mm; the bottom area of the casting cavity 3 is large, and a plurality of exhaust channels 10 uniformly distributed on the upper die 1 can uniformly exhaust gas in the casting cavity 3, so that different parts of a formed casting are fully formed, and the defects of casting air holes, under-casting or unclear outline and the like are avoided; and the molding peripheral thimble holes 13 of the casting product are 14 mm.
The bottom of the lower die 2 is provided with a die bottom plate 12, and the lower die 2 is embedded into the die bottom plate 12; a pouring gate water inlet 11 communicated with the casting cavity 3 is formed in the mold bottom plate 12 and the lower mold 2, the pouring gate water inlet 11 is formed in the center of the bottom of the casting cavity 3, and alloy solution is injected into the casting cavity 3 through the pouring gate water inlet 11 and diffuses around along the center of the casting cavity 3.
The casting width of the traveling crane gearbox reaches 326mm, the thinnest part of the wall thickness is 7.5mm, the thickest part reaches 57.5mm, and the wall thickness difference is large; after analysis: because the height of the pouring gate is not enough, the pressure provided by a feeding system is insufficient, so that the mold filling speed is slow, the temperature drop of the area in the casting cavity 3 is large, and the defects of casting air holes, under-casting or unclear outline and the like are easily caused; this embodiment has increased and has installed the electronic heater structure on the gearbox foundry goods fills the mould shell of the thinner department of type wall thickness, and electronic heater structure and mounting means are prior art, do not describe here any more, adopt this structural style can heat the mould shell that the thinner department of type wall thickness was filled to the gearbox foundry goods, avoid the 3 interior regional temperature drops of foundry goods die cavity big for aluminum alloy crystallization stress is stable, perfect foundry goods shaping effect.
The specific implementation manner of this embodiment is: use above-mentioned mould casting LYP315.2 driving gearbox box, this embodiment adopts to water the water inlet 11 and locate foundry goods die cavity 3 below middle part with watering, alloy solution pours into foundry goods die cavity 3 into by watering water inlet 11, and install the electric heater on the mould shell of the thinner department of gearbox casting mold wall thickness, improve the mobility of this regional aluminum alloy liquid, prevent the big problem of regional temperature drop in the foundry goods die cavity, make aluminum alloy crystallization stress stable, adopt the mode of low-pressure casting can effectively improve runner height inadequately, the pressure that the feeding system provided is not enough and causes the big problem of regional temperature drop in the die cavity, fully improve aluminum alloy solution mobility, prevent that the transition department of gearbox box wall thickness abrupt change from easily shrinking pine and shrinkage crack and lead to the scrapped problem of product leakage, the shaping texture of the filling foundry goods is full.
Example 2
Referring to fig. 1, 2 and 3, the present embodiment provides a casting process of a transmission case, which is used to cast a LYP315.2 transmission case by using the casting mold of the transmission case in embodiment 1, wherein the transmission case is made of an aluminum alloy consisting of the following components in percentage by weight: si: 6.5%, Mg: 0.3%, Ti: 0.1%, Cu: 2.1%, Mn: 0.2%, Fe: 0.65%, Ni: 0.25%, Zn: 0.08%, Pb: 0.15%, Sn: 0.05%, Cr: 0.12 percent, and the balance of Al and inevitable impurities, and the casting process specifically comprises the following process steps:
step (a): batching, wherein corresponding simple substance raw materials and Al are selected for batching according to the components;
step (b): smelting an alloy, namely baking an aluminum melting furnace, putting the metal alloy prepared in the step (a) into the aluminum melting furnace for smelting at 780 ℃, and carrying out refining, deoxidation and slagging-off processes to prepare an alloy solution;
step (c): reform transform the mould, reform transform into low pressure casting mould with current gravity casting mould, include following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low-pressure casting die comprises an upper die 1, a lower die 2 and a casting cavity 3 formed by matching the upper die and the lower die, wherein an upper die connecting plate 5 is installed at the upper end of the upper die 1 through a cushion block, an ejection mechanism is arranged between the upper die connecting plate 5 and the upper die 1, a static insert 7 matched with the shape of a gearbox box body is arranged on the inner side of the upper die 1, a die bottom plate 12 is installed at the bottom of the lower die, and a pouring gate water inlet 11 communicated with the casting cavity 3 is formed in the die bottom plate 12 and the lower die 2;
preparing a mold, comprising the steps of: 1.1 cleaning the die; 1.2 installing and debugging a die; 1.3 baking the mould; 1.4 spraying a mould with paint; 1.5 baking the mould, preheating the mould to 270 ℃, and uniformly spraying a layer of release agent with heat insulation and heat preservation effects in the casting cavity 3, wherein the spraying mode of the release agent is as follows: the distance from the spray gun nozzle to the surface of the mold shell is 230mm, and the spraying thickness of the release agent is 26 mu m. The coating is sprayed too close and easy to accumulate, and the coating is sprayed too far and easy to bond firmly, the spraying distance influences the coating quality, so that the quality rate of the casting is influenced, multiple experiments show that the distance between a spray gun nozzle and the spraying surface of the mold shell is 230mm, the spraying is uniform, and the surface of the coating of the mold shell is smooth; carrying out die assembly, wherein the die assembly is light and slow; in the mold closing process, if abnormity occurs, the reason is found out, and the next step is carried out after the fault is eliminated;
a step (e): transferring the alloy solution smelted in the aluminum melting furnace in the step (b) into a heat preservation furnace of a low-pressure casting machine, wherein the weight of the alloy solution transferred into the heat preservation furnace of the low-pressure casting machine is 450 Kg; introducing 99.999% high-purity nitrogen to purify the alloy solution for 15 min; keeping the temperature of the purified alloy solution at 680 ℃ for preparing die casting;
step (f): die casting, firstly, confirming whether die assembly is in place; filling the mold after the mold is closed in place; the gearbox body is die-cast in a low-pressure casting mode, and the die-casting process comprises the steps of liquid lifting and filling, pressure maintaining and crystallization, pressure relief and cooling; the die-casting process parameters are as follows: the liquid lifting pressure is 160Mpa, the liquid lifting time is 15s, and the pressure is kept for 2s and then the pressure is increased; the pressure of the pressurization stage reaches 800Mpa, and the pressurization time is 10 s; then stamping to 950Mpa in 2s, maintaining the pressure at 1100Mpa for 300s, and then slowly releasing pressure and cooling; in the die casting process, an operator carefully observes whether the die leaks or not, and if the die leaks, the operation is stopped; the operation is carried out after the fault is eliminated; after the mold filling is finished, the weight of the aluminum alloy solution entering the casting cavity 3 is 22 Kg;
step (g): opening the mould after the box body casting in the step (f) is solidified and cooled to obtain the automobile tail gas treatment box body casting; specifically, the upper die 1 is lifted, the box casting is lifted along with the upper die 1, when the box casting is lifted to a required height, the receiving tray is rotated out, the ejection mechanism is driven by the driving piece to eject a product, and the driving piece of the ejection mechanism is the prior art and is not described herein again; the receiving tray rotates to take down the product; and detecting whether the defect exists.
Table 1 embodiment 2 gearbox casing casting airtightness detection test table
Through detection, as shown in table 1, the pressure is maintained for 30s under the pressure of 0.6-1.0 Mpa, no bubbles are generated in a casting of the gearbox body, and the air tightness is qualified; the casting is completely formed, and the phenomena of shrinkage porosity and shrinkage crack do not occur at the transition part of the rapid change of the wall thickness of the gearbox body and other parts; the casting product has clear and full outline and full texture, the tensile strength of the box casting is improved by about 31.5 percent compared with the prior art, the mechanical property of the casting can be effectively improved, the use requirement of a traveling crane structural member with higher strength requirement can be met, the use performance of a traveling crane transmission is improved, and the service life is prolonged.
Example 3
Referring to fig. 1, 2 and 3, the present embodiment provides a casting process of a transmission case, which is used to cast a LYP315.2 transmission case by using the casting mold of the transmission case in embodiment 1, wherein the transmission case is made of an aluminum alloy consisting of the following components in percentage by weight: si: 7.5%, Mg: 0.4%, Ti: 0.2%, Cu: 3.5%, Mn: 0.5%, Fe: 0.55%, Ni: 0.15%, Zn: 0.06%, Pb: 0.12%, Sn: 0.08%, Cr: 0.15 percent, and the balance of Al and inevitable impurities, and the casting process specifically comprises the following process steps:
step (a): batching, wherein corresponding simple substance raw materials and Al are selected for batching according to the components;
step (b): smelting an alloy, namely baking an aluminum melting furnace, putting the metal alloy prepared in the step (a) into the aluminum melting furnace for smelting at the smelting temperature of 790 ℃, and performing refining, deoxidation and slagging-off processes to prepare an alloy solution;
step (c): reform transform the mould, reform transform into low pressure casting mould with current gravity casting mould, include following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low-pressure casting die comprises an upper die 1, a lower die 2 and a casting cavity 3 formed by matching the upper die and the lower die, wherein an upper die connecting plate 5 is installed at the upper end of the upper die 1 through a cushion block, an ejection mechanism is arranged between the upper die connecting plate 5 and the upper die 1, a static insert 7 matched with the shape of a gearbox box body is arranged on the inner side of the upper die 1, a die bottom plate 12 is installed at the bottom of the lower die, and a pouring gate water inlet 11 communicated with the casting cavity 3 is formed in the die bottom plate 12 and the lower die 2;
preparing a mold, comprising the steps of: 1.1 cleaning the die; 1.2 installing and debugging a die; 1.3 baking the mould; 1.4 spraying a mould with paint; 1.5, baking the die, preheating the die to 260 ℃, and uniformly spraying a layer of release agent with heat insulation and heat preservation effects in the casting cavity 3, wherein the spraying mode of the release agent is as follows: the distance between the spray gun nozzle and the surface of the die shell is 250mm, and the spraying thickness of the release agent is 30 mu m. The coating is sprayed too close and easy to accumulate, and the coating is sprayed too far and easy to bond firmly, the spraying distance influences the coating quality, so that the quality rate of the casting is influenced, through multiple experiments, the distance between a spray gun nozzle and the spraying surface of the mold shell is 250mm, the spraying is uniform, and the surface of the coating of the mold shell is smooth; carrying out die assembly, wherein the die assembly is light and slow; in the mold closing process, if abnormity occurs, the reason is found out, and the next step is carried out after the fault is eliminated;
a step (e): transferring the alloy solution smelted in the aluminum melting furnace in the step (b) into a heat preservation furnace of a low-pressure casting machine, wherein the weight of the alloy solution transferred into the heat preservation furnace of the low-pressure casting machine is 450 Kg; introducing 99.999% high-purity nitrogen to purify the alloy solution for 15 min; keeping the temperature of the purified alloy solution at 690 ℃ for pressure casting;
step (f): die casting, firstly, confirming whether die assembly is in place; filling the mold after the mold is closed in place; the gearbox body is die-cast in a low-pressure casting mode, and the die-casting process comprises the steps of liquid lifting and filling, pressure maintaining and crystallization, pressure relief and cooling; the die-casting process parameters are as follows: the liquid lifting pressure is 165Mpa, the liquid lifting time is 16s, and the pressure is kept for 2s and then the pressure is increased; the pressure of the pressurization stage reaches 790Mpa, and the pressurization time is 12 s; then punching to 960Mpa in 3s, maintaining the pressure at 1115Mpa for 320s, and slowly releasing pressure and cooling; in the die casting process, an operator carefully observes whether the die leaks or not, and if the die leaks, the operation is stopped; the operation is carried out after the fault is eliminated; after the mold filling is finished, the weight of the aluminum alloy solution entering the casting cavity 3 is 22 Kg;
step (g): opening the mould after the box body casting in the step (f) is solidified and cooled to obtain the automobile tail gas treatment box body casting; specifically, the upper die 1 is lifted, the box casting is lifted along with the upper die 1, when the box casting is lifted to a required height, the receiving tray is rotated out, the ejection mechanism is driven by the driving piece to eject a product, and the driving piece of the ejection mechanism is the prior art and is not described herein again; the receiving tray rotates to take down the product; and detecting whether the defect exists.
Table 2 embodiment 3 test table for detecting airtightness of casting of gearbox casing
Through detection, as shown in table 2, the pressure is maintained for 30s under the pressure of 0.6-1.0 Mpa, no bubbles are generated in a casting of the gearbox body, and the air tightness is qualified; the casting is completely formed, and the phenomena of shrinkage porosity and shrinkage crack do not occur at the transition part of the rapid change of the wall thickness of the gearbox body and other parts; the casting product has clear and full outline and full texture, the tensile strength of the box casting is improved by about 28.6 percent compared with the prior art, the mechanical property of the casting can be effectively improved, the use requirement of a traveling crane structural member with higher strength requirement can be met, the use performance of a traveling crane transmission is improved, and the service life is prolonged.
Example 4
Referring to fig. 1, 2 and 3, the present embodiment provides a casting process of a transmission case, which is used to cast a LYP315.2 transmission case by using the casting mold of the transmission case in embodiment 1, wherein the transmission case is made of an aluminum alloy consisting of the following components in percentage by weight: si: 7.2%, Mg: 0.35%, Ti: 0.16%, Cu: 2.8%, Mn: 0.35%, Fe: 0.45%, Ni: 0.21%, Zn: 0.06%, Pb: 0.11%, Sn: 0.06%, Cr: 0.02 percent, and the balance of Al and inevitable impurities, and the casting process specifically comprises the following process steps:
step (a): batching, wherein corresponding simple substance raw materials and Al are selected for batching according to the components;
step (b): smelting an alloy, namely baking an aluminum melting furnace, putting the metal alloy prepared in the step (a) into the aluminum melting furnace for smelting at the smelting temperature of 790 ℃, and performing refining, deoxidation and slagging-off processes to prepare an alloy solution;
step (c): reform transform the mould, reform transform into low pressure casting mould with current gravity casting mould, include following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low-pressure casting die comprises an upper die 1, a lower die 2 and a casting cavity 3 formed by matching the upper die and the lower die, wherein an upper die connecting plate 5 is installed at the upper end of the upper die 1 through a cushion block, an ejection mechanism is arranged between the upper die connecting plate 5 and the upper die 1, a static insert 7 matched with the shape of a gearbox box body is arranged on the inner side of the upper die 1, a die bottom plate 12 is installed at the bottom of the lower die, and a pouring gate water inlet 11 communicated with the casting cavity 3 is formed in the die bottom plate 12 and the lower die 2;
preparing a mold, comprising the steps of: 1.1 cleaning the die; 1.2 installing and debugging a die; 1.3 baking the mould; 1.4 spraying a mould with paint; 1.5 baking the mould, preheating the mould to 270 ℃, and uniformly spraying a layer of release agent with heat insulation and heat preservation effects in the casting cavity 3, wherein the spraying mode of the release agent is as follows: the distance from the spray gun nozzle to the surface of the mold shell is 230mm, and the spraying thickness of the release agent is 26 mu m. The coating is sprayed too close and easy to accumulate, and the coating is sprayed too far and easy to bond firmly, the spraying distance influences the coating quality, so that the quality rate of the casting is influenced, multiple experiments show that the distance between a spray gun nozzle and the spraying surface of the mold shell is 230mm, the spraying is uniform, and the surface of the coating of the mold shell is smooth; carrying out die assembly, wherein the die assembly is light and slow; in the mold closing process, if abnormity occurs, the reason is found out, and the next step is carried out after the fault is eliminated;
a step (e): transferring the alloy solution smelted in the aluminum melting furnace in the step (b) into a heat preservation furnace of a low-pressure casting machine, wherein the weight of the alloy solution transferred into the heat preservation furnace of the low-pressure casting machine is 450 Kg; introducing 99.999% high-purity nitrogen to purify the alloy solution for 20 min; keeping the temperature of the purified alloy solution at 700 ℃ for preparing die casting;
step (f): die casting, firstly, confirming whether die assembly is in place; filling the mold after the mold is closed in place; the gearbox body is die-cast in a low-pressure casting mode, and the die-casting process comprises the steps of liquid lifting and filling, pressure maintaining and crystallization, pressure relief and cooling; the die-casting process parameters are as follows: the liquid lifting pressure is 170Mpa, the liquid lifting time is 16s, and the pressure is kept for 3s and then the pressure is increased; the pressure of the pressurization stage reaches 786Mpa, and the pressurization time is 12 s; stamping to 980MPa in 3s, maintaining the pressure at 1120MPa for 320s, and slowly releasing pressure and cooling; in the die casting process, an operator carefully observes whether the die leaks or not, and if the die leaks, the operation is stopped; the operation is carried out after the fault is eliminated; after the mold filling is finished, the weight of the aluminum alloy solution entering the casting cavity 3 is 22 Kg;
step (g): opening the mould after the box body casting in the step (f) is solidified and cooled to obtain the automobile tail gas treatment box body casting; specifically, the upper die 1 is lifted, the box casting is lifted along with the upper die 1, when the box casting is lifted to a required height, the receiving tray is rotated out, the ejection mechanism is driven by the driving piece to eject a product, and the driving piece of the ejection mechanism is the prior art and is not described herein again; the receiving tray rotates to take down the product; and detecting whether the defect exists.
Table 3 embodiment 4 test table for detecting airtightness of casing casting of transmission
Through detection, as shown in table 3, the pressure is maintained for 30s under the pressure of 0.6-1.0 Mpa, no bubbles are generated in a casting of the gearbox body, and the air tightness is qualified; the casting is completely formed, and the phenomena of shrinkage porosity and shrinkage crack do not occur at the transition part of the rapid change of the wall thickness of the gearbox body and other parts; the casting product has clear and full outline and full texture, the tensile strength of the box casting is improved by about 30.7 percent compared with the prior art, the mechanical property of the casting can be effectively improved, the use requirement of a traveling crane structural member with higher strength requirement can be met, the use performance of a traveling crane transmission is improved, and the service life is prolonged.
The above description is only a preferred embodiment of the present invention, and not intended to limit the present invention, the scope of the present invention is defined by the appended claims, and all structural changes that can be made by using the contents of the description and the drawings of the present invention are intended to be embraced therein.
Claims (8)
1. The utility model provides a casting mould of gearbox box, includes mould, lower mould and by the foundry goods die cavity that mould and lower mould cooperation constitute, its characterized in that: an upper die connecting plate is mounted at the upper end of the upper die through a cushion block, an ejection mechanism is arranged between the upper die connecting plate and the upper die, a static insert matched with the appearance of the gearbox body is arranged on the inner side of the upper die, a die bottom plate is mounted at the bottom of the lower die, and the die bottom plate and the lower die are provided with a pouring gate water inlet communicated with a casting cavity; the ejection mechanism comprises a thimble fixing plate and a plurality of thimbles uniformly arranged at the bottom of the thimble fixing plate, and a plurality of thimble through holes corresponding to the thimbles are arranged in the upper die; the diameters of the thimble through holes are all 11-13 mm;
the casting mould of the gearbox box body is a low-pressure casting mould modified from a gravity casting mould; reform transform into low pressure casting mould with current gravity casting mould, include the following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low pressure casting mould includes mould, lower mould and by last mould and the foundry goods die cavity that the lower mould cooperation constitutes, go up the mould upper end and install the mould connecting plate through the cushion, go up and be equipped with ejection mechanism between mould connecting plate and the last mould, just the inboard of going up the mould is equipped with the quiet mold insert with gearbox box appearance assorted, the mould bottom plate is installed to the lower mould bottom, the water inlet of watering with the foundry goods die cavity intercommunication is seted up to mould bottom plate and lower mould.
2. The casting mold for a transmission case according to claim 1, wherein: the mould is gone up and evenly is equipped with many exhaust passage on, many exhaust passage's diameter is 5 mm.
3. A casting process of a gearbox body is characterized in that: the gearbox body is made of aluminum alloy which comprises the following components in percentage by weight: si: 6.5-7.5%, Mg: 0.3-0.4%, Ti: 0.1-0.2%, Cu: 2.1-3.5%, Mn: 0.2-0.5%, Fe is less than or equal to 0.75%, Ni is less than or equal to 0.35%, Zn is less than or equal to 0.1%, Pb is less than or equal to 0.2%, Sn is less than or equal to 0.1%, Cr is less than or equal to 0.2%, and the balance is Al and inevitable impurities, wherein the casting process comprises the following process steps:
step (a): batching, wherein corresponding simple substance raw materials and Al are selected for batching according to the components;
step (b): smelting an alloy, namely baking an aluminum melting furnace, putting the metal alloy prepared in the step (a) into the aluminum melting furnace for smelting at 780-790 ℃, and performing refining, deoxidation and slagging-off processes to prepare an alloy solution;
step (c): reform transform the mould, reform transform into low pressure casting mould with current gravity casting mould, include following step: step (1): milling a sprue cup and a sprue of the gravity metal mold, filling a horizontal runner, and performing repair welding on an inner sprue casting system; step (2): filling blind risers and fixing chills; and (3): the reinforcing ribs are additionally provided with vent plugs, and top pinhole holes on the periphery of the product are enlarged to 14 mm; and (4): the lower die is provided with a pouring gate water inlet communicated with the casting cavity; and (5): manufacturing a die bottom plate and an upper die connecting plate according to the connection size of the low-pressure casting machine; the low-pressure casting die comprises an upper die, a lower die and a casting cavity formed by matching the upper die and the lower die, wherein an upper die connecting plate is mounted at the upper end of the upper die through a cushion block, an ejection mechanism is arranged between the upper die connecting plate and the upper die, a static insert matched with the appearance of a gearbox body is arranged on the inner side of the upper die, a die bottom plate is mounted at the bottom of the lower die, and a pouring gate water inlet communicated with the casting cavity is formed in the die bottom plate and the lower die;
step (d): preparing a mold, after assembling and debugging the low-pressure casting mold, preheating the mold to 250-270 ℃, and uniformly spraying a release agent in a casting cavity;
a step (e): transferring the alloy solution smelted in the aluminum melting furnace in the step (b) into a heat preservation furnace of a low-pressure casting machine, and introducing 99.999% high-purity nitrogen to be used as purified alloy solution for treatment, wherein the time for purifying the alloy solution is 15-20 min;
step (f): die casting, namely die casting the gearbox body by adopting a low-pressure casting mode, wherein the die casting process comprises the processes of liquid rising and filling, pressure maintaining and crystallization, pressure relief and cooling;
step (g): and (f) opening the mold after the box body casting is solidified and cooled in the step (f), and obtaining the automobile tail gas treatment box body casting.
4. A casting process of a gearbox casing according to claim 3, wherein: keeping the temperature of the alloy solution purified in the step (e) at 680-700 ℃ for preparing die casting.
5. A casting process of a gearbox casing according to claim 3, wherein: the die-casting process parameters in the step (f) are as follows: the liquid lifting pressure is 160-180 Mpa, the liquid lifting time is 15-17 s, and the pressure is kept for 2-3 s and then the pressure is increased; the pressure in the pressurization stage reaches 780-800 Mpa, and the pressurization time is 10-12 s; then stamping the blank to 950-980 MPa for 2-3 s, maintaining the pressure at 1100-1120 MPa for 300-320 s, and then slowly releasing the pressure and cooling.
6. A casting process of a gearbox casing according to claim 3, wherein: the weight of the alloy solution which is transferred into the heat preservation furnace of the low-pressure casting machine in the step (e) is 450 Kg.
7. A casting process of a gearbox casing according to claim 3, wherein: in the step (d), the mode of spraying the release agent in the casting cavity is as follows: and spraying by the spray gun nozzle at a distance of 230-250 mm from the surface of the mold shell.
8. A casting process of a gearbox casing according to claim 3, wherein: the spraying thickness of the release agent in the step (d) is 26-32 μm.
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| CN110453115B (en) * | 2019-09-04 | 2021-11-19 | 东莞理工学院 | Novel automobile transmission shell die-casting aluminum alloy and preparation process thereof |
| CN111182752B (en) * | 2019-12-30 | 2021-04-13 | 贵州新蓝辉金属制品有限公司 | Radiator case for magnetic suspension train and casting method thereof |
| CN111872354A (en) * | 2020-08-03 | 2020-11-03 | 湖北军威机械有限公司 | Reduce plantago cap gating system of shrinkage cavity and shrinkage porosity |
| CN114433818A (en) * | 2022-02-22 | 2022-05-06 | 烟台路通精密科技股份有限公司 | Low-pressure casting method and device for thin-wall complex aluminum alloy gearbox shell |
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