CN109465406B - Casting method of rotating wheel - Google Patents
Casting method of rotating wheel Download PDFInfo
- Publication number
- CN109465406B CN109465406B CN201811411123.9A CN201811411123A CN109465406B CN 109465406 B CN109465406 B CN 109465406B CN 201811411123 A CN201811411123 A CN 201811411123A CN 109465406 B CN109465406 B CN 109465406B
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- runner
- casting
- sand core
- blade
- lower ring
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/28—Moulds for peculiarly-shaped castings for wheels, rolls, or rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/088—Feeder heads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
- B22C9/103—Multipart cores
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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
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
Abstract
The invention belongs to the field of casting, and mainly relates to a casting method of a runner, which is used for realizing the integral casting of the runner, wherein the method takes an upper crown, a lower ring and a blade of the runner as a whole for casting and processing molding; the size control design, the runner is divided into a non-flow surface and a flow surface for carrying out the paste amount design; the design of the molding process, the molding process of the runner adopts the combination of core assembly and buried box; the runner sand core is divided into an inner side sand core and an outer side sand core, and the inner side sand core and the outer side sand core are integrally formed by adopting 3D printing. The method of the invention overcomes the defects of the traditional casting method, reduces the manufacturing cost, shortens the production period, improves the casting quality, improves the manufacturing precision and realizes the near net shape of the runner casting.
Description
Technical Field
The invention belongs to the field of casting, and mainly relates to a casting method of a rotating wheel, which is used for realizing the integral casting of the rotating wheel without adopting assembly welding.
Background
The water turbine runner is a core accessory in a water turbine set, the runner mainly comprises an upper crown, a lower ring and a plurality of blades, and the water turbine runner has the characteristics of long and narrow flow channel, complex space structure and the like, and particularly, the blade part is a special-shaped curved surface with inextensible space. The traditional method for manufacturing the water turbine runner adopts the steps that the upper crown, the lower ring and the blades are cast separately, and then the integration of the runner is realized through assembly welding, so that the manufacturing process is complex and the working procedures are multiple; although the traditional casting method obviously reduces the manufacturing difficulty of a single part, the production of the whole runner is realized by adopting assembly welding, so that the period is greatly increased, meanwhile, the welding seams exist on the upper crown, the lower ring and the blades, so that the whole quality of the runner is unstable, the cost of a welding tool is high, and the manufacturing cost of the runner is increased.
Disclosure of Invention
In view of the defects of the traditional casting method, the invention provides a casting method of a runner, which aims to solve the problems of unstable casting quality, high manufacturing cost, long period and the like of the runner and realize the integral casting and near-net-shape forming of the runner.
A casting method of a runner, the runner including a crown, a band, and a plurality of blades, the casting method comprising the steps of:
the runner casting adopts an integral casting process design scheme, a chilling block is arranged on the periphery of a flange of the upper crown, a ring riser is arranged at the joint of the upper crown and each blade, and a blind riser is arranged at the joint of the lower ring and each blade; a patch is arranged between the ring riser and the upper end face of the flange of the upper crown;
the upper crown upper end surface, the upper crown inner cavity and the periphery of the lower ring are provided with non-overflowing surfaces, the upper crown, the lower ring and each blade are provided with overflowing surfaces, and the non-overflowing surfaces and the overflowing surfaces are subjected to fitting amount design;
designing a runner sand core by adopting 3D printing, wherein the runner sand core comprises an inner side sand core and an outer side sand core, each blade, the upper crown and the ring riser are designed into the inner side sand core, and the lower ring and the blind riser are designed into the outer side sand core;
molding and assembling the box and placing the outer sand core;
placing an inner sand core;
the outside sand core and the inside sand core are combined to form the runner sand core;
placing a sand box, and carrying out sand burying operation between the rotary wheel sand core and the sand box;
and pouring and boxing to obtain the runner casting.
Preferably, in the above technical solution, a joint portion of the lower ring and each of the blades is communicated with the blind riser through a blind riser neck.
Preferably, in the above technical solution, the number of the blind riser necks is equal to the number of the blades, and the blind riser necks are circumferentially and uniformly arranged.
Preferably, the blind riser is arranged outside the lower ring.
Preferably, the patches are uniformly distributed on the circumference, and the width of each patch is 200-300 mm.
Preferably, at least 6 patches are provided.
Preferably, the sticking amount of the upper end face of the upper crown is 8-12 mm, and the sticking amount of the inner cavity of the upper crown and the periphery of the lower ring is 5-8 mm.
Preferably, the attaching amount of the upper crown overflow surface and the lower ring overflow surface is 2 mm-4 mm, the attaching amount of the overflow surface part at the position of 200 mm-300 mm away from the edge of the water inlet edge of each blade is 3 mm-5 mm, the attaching amount of the residual overflow surface of each blade is 1 mm-3 mm, and the attaching amount of the overflow surface of the water outlet edge of each blade is 1 mm-3 mm.
Preferably, at least two layers of deformation-preventing lacing wires are arranged on the water outlet edge of the blade; the deformation-preventing lacing wire is arranged at the position which is 30 mm-50 mm away from the edge of the water outlet edge.
Preferably, the cross section of the anti-deformation lacing wire is circular.
Preferably, the diameter of the deformation-preventing lacing wire is 1-1.2 times of the wall thickness of the blade at the shape following position.
The invention provides a casting method of a runner, because the integral runner is a complex spiral rotary casting formed by blades, an upper crown and a lower ring, wherein the wall thickness difference of the blades is large, the minimum wall thickness is 5-20 mm, and the casting difficulty is large.
Drawings
FIG. 1 is a schematic view of a rotary wheel casting process according to the present invention;
FIG. 2 is a schematic view of the wheel sizing control of the present invention;
FIG. 3 is a schematic view of the arrangement of the deformation-preventing tie bars at the water outlet side of the runner blade according to the present invention;
FIG. 4 is a schematic view of the rotary wheel core of the present invention;
1-runner casting, 2-ring of risers, 3-patching, 4-blind risers, 5-blind riser necks, 6-chill, 7-upper crown upper end face, 8-upper crown inner cavity, 9-upper crown overflow surface, 10-lower ring periphery, 11-lower ring overflow surface, 12-blade water inlet edge, 13-blade residual overflow surface, 14-anti-deformation lacing wire, 15-runner sand core, 151-outer sand core and 152-inner sand core.
Detailed Description
Other advantages and capabilities of the present invention will be readily apparent to those skilled in the art from the present disclosure by describing the embodiments of the present invention by specific examples with reference to the accompanying drawings. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention.
It should be noted that the structures, ratios, sizes, and the like shown in the drawings attached to the present specification are only used for matching the disclosure of the present specification, so as to be understood and read by those skilled in the art, and are not used to limit the conditions of the present invention, so that the present invention has no technical essence, and any structural modification, ratio relationship change, or size adjustment should still fall within the scope of the present invention without affecting the efficacy and the achievable purpose of the present invention. In addition, the terms "outer periphery", "upper end surface", "outer side" and "inner side" used in the present specification are for clarity of description, and are not intended to limit the scope of the present invention, and changes or adjustments of the relative relationship thereof are considered to be the scope of the present invention without substantial changes in the technical contents.
A casting method of a runner, the runner comprises an upper crown, a lower ring and a plurality of blades, and the casting method comprises the following processes:
s001, referring to the attached drawing 1, the runner casting 1 adopts an integral casting process design scheme, a chill 6 is arranged on the periphery of a flange of an upper crown, a ring riser 2 is arranged at the joint part of the upper crown and each blade, and a blind riser 4 is arranged at the joint part of a lower ring and each blade; and a patch 3 is arranged between the ring riser 2 and the upper end face of the flange of the upper crown.
In one embodiment, the joint part of the lower ring and each blade is communicated with the blind riser 4 through the blind riser necks 5, the number of the blind riser necks 5 is equal to that of the blades, and the blind riser necks 5 are uniformly arranged on the circumference. The distance difference between the hidden riser neck 5 and the highest position of the lower ring is 50 mm-80 mm. The blind riser 4 is arranged outside the lower ring. The patches 3 are uniformly distributed on the circumference, the width of the patches 3 is 200-300 mm, and at least 6 patches are arranged.
Specifically, the integral runner is a complex spiral rotary casting composed of blades, an upper crown and a lower ring, wherein the wall thickness difference of the blades is large, the minimum wall thickness is 5-20 mm, a hot joint at the joint part of the upper crown and the blades is a spiral-shaped strip-shaped hot joint and is uniformly distributed along the circle of the rotating center of the runner, and meanwhile, the joint part of the blades and the lower ring is also provided with a similar hot joint which is positioned in a relatively closed space, so when the casting process is designed, a cold iron 6 is arranged on the periphery of a flange of the upper crown, and a ring riser 2 is arranged at the spiral-shaped strip-shaped hot joint at the joint part of the upper crown and the blades, so that the feeding problem of the hot joint at the joint part of the upper crown and the blades is solved; a blind riser neck 5 is arranged at the position of a hot spot at the joint of the lower ring and the blade, and a blind riser 4 is arranged on the blind riser neck 5 so as to solve the feeding problem of the hot spot at the joint of the blade and the lower ring; and (3) arranging a patch 3 at the contact part of the ring riser 2 and the upper end surface of the upper crown flange, and opening a feeding channel of the ring riser 2 to the upper crown flange. The casting process design of the invention utilizes the characteristic of larger wall thickness of the upper crown and the lower ring, and the hot joint of the blade is combined to the upper crown and the lower ring, so that the blade can obtain a good structure in the runner by self feeding of a casting without adding other process information, and the dimensional precision of the molded line of the blade can be better ensured.
S002, referring to fig. 2, the upper crown end surface 7, the upper crown inner cavity 8 and the lower ring periphery 10 all have non-flow surfaces, the upper crown, the lower ring and each of the blades all have flow surfaces, and the non-flow surfaces and the flow surfaces are designed in a fitting manner;
in one embodiment, the non-overflowing surface comprises an upper crown end surface 7, an upper crown inner cavity 8 and a lower ring periphery 10, wherein the sticking amount of the upper crown end surface 7 is 8-12 mm, and the sticking amount of the upper crown inner cavity 8 and the lower ring periphery 10 is 5-8 mm; the overflowing surface comprises an upper crown overflowing surface 9, a lower ring overflowing surface 11 and a blade water inlet edge 12, the adhering amount of the upper crown overflowing surface 9 and the lower ring overflowing surface 11 is 2-4 mm, the adhering amount of the overflowing surface part of the blade water inlet edge 12, which is 200-300 mm away from the edge of the water inlet edge, is 3-5 mm, and the adhering amount of the residual overflowing surface 13 of the blade is 1-3 mm. The overflowing surface also comprises a blade water outlet edge, and the attaching quantity of the overflowing surface on the blade water outlet edge is 1-3 mm. Referring to fig. 3, at least two layers of anti-deformation lacing wires 14 are arranged at the water outlet edge of the blade; the anti-deformation lacing wire 14 is arranged at the position 30 mm-50 mm away from the edge of the water outlet edge. The cross section of the anti-deformation lacing wire 14 is circular, the diameter of the anti-deformation lacing wire 14 is 1-1.2 times of the wall thickness of the blade at the shape following position, and the shape following position is specifically equal to the position of the anti-deformation lacing wire 14 matched with the shape following position.
Specifically, during the size control design, the rotating wheel is divided into a non-overflow surface and an overflow surface for carrying out the paste amount design, wherein the overflow surface can be processed, the non-overflow surface is difficult to process because the space between adjacent blades is too small, about 60-70% of the surface of the overflow surface is difficult to process, but the part is required to have precise size and good surface roughness in the process, the paste amount of an upper crown upper end surface 7 is 8-12 mm, the paste amount of an upper crown inner cavity 8 and a lower ring periphery 10 is 5-8 mm, the paste amount of an upper crown overflow surface 9 and a lower ring overflow surface 11 is 2-4 mm, the paste amount of an overflow surface part of a blade water inlet edge 12 which is 200-300 mm far away from a water inlet edge is 3-5 mm, and the paste amount of a blade residual overflow surface 13 is 1-3 mm, the sticking quantity of the water outlet edge of the blade on the flow surface is 1 mm-3 mm. Meanwhile, considering that the wall thickness of the water outlet edge of the casting is small, the warping degree is large, in order to prevent the water outlet edge from deforming in the processes of solidification, boxing and heat treatment, at least two layers of deformation-preventing tie bars 14 are arranged on the water outlet edge of the blade, and the tie bars are directly manufactured through 3D printing; after the quality heat treatment and welding of the casting wheel 1, the anti-deformation lacing wires 14 are removed when the size and the surface roughness of the casting are finally finished.
S003, combining a core assembly and a buried box in a rotating wheel molding process; referring to fig. 4, the runner core 15 is designed by 3D printing, including an inside core 152 and an outside core 151, the blades, the crown and the ring riser 2 are designed as the inside core, and the lower ring and the blind riser 4 are designed as the outside core 151.
S004, molding, assembling and placing the outer sand core 151;
s005, placing the inside sand core 152;
s006, combining the outside sand core 151 and the inside sand core 152 to form the runner sand core 15;
s007, placing a sand box, and carrying out sand burying operation between the runner sand core 15 and the sand box;
and S008, pouring and boxing to obtain the runner casting.
Specifically, as the runner flow channel is long and narrow, the distance between two blades is small, and the traditional forming method is difficult to lift or large in core assembly accumulated error, the forming process of the invention is adopted, the core assembly and the buried box are combined, the runner sand core 15 is divided into an inner sand core 152 and an outer sand core 151, and the inner sand core 152 and the outer sand core 151 are integrally formed by 3D printing.
By adopting the casting method of the runner, the upper crown, the lower ring and the blades of the runner are cast and formed as a whole, so that the combined welding is avoided, the manufacturing cost is reduced, the production period is shortened, the quality of the casting is improved, the manufacturing precision is improved, and the finally obtained runner casting is manufactured into a near-net shape.
The steps in the method of the embodiment of the invention can be sequentially adjusted, combined and deleted according to actual needs.
The technical solutions provided by the present application are introduced in detail, and the principles and embodiments of the present application are explained herein by applying embodiments, and the descriptions of the embodiments are only used to help understand the method and the core ideas of the present application; meanwhile, for a person skilled in the art, according to the idea of the present application, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present application.
Claims (10)
1. A casting method of a runner, the runner including a crown, a band, and a plurality of blades, the casting method comprising:
the runner casting adopts an integral casting process design scheme, a chilling block is arranged on the periphery of a flange of the upper crown, a ring riser is arranged at the joint of the upper crown and each blade, and a blind riser is arranged at the joint of the lower ring and each blade; a patch is arranged between the ring riser and the upper end face of the flange of the upper crown;
the upper crown upper end surface, the upper crown inner cavity and the periphery of the lower ring are provided with non-overflowing surfaces, the upper crown, the lower ring and each blade are provided with overflowing surfaces, and the non-overflowing surfaces and the overflowing surfaces are subjected to fitting amount design;
designing a runner sand core by adopting 3D printing, wherein the runner sand core comprises an inner side sand core and an outer side sand core, each blade, the upper crown and the ring riser are designed into the inner side sand core, and the lower ring and the blind riser are designed into the outer side sand core;
molding and assembling the box and placing the outer sand core;
placing an inner sand core;
the outside sand core and the inside sand core are combined to form the runner sand core;
placing a sand box, and carrying out sand burying operation between the rotary wheel sand core and the sand box;
and pouring and boxing to obtain the runner casting.
2. The method of casting a rotor according to claim 1, wherein the junction of the lower ring and each of the plurality of vanes is in communication with the blind riser via a blind riser neck.
3. The method of casting a rotor according to claim 2, wherein the blind riser necks are equal in number to the number of the blades, and are circumferentially uniformly arranged.
4. The method of casting a rotor according to claim 1, wherein the patches are evenly circumferentially distributed, and the patch width is 200mm to 300 mm.
5. The method of casting a rotor as in claim 4, wherein at least 6 patches are provided.
6. The method for casting a runner according to claim 1, wherein a sticking amount of an upper end surface of the crown is 8mm to 12mm, and a sticking amount of an inner cavity of the crown and an outer periphery of the lower ring is 5mm to 8 mm.
7. The method for casting the runner of claim 1, wherein the attachment of the flow surfaces of the upper crown and the lower ring is 2mm to 4mm, the attachment of the flow surface at a position 200mm to 300mm away from the edge of the water inlet side of each blade is 3mm to 5mm, the attachment of the remaining flow surface of each blade is 1mm to 3mm, and the attachment of the flow surface at the water outlet side of each blade is 1mm to 3 mm.
8. The casting method of the runner according to claim 7, wherein the blade water outlet edge is provided with at least two layers of anti-deformation lacing wires; the deformation-preventing lacing wire is arranged at the position which is 30 mm-50 mm away from the edge of the water outlet edge.
9. The method of casting a rotor according to claim 8, wherein the anti-deformation tie bars are circular in cross-section.
10. The casting method for a runner according to claim 9, wherein the diameter of the anti-deformation tie bar is 1 to 1.2 times the thickness of the blade wall at the profile.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201811411123.9A CN109465406B (en) | 2018-11-24 | 2018-11-24 | Casting method of rotating wheel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201811411123.9A CN109465406B (en) | 2018-11-24 | 2018-11-24 | Casting method of rotating wheel |
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| Publication Number | Publication Date |
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| CN109465406A CN109465406A (en) | 2019-03-15 |
| CN109465406B true CN109465406B (en) | 2020-09-22 |
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| CN201811411123.9A Active CN109465406B (en) | 2018-11-24 | 2018-11-24 | Casting method of rotating wheel |
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Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110434283B (en) * | 2019-07-30 | 2020-11-13 | 共享铸钢有限公司 | Method for casting crown and outer ring casting of water turbine in same box |
| CN110508757A (en) * | 2019-08-31 | 2019-11-29 | 共享铸钢有限公司 | A kind of casting method of blade |
| CN110773707B (en) * | 2019-10-30 | 2021-03-23 | 四川共享铸造有限公司 | Casting method of P-type blade |
| CN111318683A (en) * | 2020-04-21 | 2020-06-23 | 石钢京诚装备技术有限公司 | Production method of large-scale marine anchor lip |
| CN111644577A (en) * | 2020-06-12 | 2020-09-11 | 内蒙古第一机械集团股份有限公司 | Casting method for moving wheel and fixed wheel of comprehensive transmission system of tracked vehicle |
| CN113020547A (en) * | 2021-02-23 | 2021-06-25 | 共享铸钢有限公司 | Casting process of rotating wheel with shaft |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN101987349B (en) * | 2009-07-31 | 2013-01-02 | 鞍钢重型机械有限责任公司 | Casting technology of stainless steel hydroelectric runner lower ring |
| CN104668475A (en) * | 2015-03-12 | 2015-06-03 | 哈尔滨电机厂有限责任公司 | Technical method for modeling integrally-cast bucket runner of water turbine |
| CN108356230A (en) * | 2018-04-27 | 2018-08-03 | 共享智能铸造产业创新中心有限公司 | The casting method and Hydraulic Turbine Rotor of Hydraulic Turbine Rotor |
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