CN110328332A - A kind of sand casting process optimization and preferred method for defect repair - Google Patents

A kind of sand casting process optimization and preferred method for defect repair Download PDF

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Publication number
CN110328332A
CN110328332A CN201910588704.8A CN201910588704A CN110328332A CN 110328332 A CN110328332 A CN 110328332A CN 201910588704 A CN201910588704 A CN 201910588704A CN 110328332 A CN110328332 A CN 110328332A
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optimization
parameter
casting
defect
technique
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Chinese (zh)
Inventor
郑军
周行健
陈安凯
张云
马红萍
凌玮
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Zhejiang Lover Health Science and Technology Development Co Ltd
Zhejiang University of Science and Technology ZUST
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Zhejiang University of Science and Technology ZUST
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Priority to CN201910588704.8A priority Critical patent/CN110328332A/en
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/18—Finishing
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation

Abstract

The invention discloses a kind of for the sand casting process optimization of defect repair and preferred method, method is made of five steps, three kinds of different optimisation strategies are proposed from the angle of parametric classification for existing but incomplete technique, and propose that three kinds of schemes carry out process optimization, finally optimization technique is selected by evaluation index and production requirement.The invention proposes a kind of for the sand casting process optimization of defect repair and preferred method, it can be optimized for the technique for being also easy to produce misrun casting in the design phase, and a variety of optimization directions are provided, multiple-objection optimization can be carried out under the premise of meeting quality requirement；Technological design strategy proposed by the invention can provide optimum ideals for traditional diamond-making techniques such as sand casting, and designer is supported to establish the process program of energy-saving low-carbon in the technological design stage；Implementation of the invention can help traditional sand casting to realize energy-saving and emission-reduction, to support the green and sustainable development of traditional industry.

Description

A kind of sand casting process optimization and preferred method for defect repair
[technical field]
The present invention relates to the technical fields of sand casting, more particularly to the technical field of sand casting process optimization.
[background technique]
In the industrial system of modern society, foundry industry is still in occupation of critical role, wherein most factories also retain Past extensive production method.The energy of these production methods, material utilization are lower, and can generate a large amount of unnecessary carbon Discharge.These all hamper the sustainable development of conventional cast industry.Instantly, realize that the sustainable development of foundry industry has become one A important topic.
The resource rational utilization of traditional manufacture and energy-saving and emission-reduction are always the topical subject that scholars study, and most of Research is all unfolded close around " energy consumption ".In sand casting process, technological level, operational capacity, quality control and production pipe The limitation of the factors such as reason can all cause casting to generate defect, and then influence workpiece quality, increase unnecessary energy consumption.To enterprise For, what is be generally concerned in the past is how to save process time and cost, in the hope of benefit.With mentioning for professional standard The problems such as height, enterprise also increasingly pay attention to environmental protection and energy-saving and emission-reduction, carbon emission seems more and more important.Comprehensively consider casting Part defect and carbon emission problem are optimized and are selected to technique, are the problems in the urgent need to address in the case where low-carbon manufactures background.
In the actual production process, defect Prevention and process optimization be mainly according to computer simulation analysis and field test, And it is carried out with reference to the rule summarized in the past.Although these different methods can improve casting quality, due to causes of defects It is excessively complicated, it can not often optimize from the source of defect, can only be carried out repeatedly by the experience of engineer under normal circumstances It attempts.This is both time-consuming or will increase unnecessary production energy consumption.Therefore, it is necessary to find a kind of process optimization strategy to make to optimize Journey becomes easier and clear.
[summary of the invention]
In order to fill up blank in the prior art, the present invention proposes that a kind of sand casting process for defect repair optimizes And preferred method, it is characterised in that: method comprises the steps of:
Step 1: parametric classification；According to being associated with for design parameter and defect, sand casting process design parameter is divided into casting Part structure class parameter SP, running gate system class parameter GP, process class parameter PP and objectively it is difficult to the parameter DaP tetra- adjusted Part；
Step 2: optimisation strategy and optimization technique are established；To optimize SP, optimize GP and optimize PP as three optimization directions, Building is directed to the optimisation strategy of each autoregressive parameter respectively；It is source from three using initial process and according to the actual demand of specific workpiece A direction, which is set out, to be established three sets and completely optimizes technique: OSP, OGP and OPP, and optimization method is referring to the corresponding ginseng of processing experience adjustments Number；
Step 3: technology assessment standard is determined；Building is with technical process total carbon emission CT, average process process carbon emissionProcess flow material carbon emission CMT, process flow energy carbon emission CET, process flow machine carbon emission CPT, defect area Domain volume ratio η, different schemes are to the contributive rate of carbon sourceRecyclable energy consumption ratio RT′, casting technique yield rate py, new process Setup Cost Δ ET′Etc. evaluation indexes be foundation appraisement system, according to demand determine parameter type and way of contrast；
Step 4: mock survey defect repair situation；Analog simulation is carried out to three sets of optimization techniques respectively, checks emulation knot Whether fruit meets casting quality requirement；It if met, carries out in next step, if do not met, repeats step 2 and re-establish the direction Optimization technique, until technique meets casting quality requirement；
Step 5: evaluation optimization technique；By technology assessment index, from four angles (casting qualities, casting consumption, ring Border influences and economy) optimization method is evaluated, the advantage and disadvantage of each scheme of induction and conclusion, and finally according to the production of factory Condition and castings production need, and each prioritization scheme is merged into preferred plan according to actual processing condition.
Preferably, the casting structure class parameter SP expression is likely to form scarce due to casting structural design problem Sunken parameter includes Element Design size, machining allowance, pattern draft etc.；The running gate system class parameter GP is indicated because of casting System design problem may cause the parameter of defect, include running channel size, cast gate area, pouring type etc.；The process Class parameter PP indicates the parameter that may cause defect because of the unreasonable design in process, includes cooling time, molten metal Temperature, casting rate etc.；The parameter DaP adjusted that is objectively difficult to indicates that defect can be caused but objectively to be difficult to adjust (such as Raw material quality, customer requirement, equipment operation condition etc.) or can not easily optimize (such as raw material ratio, equipment mean power, Operating instruction etc.) sand casting process design parameter.
Preferably, the OSP refers to the optimization technique of optimization structure class parameter SP；The OGP refers to optimizing pouring system class The optimization technique of parameter GP；The OPP refers to the optimization technique of optimization process class parameter PP；The initial process was calculating Ori is expressed as in journey.
Preferably, the part calculation of evaluation index described in step 3 is as follows:
(1)CT=CMT+CET+CPT, wherein T indicates different technical process；
(2)Wherein θTFor casting yield；
(3)Wherein VpTo be poured total volume, VaIndicate the volume of a-th of defect area；
(4)Wherein KT′Indicate the carbon emission in the middle K class carbon source of technical process T ', K0Table Show that the carbon emission of K class carbon source in original process, carbon source include material carbon source CM, energy carbon source CE and machining carbon source CP；
(5)Wherein EcIndicate the economic cost of adjustment c element, EtIndicate that adjustment t is wanted The time cost of element；
Remaining evaluation index can be calculated by given data in production process and detection data；It is described recyclable Energy consumption ratio RT′What is calculated is the percentage for being recovered part resource and accounting for total resources.
Beneficial effects of the present invention: the invention proposes a kind of sand casting process optimization for defect repair and preferably Method can optimize in the design phase for the technique for being also easy to produce misrun casting, and provide a variety of optimization directions, can be full Multiple-objection optimization is carried out under the premise of sufficient quality requirement；Technological design strategy proposed by the invention can pass for sand casting etc. Processing method of uniting provides optimum ideals, and designer is supported to establish the process program of energy-saving low-carbon in the technological design stage；This hair Bright implementation can help traditional sand casting to realize energy-saving and emission-reduction, to support the green and sustainable development of traditional industry.
Feature and advantage of the invention will be described in detail by way of example combination attached drawing.
[Detailed description of the invention]
Fig. 1 is that the present invention is a kind of to be illustrated for the sand casting process optimization of defect repair and the execution process of preferred method Figure；
Fig. 2 is a kind of process design parameter of sand casting process optimization and preferred method for defect repair of the present invention Classification, optimization direction and specific optimization method secondary relationship schematic diagram；
Fig. 3 is that the present invention is a kind of specifically to be optimized for the sand casting process optimization of defect repair and the OSP of preferred method Part and analog result；
Fig. 4 is that the present invention is a kind of specifically to be optimized for the sand casting process optimization of defect repair and the OGP of preferred method Part and analog result；
Fig. 5 is that the present invention is a kind of specifically to be optimized for the sand casting process optimization of defect repair and the OPP of preferred method Part and analog result；
Fig. 6 is that the present invention is a kind of average for the sand casting process optimization of defect repair and whole techniques of preferred method Process flow carbon emission contrast schematic diagram.
[specific embodiment]
Refering to fig. 1~Fig. 6, the present invention is a kind of for the sand casting process optimization of defect repair and preferred method, special Sign is: method comprises the steps of:
Step 1: parametric classification；According to being associated with for design parameter and defect, sand casting process design parameter is divided into casting Part structure class parameter SP, running gate system class parameter GP, process class parameter PP and objectively it is difficult to the parameter DaP tetra- adjusted Part；
Step 2: optimisation strategy and optimization technique are established；To optimize SP, optimize GP and optimize PP as three optimization directions, Building is directed to the optimisation strategy of each autoregressive parameter respectively；It is source from three using initial process and according to the actual demand of specific workpiece A direction, which is set out, to be established three sets and completely optimizes technique: OSP, OGP and OPP, and optimization method is referring to the corresponding ginseng of processing experience adjustments Number；
Step 3: technology assessment standard is determined；Building is with technical process total carbon emission CT, average process process carbon emissionProcess flow material carbon emission CMT, process flow energy carbon emission CET, process flow machine carbon emission CPT, defect area Domain volume ratio η, different schemes are to the contributive rate of carbon sourceRecyclable energy consumption ratio RT′, casting technique yield rate py, new process Setup Cost Δ ET′Etc. evaluation indexes be foundation appraisement system, according to demand determine parameter type and way of contrast；
Step 4: mock survey defect repair situation；Analog simulation is carried out to three sets of optimization techniques respectively, checks emulation knot Whether fruit meets casting quality requirement；It if met, carries out in next step, if do not met, repeats step 2 and re-establish the direction Optimization technique, until technique meets casting quality requirement；
Step 5: evaluation optimization technique；By technology assessment index, from four angles (casting qualities, casting consumption, ring Border influences and economy) optimization method is evaluated, the advantage and disadvantage of each scheme of induction and conclusion, and finally according to the production of factory Condition and castings production need, and each prioritization scheme is merged into preferred plan according to actual processing condition.
Specifically, the casting structure class parameter SP indicates to be likely to form defect due to casting structural design problem Parameter, comprising Element Design size, machining allowance, pattern draft etc.；The running gate system class parameter GP is indicated System design problem may cause the parameter of defect, include running channel size, cast gate area, pouring type etc.；The process class Parameter PP indicates the parameter that may cause defect because of the unreasonable design in process, includes cooling time, molten metal temperature Degree, casting rate etc.；The parameter DaP adjusted that is objectively difficult to indicates that defect can be caused but objectively to be difficult to adjust (such as original Quality of materials, customer requirement, equipment operation condition etc.) or can not easily optimize (such as raw material ratio, equipment mean power, behaviour Make regulation etc.) sand casting process design parameter.
Specifically, the OSP refers to the optimization technique of optimization structure class parameter SP；The OGP refers to that optimizing pouring system class is joined The optimization technique of number GP；The OPP refers to the optimization technique of optimization process class parameter PP；The initial process is in calculating process In be expressed as Ori.
Specifically, the part calculation of evaluation index described in step 3 is as follows:
(1)CT=CMT+CET+CPT, wherein T indicates different technical process；
(2)Wherein θTFor casting yield；
(3)Wherein VpTo be poured total volume, VaIndicate the volume of a-th of defect area；
(4)Wherein KT′It indicates in technical process T′The carbon emission of middle K class carbon source, K0Table Show that the carbon emission of K class carbon source in original process, carbon source include material carbon source CM, energy carbon source CE and machining carbon source CP；
(5)Wherein EcIndicate the economic cost of adjustment c element, EtIndicate that adjustment t is wanted The time cost of element；
Remaining evaluation index can be calculated by given data in production process and detection data；It is described recyclable Energy consumption ratio RT′What is calculated is the percentage for being recovered part resource and accounting for total resources.
The course of work of the invention:
The present invention is a kind of for the sand casting process optimization of defect repair and preferred method, is described with reference to the drawings.
Process optimization is carried out by taking certain wheel-type casting as an example.The casting is made of the trade mark of the gray cast iron of HT200, and quality is 85.53kg, design requirement final finished cannot have the defects of any shrinkage cavity shrinkage porosity.The full-size of casting is 450mm × 450mm × 136mm, thickness wall thickness are about 55mm.The part design parameter of casting initial process is as shown in the table:
Production and simulated experiment are carried out with the parameter.Production is the results show that there is part shrinkage cavity on the cast-internal and surface；It is soft Part analog result shows that defect appears in solidification end, thermal center and wall thickness larger part mostly, referring to Fig. 1, according to mentioning herein Out the step of carry out process optimization and preferably.
Step 1: according to being associated with for design parameter and defect, sand casting process design parameter is divided into casting structure class Parameter SP, running gate system class parameter GP, process class parameter PP and objectively it is difficult to tetra- part parameter DaP adjusted.Respectively Partial key parameter is as follows: SP is wall thickness, machining allowance, processing fillet；GP is riser, running channel size, pouring type；PP is Molten metal temperature, poring rate, equipment adjustable parameter.
Step 2: establishing optimisation strategy and proposes optimization technique；Optimisation strategy is as shown in Fig. 2, specific prioritization scheme is as follows: OSP corresponds to the corresponding increase feeding of adjustment casting section thickness, OGP and simultaneously adjusts running channel size, when OPP corresponds to change mold filling temperature and fills type Between；Prioritization scheme parameter change is as shown in Fig. 3~Fig. 5.
Step 3: technology assessment standard is determined；In this example, technique hardness index is that final finished cannot have any shrinkage cavity to contract The defects of loose, technology assessment index include average process process carbon emissionProcess flow material carbon emission CMT, process flow Energy carbon emission CET, process flow machine carbon emission CPT, defect area volume ratio η, different schemes are to the contributive rate of carbon sourceRecyclable energy consumption ratio RT′, casting technique yield rate py and new process Setup Cost Δ ET′。
Step 4: mock survey defect repair situation；Analog simulation is carried out respectively to three sets of optimization techniques, simulation result is such as Shown in Fig. 3~Fig. 5, three kinds of schemes do not find apparent defect, meet casting quality requirement.
Step 5: evaluation optimization technique；It is to calculate reference standard with average completion single-piece castings, utilizes calculation formula And evaluation method, by initial process and three kinds of optimization techniques respectively to corresponding index calculated wherein to the calculating of carbon emission such as Shown in Fig. 6.This it appears that comparison initial scheme, three kinds of prioritization schemes reduce casting technique carbon row to some extent It puts, the range of decrease is between 21%~24%；Remaining index calculated result of three kinds of prioritization schemes and comparison are as shown in the table:
The information provided according to Fig. 6 and upper table, it is known that three kinds of schemes played in terms of the carbon emission for reducing different carbon source It acts on different.In conjunction with casting medium quantity batch processing, required precision is not high and enterprise is changed without the requirement of equipment and tool as far as possible, Final choice OGP and OPP are incorporated as final production technique.After producing and analogue simulation is tested, the production technology is confirmed It is practical, meet production requirement, and reduce 20% or more average process process carbon emission.
In conjunction with case, the invention proposes a kind of for the sand casting process optimization of defect repair and preferred method, energy It is enough to be optimized for the technique for being also easy to produce misrun casting in the design phase, and a variety of optimization directions are provided, quality can met Multiple-objection optimization is carried out under the premise of it is required that；Technological design strategy proposed by the invention can be the traditional processings such as sand casting Method provides optimum ideals, and designer is supported to establish the process program of energy-saving low-carbon in the technological design stage；Reality of the invention Applying can help traditional sand casting to realize energy-saving and emission-reduction, to support the green and sustainable development of traditional industry.
Above-described embodiment is the description of the invention, is not limitation of the invention, after any pair of simple transformation of the present invention Scheme all belong to the scope of protection of the present invention.

Claims (4)

1. a kind of for the sand casting process optimization of defect repair and preferred method, it is characterised in that: method is by following steps Composition:
Step 1: parametric classification；According to being associated with for design parameter and defect, sand casting process design parameter is divided into casting knot Structure class parameter SP, running gate system class parameter GP, process class parameter PP and objectively it is difficult to parameter DaP tetra- adjusted Point；
Step 2: optimisation strategy and optimization technique are established；To optimize SP, optimization GP and optimization PP for three optimization directions, respectively Building is directed to the optimisation strategy of each autoregressive parameter；It is source from three sides using initial process and according to the actual demand of specific workpiece Establish three sets to setting out and completely optimize technique: OSP, OGP and OPP, optimization method correspond to parameter referring to processing experience adjustments；
Step 3: technology assessment standard is determined；Building is with technical process total carbon emission CT, average process process carbon emission Process flow material carbon emission CMT, process flow energy carbon emission CET, process flow machine carbon emission CPT, defect area body Product is than η, different schemes to the contributive rate of carbon sourceRecyclable energy consumption ratio RT′, casting technique yield rate py, new process tune It is made into this Δ ET′Etc. evaluation indexes be foundation appraisement system, according to demand determine parameter type and way of contrast；
Step 4: mock survey defect repair situation；Analog simulation is carried out to three sets of optimization techniques respectively, checks that simulation result is It is no to meet casting quality requirement；It if met, carries out in next step, if do not met, repeats step 2 and re-establish the excellent of the direction Chemical industry skill, until technique meets casting quality requirement；
Step 5: evaluation optimization technique；By technology assessment index, from four angles (casting qualities, casting consumption, environment shadow Loud and economy) optimization method is evaluated, the advantage and disadvantage of each scheme of induction and conclusion, and finally according to the working condition of factory It is needed with castings production, each prioritization scheme is merged into preferred plan according to actual processing condition.
2. a kind of sand casting process for defect repair as described in claim 1 optimizes and preferred method, feature exist In: the casting structure class parameter SP indicates the parameter that defect is likely to form due to casting structural design problem, includes Element Design size, machining allowance, pattern draft etc.；The running gate system class parameter GP is indicated because Design of Runner System problem can It can lead to the parameter of defect, include running channel size, cast gate area, pouring type etc.；The process class parameter PP indicate because Unreasonable design in process and the parameter that may cause defect, include cooling time, molten metal temperature, casting rate Deng；The parameter DaP adjusted that is objectively difficult to indicates that defect can be caused but objectively to be difficult to adjust (such as raw material quality, visitor Family requirement, equipment operation condition etc.) or can not easily optimize (such as raw material ratio, equipment mean power, operating instruction) Sand casting process design parameter.
3. a kind of sand casting process for defect repair as described in claim 1 optimizes and preferred method, feature exist In: the OSP refers to the optimization technique of optimization structure class parameter SP；The OGP refers to the optimization work of optimizing pouring system class parameter GP Skill；The OPP refers to the optimization technique of optimization process class parameter PP；The initial process is expressed as Ori in calculating process.
4. a kind of sand casting process for defect repair as described in claim 1 optimizes and preferred method, feature exist In: the part calculation of evaluation index described in step 3 is as follows:
(1)CT=CMT+CET+CPT, wherein T indicates different technical process；
(2)Wherein θTFor casting yield；
(3)Wherein VpTo be poured total volume, VaIndicate the volume of a-th of defect area；
(4)Wherein KT′Indicate the carbon emission in the middle K class carbon source of technical process T ', K0Indicate former The carbon emission of K class carbon source in beginning technique, carbon source include material carbon source CM, energy carbon source CE and machining carbon source CP；
(5)Wherein EcIndicate the economic cost of adjustment c element, EtIndicate adjustment t element Time cost；
Remaining evaluation index can be calculated by given data in production process and detection data；The recyclable energy consumption Ratio RT′What is calculated is the percentage for being recovered part resource and accounting for total resources.
CN201910588704.8A 2019-07-02 2019-07-02 A kind of sand casting process optimization and preferred method for defect repair Pending CN110328332A (en)

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Application publication date: 20191015