CN110640087A - Iron mold sand-lined production process of grouting sleeve - Google Patents
Iron mold sand-lined production process of grouting sleeve Download PDFInfo
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- CN110640087A CN110640087A CN201910964435.0A CN201910964435A CN110640087A CN 110640087 A CN110640087 A CN 110640087A CN 201910964435 A CN201910964435 A CN 201910964435A CN 110640087 A CN110640087 A CN 110640087A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/068—Semi-permanent moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C5/00—Machines or devices specially designed for dressing or handling the mould material so far as specially adapted for that purpose
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/065—Cooling or heating equipment for moulds
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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
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/06—Cast-iron alloys containing chromium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
Abstract
The invention provides an iron mold sand-lined production process of a grouting sleeve, and particularly relates to the technical field of grouting sleeve casting. The invention adopts the sand-lined iron mold process to cast the grouting sleeve, and combines the two technologies of corona film-covering treatment and cooling water temperature reduction, so that the obtained grouting sleeve is not easy to generate air holes and shrinkage porosity defects, the yield is improved, the cost is reduced, and meanwhile, the molten iron formula, the smelting process and the resin for sand-lining are explored and improved, so that the poured grouting sleeve has high mechanical performance. The grouting sleeve obtained by the invention has high dimensional accuracy, has no air holes, shrinkage porosity, slag inclusion, sand holes, cracks and cold shut, has a spheroidization rate of more than or equal to 85 percent, a tensile strength of more than or equal to 650MPa, a hardness of more than or equal to 230HB and an elongation after fracture of more than or equal to 7 percent. The method has the advantages of high yield of 90%, simple operation, controllable parameters, easy realization and suitability for large-scale production.
Description
[ technical field ] A method for producing a semiconductor device
The invention relates to the technical field of grouting sleeve casting, in particular to an iron mold sand-lined production process of a grouting sleeve.
[ background of the invention ]
The grouting sleeve is a connecting part for efficiently and quickly connecting a bearing platform, a pier, a capping beam and a bridge abutment in bridge construction, the mechanical mechanism of the connection is that a high-strength and quick-hardening non-shrinkage cement grouting material is filled in a gap between the grouting sleeve and two steel bars inserted into the grouting sleeve, a joint with a hardened component of the grouting material promotes the two steel bars to form stable connection, and the force in one steel bar is transmitted to the other steel bar.
The grouting sleeve is adopted for splicing and connecting the bridges, is an efficient, environment-friendly, high-quality and low-cost advantageous method, and is a development trend of future bridge construction. At present, the casting method of the grouting sleeve is not reported in documents, so that the uniform casting standard is lacked, the quality of the grouting sleeve on the market is uneven, and the defects of air holes, shrinkage porosity, slag inclusion, sand holes, cracks and cold shut are frequently existed. In order to promote the development and application of the grouting sleeve, it is necessary to provide a sand-lined iron mold production process of the grouting sleeve.
[ summary of the invention ]
The invention aims to: aiming at the problems of few researches on casting methods of grouting sleeves, uneven quality, and defects of air holes, shrinkage porosity, slag inclusion, sand holes, cracks and cold shut, the iron mold sand-lined production process of the grouting sleeves is provided. The grouting sleeve obtained by the invention has high dimensional accuracy, the length deviation is less than +/-4 mm, the outer diameter deviation is less than +/-0.5 mm, the wall thickness deviation is less than +/-0.5 mm, the weight deviation is less than +/-100 g, no pores, shrinkage porosity, slag inclusion, sand holes, cracks and cold shut are generated, the spheroidization rate is more than or equal to 85 percent, the tensile strength is more than or equal to 650MPa, the hardness is more than or equal to 230HB, and the elongation after fracture is more than or equal to 7 percent. The method has the advantages of high yield of 90%, simple operation, controllable parameters, easy realization and suitability for large-scale production.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 4-10mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
b1. cooling: spraying cooling water on the back surface of the film-coated iron mold and the back surface of the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to be below 100 ℃;
c1. making a sand core: taking a core box, and shooting sand to manufacture an integral sand core;
d1. core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 25-35 parts of pig iron, 40-60 parts of scrap steel, 15-25 parts of foundry returns, 2-6 parts of carburant, 1-2 parts of ferrosilicon, 0.1-1 part of copper, 0.1-0.5 part of chromium, 0.5-1.5 parts of manganese, 1-2 parts of nodulizer, 0.5-1.5 parts of silicon-barium inoculant and 0.2-0.8 part of punching sheet;
f1. opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Preferably, the method for preparing molten iron in step e1 includes:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1350-;
b2. arranging a foundry ladle: heating a ladle to 500-600 ℃, adding a nodulizer into the groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel;
c2. spheroidizing: and (4) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1385 and 1415 ℃ to obtain molten iron.
Preferably, the punched sheet is a sheet plane with the thickness of 2-4mm, and the area of the plane is 100-300mm 2.
Further preferably, the pouring method of the molten iron comprises the following steps: controlling the pouring within 5-15 minutes, and adding a silicon-barium inoculant which accounts for 0.1-0.2% of the weight of the molten iron for stream inoculation while pouring.
Still more preferably, the temperature of the cooling water in step b1 is 20-40 ℃, the water pressure is 0.2-0.8MPa, and the flow rate is 600-1000L/h.
Still further preferably, the resin sand is pretreated before being coated with sand in step a1, and the pretreatment method comprises the following steps: taking 31-43 parts of resin sand and 12-24 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:4-8, soaking for 22-36 minutes, then adding 4.5-9.5 parts of soybean protein and 4-14 parts of cyclic olefin copolymer, stirring for 41-61 minutes at the temperature of 120-455 ℃, then filtering, and heating the obtained precipitate for 90-164 minutes at the temperature of 345-455 ℃.
Still further preferably, the resin sand is subjected to corona treatment before sand coating.
Still further preferably, the resin sand is spread flatly to a thickness of 5-15cm for corona treatment.
Still further preferably, the voltage of the corona treatment is 5000-7000V, and the pulse frequency is 15-25 KHz.
Further preferably, the heating temperature of the upper iron mold and the lower iron mold during sand coating in the step a1 is 220 ℃ and 240 ℃, and the curing time is 40-80 seconds; in the step c1, the heating temperature of the core box is 220-240 ℃, and the curing time is 40-80 seconds.
Still further preferably, the upper core and the lower core are manufactured according to the external shape and size of the grouting sleeve, and the combination of the upper core and the lower core can form the external profile of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the shape of the cavity of the lower iron mold is the same as that of the lower core, but the size of the cavity is smaller than that of the lower core, and the size is small enough to just accommodate the sand coating layer; the inner cavity of the core box is manufactured according to the shape and the size of the inner cylinder of the grouting sleeve.
In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:
1. the invention adopts the sand-lined iron mold process to cast the grouting sleeve, and combines the two technologies of corona film-covering treatment and cooling water temperature reduction, so that the obtained grouting sleeve is not easy to generate air holes and shrinkage porosity defects, the yield is improved, the cost is reduced, and meanwhile, the molten iron formula, the smelting process and the resin for sand-lining are explored and improved, so that the poured grouting sleeve has high mechanical performance. The grouting sleeve obtained by the invention has high dimensional accuracy, the length deviation is less than +/-4 mm, the outer diameter deviation is less than +/-0.5 mm, the wall thickness deviation is less than +/-0.5 mm, the weight deviation is less than +/-100 g, no pores, shrinkage porosity, slag inclusion, sand holes, cracks and cold shut are generated, the spheroidization rate is more than or equal to 85 percent, the tensile strength is more than or equal to 650MPa, the hardness is more than or equal to 230HB, and the elongation after fracture is more than or equal to 7 percent. The method has the advantages of high yield of 90%, simple operation, controllable parameters, easy realization and suitability for large-scale production.
2. The resin sand can be more firmly attached to the iron mold to form a uniform sand-coated layer and is not easy to fall off by performing corona pretreatment operation on the resin sand, so that the preparation of the grouting sleeve without slag inclusion and sand holes is facilitated, the dimensional precision and the mechanical property of the grouting sleeve are improved, and the yield is improved. After the resin sand is subjected to high-voltage corona, the surface roughness is increased, the contact area with an iron mold is increased, and the adhesive force is improved. In order to enable the resin sand to receive high-pressure treatment more uniformly, the resin sand is laid to a certain thickness, and proper corona treatment voltage and pulse frequency are fixed, so that the adhesive force of the resin sand after corona is improved to the maximum extent.
The invention also pretreats the resin sand, so that the resin sand has the adsorption function, high air permeability and strong cohesiveness, and the grouting sleeve has a smooth surface, does not have the defects of slag inclusion and sand holes and has high mechanical performance. The added carbon aerogel is a porous three-dimensional network structure, can resist the high temperature of 2000 ℃, and is a gas adsorbent with excellent gas and a gas discharge channel. Adding soybean protein and cycloolefin copolymer, stirring at high temperature with ethanol as solvent to degrade soybean protein into chain structure, wherein amino and hydroxyl can form hydrogen bond with cycloolefin copolymer and resin sand, so that pretreated resin sand has viscosity and is easy to adhere to form stable sand-coated layer. The added ethanol is used as a solvent, has a purifying effect on the resin sand and the carbon aerogel, and can dissolve out impurities to remove the impurities together, so that the exhaust effect of the resin sand is enhanced.
3. The invention adopts cooling water to cool the coated iron mold, can rapidly reduce the temperature of the coated iron mold, and avoids the defects of air holes and shrinkage porosity of the grouting sleeve. Under the general condition, do not have the cooling process just directly to close the case and pour after the iron mold tectorial membrane, resin sand arranges closely this moment, is unfavorable for the discharge of a large amount of gases in the pouring process, makes cast product gas pocket and shrinkage porosity defect appear, and gas discharge is not smooth simultaneously can make product inner structure change, influences the size precision and the mechanical properties of product. Researchers try to place the iron mold after being coated on a production field and naturally cool the iron mold, but the arrangement compactness of resin sand in a sand coating layer after being naturally cooled is not improved, quality defects and precision deviation still occur, and the mechanical performance is not improved. Through multiple creative experimental researches, the invention explores a method for rapidly cooling the film-coated iron mold by using cooling water, so that the resin sand attached to the iron mold shrinks when being instantly cooled, gaps are formed between sand grains, a large amount of gas generated in the casting process is favorably discharged smoothly through the gaps of the resin sand and sand shooting holes, the generation of air holes and shrinkage porosity is effectively avoided, the product yield is improved, the production cost is reduced through the improvement of the yield, and the size precision and the mechanical performance of the product are improved.
The invention can cool the coated iron mold rapidly in a short time by reasonably controlling the temperature, the water pressure and the flow of the cooling water, and form smooth exhaust gaps among resin particles. The excessive water pressure, flow and temperature cannot enhance the exhaust effect of the iron mold, but increase the production cost; and the too small water pressure, flow and too high temperature can make the iron mold cooling incomplete, cause resin sand-lined layer not to exhaust smoothly enough.
4. Through repeated creative experiments, the invention screens out the molten iron formula with low pig iron proportion, obtains products with high yield and high mechanical property, simultaneously reduces the addition of pig iron to the maximum extent, and reduces the production cost from the use of raw materials. The invention adopts the punching sheet to replace the covering agent, and is matched with carburant, ferrosilicon, copper, chromium, manganese, nodulizer and silicon barium inoculant in proper proportion, so that the dosage of pig iron can be reduced, and the grouting sleeve with high mechanical property, no slag inclusion, cold shut, cracks and high mechanical property can be obtained.
The conventional covering agent is easy to form inclusions on the surface of liquid iron, so that the liquid iron is polluted, the flowing property of the liquid iron is influenced, and the manufactured product has slag inclusion, cold shut and cracks. The covering agent is replaced by the Q235 common carbon steel stamping sheet, the stamping sheet is made into a sheet plane with a certain size, so that the stamping sheet can uniformly float on the surface of liquid iron to play a role in heat preservation, meanwhile, the component composition of the stamping sheet is close to that of molten iron, the stamping sheet cannot be encrusted to form inclusions, the performance of the molten iron is not affected, the defects of slag inclusion, cold shut and cracks of products are avoided, and the yield is improved. Wherein, too small a punching sheet causes great processing difficulty, and too large a punching sheet causes no floating on the surface of the liquid iron.
[ detailed description ] embodiments
The present invention will be further described with reference to the following examples.
Example 1
A sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 10mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
the upper mold core and the lower mold core are manufactured according to the shape and the size of the outer cylinder of the grouting sleeve, and the upper mold core and the lower mold core are combined to form the outer contour of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the cavity of the lower iron mold is the same as the lower core in shape, but is smaller than the lower core in size, and the size is small enough to just accommodate the sand coating.
b1. Cooling: spraying cooling water on the back surfaces of the film-coated iron mold and the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to be below 100 ℃;
c1. making a sand core: shooting sand into the inner cavity of the core box to manufacture an integral sand core;
d1. core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup, and adding a silicon-barium inoculant accounting for 0.2 percent of the weight of the molten iron into the molten iron for stream inoculation while pouring the molten iron; the molten iron comprises the following raw materials in parts by weight: 35 parts of pig iron, 60 parts of scrap steel, 25 parts of foundry returns, 6 parts of carburant, 2 parts of ferrosilicon, 1 part of copper, 0.5 part of chromium, 1.5 parts of manganese, 2 parts of nodulizer, 1.5 parts of silicon-barium inoculant and 0.8 part of punching sheet.
The preparation method of the molten iron comprises the following steps:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, a carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1450 ℃, slagging off, and heating to 1600 ℃ to obtain liquid iron;
b2. arranging a foundry ladle: heating a ladle to 600 ℃, adding a nodulizer into the groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel;
c2. spheroidizing: and (4) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1415 ℃ to obtain molten iron.
f1. Opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Example 2
A sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 4mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
the upper mold core and the lower mold core are manufactured according to the shape and the size of the outer cylinder of the grouting sleeve, and the upper mold core and the lower mold core are combined to form the outer contour of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the cavity of the lower iron mold is the same as the lower core in shape, but is smaller than the lower core in size, and the size is small enough to just accommodate the sand coating.
The heating temperature of the upper iron mold and the lower iron mold during sand coating is 220 ℃, and the curing time is 40 seconds.
The resin sand is pretreated before being coated with sand, and the pretreatment method comprises the following steps: taking 31 parts of resin sand and 12 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:4, soaking for 22 minutes, then adding 4.5 parts of soybean protein and 4 parts of cycloolefin copolymer, stirring for 41 minutes at 120 ℃, then filtering, and heating the obtained precipitate for 90 minutes at 345 ℃.
Before sand coating, the pretreated resin sand is flatly paved into a thickness of 5cm for corona treatment, wherein the voltage of the corona treatment is 5000V, and the pulse frequency is 15 KHz.
b1. Cooling: spraying cooling water on the back surfaces of the film-coated iron mold and the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to below 50 ℃;
wherein the temperature of the cooling water is 20 ℃, the water pressure is 0.2MPa, and the flow rate is 600L/h.
c1. Making a sand core: shooting sand into the inner cavity of the core box to manufacture an integral sand core, wherein the inner cavity of the core box is manufactured according to the shape and the size of the inside of the grouting sleeve;
wherein, the heating temperature of the core box is 220 ℃ and the curing time is 40 seconds when the sand core is manufactured.
d1. Core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 25 parts of pig iron, 40 parts of scrap steel, 15 parts of foundry returns, 2 parts of carburant, 1 part of ferrosilicon, 0.1 part of copper, 0.1 part of chromium, 0.5 part of manganese, 1 part of nodulizer, 0.5 part of silicon-barium inoculant and 0.2 part of punching sheet;
the preparation method of the molten iron comprises the following steps:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, a carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1350 ℃, slagging off, and heating to 1500 ℃ to obtain liquid iron;
b2. arranging a foundry ladle: heating a ladle to 500 ℃, adding a nodulizer into the groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel; the punched sheet is a sheet plane with the thickness of 2mm, and the area of the plane is 100mm2；
c2. Spheroidizing: and (c) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1385 ℃ to obtain molten iron.
The pouring method of the molten iron comprises the following steps: and controlling the pouring within 5 minutes, and adding a silicon-barium inoculant accounting for 0.1 percent of the weight of the molten iron for stream inoculation while pouring.
f1. Opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Example 3
A sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 9mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
the upper mold core and the lower mold core are manufactured according to the shape and the size of the outer cylinder of the grouting sleeve, and the upper mold core and the lower mold core are combined to form the outer contour of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the cavity of the lower iron mold is the same as the lower core in shape, but is smaller than the lower core in size, and the size is small enough to just accommodate the sand coating.
The heating temperature of the upper iron mold and the lower iron mold during sand coating is 240 ℃, and the curing time is 80 seconds.
The resin sand is pretreated before being coated with sand, and the pretreatment method comprises the following steps: taking 43 parts of resin sand and 24 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:8, soaking for 36 minutes, then adding 9.5 parts of soybean protein and 14 parts of cyclic olefin copolymer, stirring for 61 minutes at 150 ℃, filtering, and heating the obtained precipitate for 164 minutes at 455 ℃.
Before sand coating, the pretreated resin sand is paved into a thickness of 15cm for corona treatment, wherein the voltage of the corona treatment is 7000V, and the pulse frequency is 25 KHz.
b1. Cooling: spraying cooling water on the back surfaces of the film-coated iron mold and the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to below 60 ℃;
wherein the temperature of the cooling water is 40 ℃, the water pressure is 0.8MPa, and the flow rate is 1000L/h.
c1. Making a sand core: shooting sand into the inner cavity of the core box to manufacture an integral sand core, wherein the inner cavity of the core box is manufactured according to the shape and the size of the inside of the grouting sleeve;
wherein, the heating temperature of the core box is 240 ℃ and the curing time is 80 seconds when the sand core is manufactured.
d1. Core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 26 parts of pig iron, 43 parts of scrap steel, 16 parts of foundry returns, 2.5 parts of carburant, 1.1 parts of ferrosilicon, 0.2 part of copper, 0.3 part of chromium, 0.9 part of manganese, 1.3 parts of nodulizer, 0.9 part of silicon-barium inoculant and 0.3 part of stamping sheet;
the preparation method of the molten iron comprises the following steps:
a2. preparing liquid iron: adding pig iron, scrap steel, foundry returns, carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace in sequence according to the weight part ratio, heating to 1370 ℃, slagging off, and heating to 1520 ℃ to obtain liquid iron;
b2. arranging a foundry ladle: heating a ladle to 510 ℃, adding a nodulizer into the groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel; the punched sheet is a sheet plane with the thickness of 4mm, and the area of the plane is 120mm2。
c2. Spheroidizing: and (c) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1390 ℃ to obtain molten iron.
The pouring method of the molten iron comprises the following steps: and controlling the pouring within 5 minutes, and adding a silicon-barium inoculant accounting for 0.11 percent of the weight of the molten iron for stream inoculation while pouring.
f1. Opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Example 4
A sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 6mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
the upper mold core and the lower mold core are manufactured according to the shape and the size of the outer cylinder of the grouting sleeve, and the upper mold core and the lower mold core are combined to form the outer contour of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the cavity of the lower iron mold is the same as the lower core in shape, but is smaller than the lower core in size, and the size is small enough to just accommodate the sand coating.
The heating temperature of the upper iron mold and the lower iron mold during sand coating is 225 ℃, and the curing time is 50 seconds.
The resin sand is pretreated before being coated with sand, and the pretreatment method comprises the following steps: taking 33 parts of resin sand and 15 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:5, soaking for 25 minutes, then adding 6 parts of soybean protein and 6.5 parts of cyclic olefin copolymer, stirring for 46 minutes at 127 ℃, then filtering, and heating the obtained precipitate for 108 minutes at 372 ℃.
Before sand coating, the pretreated resin sand is spread to be 7cm thick for corona treatment, wherein the voltage of the corona treatment is 5500 volts, and the pulse frequency is 17 KHz.
b1. Cooling: spraying cooling water on the back surfaces of the film-coated iron mold and the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to below 70 ℃;
wherein the temperature of the cooling water is 25 ℃, the water pressure is 0.35MPa, and the flow rate is 700L/h.
c1. Making a sand core: shooting sand into the inner cavity of the core box to manufacture an integral sand core, wherein the inner cavity of the core box is manufactured according to the shape and the size of the inside of the grouting sleeve;
wherein, the heating temperature of the core box is 225 ℃ and the curing time is 50 seconds when the sand core is manufactured.
d1. Core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 28 parts of pig iron, 45 parts of scrap steel, 17 parts of foundry returns, 3 parts of carburant, 1.35 parts of ferrosilicon, 0.4 part of copper, 0.2 part of chromium, 0.8 part of manganese, 1.2 parts of nodulizer, 0.7 part of silicon-barium inoculant and 0.5 part of punching sheet;
the preparation method of the molten iron comprises the following steps:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, a carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1390 ℃, slagging off, and heating to 1540 ℃ to obtain liquid iron;
b2. arranging a foundry ladle: heating a ladle to 525 ℃, adding a nodulizer into the groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel; the punched sheet is a sheet plane with the thickness of 2.5mm, and the area of the plane is 150mm2。
c2. Spheroidizing: and (c) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1395 ℃ to obtain molten iron.
The pouring method of the molten iron comprises the following steps: and controlling the pouring within 5 minutes, and adding a silicon-barium inoculant accounting for 0.13 percent of the weight of the molten iron for stream inoculation while pouring.
f1. Opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Example 5
A sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 8mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
the upper mold core and the lower mold core are manufactured according to the shape and the size of the outer cylinder of the grouting sleeve, and the upper mold core and the lower mold core are combined to form the outer contour of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the cavity of the lower iron mold is the same as the lower core in shape, but is smaller than the lower core in size, and the size is small enough to just accommodate the sand coating.
The heating temperature of the upper iron mold and the lower iron mold during sand coating is 235 ℃, and the curing time is 70 seconds.
The resin sand is pretreated before being coated with sand, and the pretreatment method comprises the following steps: taking 40 parts of resin sand and 21 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:7, soaking for 32 minutes, then adding 8 parts of soybean protein and 11.5 parts of cyclic olefin copolymer, stirring for 56 minutes at 143 ℃, filtering, and heating the obtained precipitate for 145 minutes at 427 ℃.
Before sand coating, the pretreated resin sand is paved into a thickness of 13cm for corona treatment, wherein the voltage of the corona treatment is 6500V, and the pulse frequency is 22 KHz.
b1. Cooling: spraying cooling water on the back surfaces of the film-coated iron mold and the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to below 85 ℃;
wherein the temperature of the cooling water is 35 ℃, the water pressure is 0.65MPa, and the flow rate is 900L/h.
c1. Making a sand core: shooting sand into the inner cavity of the core box to manufacture an integral sand core, wherein the inner cavity of the core box is manufactured according to the shape and the size of the inside of the grouting sleeve;
wherein, the heating temperature of the core box is 235 ℃ and the curing time is 70 seconds when the sand core is manufactured.
d1. Core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 33 parts of pig iron, 55 parts of scrap steel, 23 parts of foundry returns, 5 parts of carburant, 1.7 parts of ferrosilicon, 0.8 part of copper, 0.4 part of chromium, 1.3 parts of manganese, 1.8 parts of nodulizer, 1.2 parts of silicon-barium inoculant and 0.6 part of punching sheet;
the preparation method of the molten iron comprises the following steps:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, a carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1425 ℃, slagging off, and heating to 1570 ℃ to obtain liquid iron;
b2. arranging a foundry ladle: heating a ladle to 575 ℃, adding a nodulizer into a groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel; the punched sheet is a sheet plane with the thickness of 3.5mm, and the area of the plane is 250mm2。
c2. Spheroidizing: and c, adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1410 ℃ to obtain molten iron.
The pouring method of the molten iron comprises the following steps: and controlling the pouring within 5 minutes, and adding a silicon-barium inoculant accounting for 0.17 percent of the weight of the molten iron for stream inoculation while pouring.
f1. Opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Example 6
A sand-lined iron mold production process of a grouting sleeve at least comprises the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 7mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
the upper mold core and the lower mold core are manufactured according to the shape and the size of the outer cylinder of the grouting sleeve, and the upper mold core and the lower mold core are combined to form the outer contour of the whole grouting sleeve; the shape of the upper iron mold cavity is the same as that of the upper core, but the size of the upper iron mold cavity is smaller than that of the upper core, and the size of the upper iron mold cavity is small enough to just accommodate the sand coating; the cavity of the lower iron mold is the same as the lower core in shape, but is smaller than the lower core in size, and the size is small enough to just accommodate the sand coating.
The heating temperature of the upper iron mold and the lower iron mold during sand coating is 230 ℃, and the curing time is 60 seconds.
The resin sand is pretreated before being coated with sand, and the pretreatment method comprises the following steps: taking 37 parts of resin sand and 18 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:6, soaking for 29 minutes, then adding 7 parts of soybean protein and 9 parts of cyclic olefin copolymer, stirring for 51 minutes at 135 ℃, then filtering, and heating the obtained precipitate for 127 minutes at 400 ℃.
Before sand coating, the pretreated resin sand is paved into a thickness of 10cm for corona treatment, wherein the voltage of the corona treatment is 6000V, and the pulse frequency is 20 KHz.
b1. Cooling: spraying cooling water on the back surfaces of the film-coated iron mold and the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to below 75 ℃;
wherein the temperature of the cooling water is 30 ℃, the water pressure is 0.5MPa, and the flow rate is 800L/h.
c1. Making a sand core: shooting sand into the inner cavity of the core box to manufacture an integral sand core, wherein the inner cavity of the core box is manufactured according to the shape and the size of the inside of the grouting sleeve;
wherein, the heating temperature of the core box is 230 ℃ and the curing time is 60 seconds when the sand core is manufactured.
d1. Core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 30 parts of pig iron, 50 parts of scrap steel, 20 parts of foundry returns, 3.9 parts of carburant, 1.5 parts of ferrosilicon, 0.6 part of copper, 0.3 part of chromium, 1 part of manganese, 1.5 parts of nodulizer, 1 part of silicon-barium inoculant and 0.4 part of punching sheet;
the preparation method of the molten iron comprises the following steps:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, a carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1400 ℃, slagging off, and heating to 1550 ℃ to obtain liquid iron;
b2. arranging a foundry ladle: heating the ladle to 550 ℃, and adding the balls into the groove of the ladleFlattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer for compaction; the stamping sheet is made of Q235 common carbon steel; the punched sheet is a sheet plane with the thickness of 3mm, and the area of the plane is 200mm2。
c2. Spheroidizing: and (c) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1400 ℃ to obtain molten iron.
The pouring method of the molten iron comprises the following steps: and controlling the pouring within 5 minutes, and adding a silicon-barium inoculant accounting for 0.15 percent of the weight of the molten iron for stream inoculation while pouring.
f1. Opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
Example 7
The difference from example 6 is that natural cooling is used in step b1, and cooling water is not used. The rest of the procedure was the same as in example 6.
Example 8
The difference from example 6 is that in step b1, no cooling is performed, and core mounting and mould assembling are performed directly for casting. The other methods are the same as
Example 6.
Example 9
The difference from example 6 is that the temperature of the cooling water in step b1 was 45 ℃. The rest of the procedure was the same as in example 6.
Example 10
The difference from example 6 is that the water pressure of the cooling water in step b1 was 0.15 MPa. The rest of the procedure was the same as in example 6.
Example 11
The difference from example 6 is that the flow rate of the cooling water in step b1 was 570L/hr. The rest of the procedure was the same as in example 6.
Example 12
The difference from example 6 is that the resin sand was not subjected to corona treatment in step a1. The rest of the procedure was the same as in example 6.
Example 13
The difference from example 6 is that step a1 does not pretreat the resin sand, but does corona treatment. The other methods are the same as
Example 6.
Example 14
The difference from example 6 is that conventional covering agent was used instead of punched out sheet in step c1. The rest of the procedure was the same as in example 6.
Example 15
The difference from example 6 is that the thickness of the punched piece in step c1 is 5 mm. The rest of the procedure was the same as in example 6.
Example 16
The difference from example 6 is that the area of the plane of the punched piece in step c1 is 350mm2. The rest of the procedure was the same as in example 6.
Example 17 comparison of effects
1. Preparation of test samples
Prepared according to the methods of examples 1, 4, 6, 7-16, 50 replicates of each example were prepared to yield experimental samples 1, 4, 6, 7-16.
2. Evaluation method
The test samples 1, 4, 6, and 7 to 16 were subjected to appearance evaluation, and the length variation, outer diameter variation, wall thickness variation, weight variation, spheroidization ratio, tensile strength, hardness, and elongation after fracture were measured. The nodulizing rate is positively correlated with the mechanical property of the product, but the mechanical property of the product is also influenced by other links in the production process, so that the nodulizing rate can only reflect the quality of the mechanical property from one side surface and is not a determining factor, and therefore, the indicating function of the nodulizing rate can be embodied under the condition that all production links are reasonably controlled, and the grouting sleeve with excellent mechanical property is obtained.
3. Evaluation results
TABLE 1 evaluation results of appearance and size of grouting sleeve
Table 2 evaluation results of physical properties of grouting sleeve
4. Results of the experiment
As can be seen from tables 1 and 2, the quality of experimental sample 6 was the best.
The experimental sample 7 does not adopt cooling water to cool the iron mold, but naturally cools the iron mold, and the experimental sample 8 does not cool the iron mold, so that good gaps are not formed among resin sand particles of a sand-coated layer, and the air is difficult to exhaust during pouring, so that the product has obvious air holes and shrinkage porosity, and has very large size deviation and weight deviation and very poor mechanical performance.
The cooling water temperature of 9 cooling iron types of experimental sample is higher, and the cooling water pressure of 10 cooling iron types of experimental sample is lower, and the cooling water flow of 11 cooling iron types of experimental sample is less, all can't fully permeate the iron type depths, makes the iron type cooling thoroughly inadequately, and it is not smooth to appear covering sand layer exhaust when making the pouring, makes the product appear gas pocket and shrinkage porosity of different degrees, and size deviation and weight deviation increase, and mechanical properties descends.
Experimental sample 12 does not carry out corona treatment to resin sand, and experimental sample 13 does not carry out preliminary treatment to resin sand, all can make tectorial membrane sand distribution inhomogeneous, has influenced subsequent pouring, leads to the product size deviation and weight deviation to appear, and mechanical properties also reduces thereupon.
When the experimental sample 14 is used for smelting molten iron, the conventional covering agent is adopted to replace a punching sheet, so that the product has obvious slag inclusion, cracks and cold shut, the size deviation and the weight deviation are increased, and the mechanical property is obviously reduced.
When the experimental sample 15 is used for smelting molten iron, the punching sheet is too thick, and when the experimental sample 16 is used for smelting molten iron, the area of the punching sheet is too large, so that slag inclusion, cracks and cold shut of products in different degrees can be caused, the size deviation and the weight deviation are increased, and the mechanical performance is reduced.
The above description is intended to describe in detail the preferred embodiments of the present invention, but the embodiments are not intended to limit the scope of the claims of the present invention, and all equivalent changes and modifications made within the technical spirit of the present invention should fall within the scope of the claims of the present invention.
Claims (7)
1. The sand-lined iron mold production process of the grouting sleeve is characterized by at least comprising the following steps:
a1. modeling: taking an upper iron mold with a cavity on the front surface, placing the upper mold core into the cavity, injecting resin sand from a sand injection hole to sand the front surface of the upper iron mold, wherein the thickness of the sand-coated layer is 4-10mm to obtain a coated upper iron mold, and performing sand coating on the front surface of a lower iron mold by adopting a lower mold core same method to obtain a coated lower iron mold;
b1. cooling: spraying cooling water on the back surface of the film-coated iron mold and the back surface of the film-coated iron mold to reduce the temperature of the film-coated iron mold and the film-coated iron mold to be below 100 ℃;
c1. making a sand core: taking a core box, and shooting sand to manufacture an integral sand core;
d1. core assembling and mould assembling: placing the sand core into a cavity of the iron mold under the film, combining the cavity of the iron mold on the film with the cavity of the iron mold under the film, and installing a pouring cup after fixing;
e1. pouring: pouring molten iron into the cavity through the pouring cup; the molten iron comprises the following raw materials in parts by weight: 25-35 parts of pig iron, 40-60 parts of scrap steel, 15-25 parts of foundry returns, 2-6 parts of carburant, 1-2 parts of ferrosilicon, 0.1-1 part of copper, 0.1-0.5 part of chromium, 0.5-1.5 parts of manganese, 1-2 parts of nodulizer, 0.5-1.5 parts of silicon-barium inoculant and 0.2-0.8 part of punching sheet;
f1. opening the box: after the casting is finished and the casting is solidified, opening the iron mold, and taking out the casting to obtain a blank;
g1. cleaning: and cleaning, shot blasting and polishing the blank to obtain the grouting sleeve.
2. The sand-lined metal mold production process of a grouting sleeve as claimed in claim 1, wherein the molten iron in the step e1 is prepared by the following steps:
a2. preparing liquid iron: sequentially adding pig iron, scrap steel, foundry returns, carburant, ferrosilicon, copper, chromium and manganese into a smelting furnace according to the weight part ratio, heating to 1350-;
b2. arranging a foundry ladle: heating a ladle to 500-600 ℃, adding a nodulizer into the groove of the ladle, flattening, adding a silicon-barium inoculant to cover the nodulizer, and covering a stamping sheet on the nodulizer to compact; the stamping sheet is made of Q235 common carbon steel;
c2. spheroidizing: and (4) adding liquid iron into the ladle arranged in the step b2 for spheroidization, and then cooling to 1385 and 1415 ℃ to obtain molten iron.
3. The sand-lined metal mold production process for grouting sleeves as claimed in claim 2, wherein the stamping sheet is a sheet-shaped plane with a thickness of 2-4mm, and the area of the plane is 100-300mm2。
4. The sand-lined metal mold production process of the grouting sleeve according to claim 2 or 3, wherein the molten iron pouring method comprises the following steps: controlling the pouring within 5-15 minutes, and adding a silicon-barium inoculant which accounts for 0.1-0.2% of the weight of the molten iron for stream inoculation while pouring.
5. The sand-lined metal mold production process of a grouting sleeve as claimed in claim 1, wherein the temperature of the cooling water in step b1 is 20-40 ℃, the water pressure is 0.2-0.8MPa, and the flow rate is 600-1000L/h.
6. The sand lined metal mold production process of a grouting sleeve as claimed in claim 1, wherein the resin sand is pretreated before being coated with sand in step a1, and the pretreatment method comprises the following steps: taking 31-43 parts of resin sand and 12-24 parts of carbon aerogel according to the weight part ratio, uniformly mixing, adding ethanol according to the material-liquid ratio of 1:4-8, soaking for 22-36 minutes, then adding 4.5-9.5 parts of soybean protein and 4-14 parts of cyclic olefin copolymer, stirring for 41-61 minutes at the temperature of 120-455 ℃, then filtering, and heating the obtained precipitate for 90-164 minutes at the temperature of 345-455 ℃.
7. The sand lined swage production process of claim 1 or 6, wherein the resin sand is subjected to corona treatment before sand lining.
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| CN112878507A (en) * | 2021-03-24 | 2021-06-01 | 济南一建集团绿色建筑产业有限公司 | Reinforced full grouting sleeve and casting molding method thereof |
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