CN110788276A - Novel casting process for main bearing cap - Google Patents
Novel casting process for main bearing cap Download PDFInfo
- Publication number
- CN110788276A CN110788276A CN201911012848.5A CN201911012848A CN110788276A CN 110788276 A CN110788276 A CN 110788276A CN 201911012848 A CN201911012848 A CN 201911012848A CN 110788276 A CN110788276 A CN 110788276A
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- China
- Prior art keywords
- main bearing
- bearing cap
- casting
- casting process
- wood pattern
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Classifications
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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
- B22C9/22—Moulds for peculiarly-shaped castings
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Sliding-Contact Bearings (AREA)
Abstract
The invention discloses a novel main bearing cap casting process, which comprises the following specific steps of S1, manufacturing a wood pattern according to a casting process diagram, horizontally connecting two main bearing cap blanks to form an X shape, forming an octave inclination angle with the horizontal direction to manufacture an integral wood pattern, fixing the obtained wood pattern on a template in the center, and adopting a frame type wood pattern as a whole and a stripping type wood pattern at the periphery for facilitating pattern stripping. The invention adopts the method of two blanks for conjoined casting, improves the production efficiency, reduces the production cost, saves special tools, replaces a machining cutting mode, improves the processing efficiency, avoids the cost increase caused by the abrasion of a cutter, and can solve the problem of the shrinkage and loosening defect of the main bearing cover of the large-scale engine by controlling the casting process conditions, thereby improving the shrinkage and loosening of the castings, obviously reducing the consumption of metal materials and ensuring the product quality, obviously improving the process yield, having strong practicability and being worthy of popularization.
Description
Technical Field
The invention relates to the technical field of manufacturing of main bearing caps, in particular to a novel casting process of a main bearing cap.
Background
The main bearing cover is known to be one of important parts in diesel engine parts, is made of nodular cast iron (hereinafter referred to as nodular cast iron), is matched with an engine body, needs to bear large alternating impact load, has high quality requirement, does not allow welding repair, does not allow casting defects such as shrinkage cavities (looseness), air holes, slag inclusion, cracks and the like, and the like.
At present, the common main bearing cap casting process has the problems of high production cost and low yield, greatly influences the economic benefit of manufacturers, and solves the problems by urgently needing a novel main bearing cap casting process.
Disclosure of Invention
The invention aims to provide a novel main bearing cap casting process to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a novel main bearing cap casting process comprises the following specific steps:
s1, manufacturing a wood pattern according to a casting process diagram, namely, flatly laying and connecting two main bearing cover blanks to form an X shape, forming an octave inclination angle with the horizontal direction to manufacture an integral wood pattern, fixing the center of the obtained wood pattern on a template, wherein the wood pattern is integrally frame-type and is separated from the periphery in order to facilitate pattern stripping;
s2, filling configured molding sand into the manufactured wood mold, tamping, scraping, and after the molding sand in the wood mold is hardened, pulling out the molding sand in the wood mold from the wood mold to form a sand core;
s3, adopting phenolic resin self-hardening sand for modeling, wherein ferrochrome ore is used in areas of a bearing hole and a riser, a single riser is arranged in the center of an upper plane at the joint of two main bearing cover blanks, a sprue seat is placed at a sprue gate when a group of main bearing covers are poured, the sprue gate is connected with the bottoms of the two main bearing cover blanks, a plurality of conformal chills are connected with the bearing hole of the two main bearing cover blanks, and an exhaust hole is formed in the upper plane of the two main bearing cover blanks to complete the modeling of an upper box and a lower box of a casting;
s4, drying the casting mould by hot air, and then finishing the pouring work;
s5, smelting molten metal by using an induction furnace, wherein the tapping temperature of the molten metal is controlled to be 1400-1500 ℃, the carbon equivalent in the molten iron is controlled to be 3.3-5.5%, and the pouring temperature is 1300-1350 ℃;
s6, performing shakeout, riser cutting, artificial aging, body performance sample extraction according to batches, shot blasting, grinding and heat treatment on the poured main bearing cap;
and S7, carrying out magnetic powder inspection on the surface of the casting, and then inspecting the body performance and appearance of the main bearing cap according to the pouring batch.
Preferably, the upper casting box and the lower casting box are fastened by a mechanical method.
Preferably, the 24-hour tensile strength of the sand mold in S3 is 2.5-2.8 MPa.
Preferably, the carton clamping time in the S3 is 15-22 h.
Preferably, a filter is arranged inside the sprue seat in the step S3.
Preferably, the spacing between the two main bearing cap blanks in S1 is 42-66 mm.
Compared with the prior art, the invention has the beneficial effects that:
the invention adopts the method of conjoined casting of two blanks, improves the production efficiency, reduces the production cost, saves special tools, replaces a machining cutting mode, improves the processing efficiency, avoids the cost increase caused by the abrasion of a cutter, and can control the casting process condition to realize the combined casting of two blanks
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
Examples
The invention provides a novel main bearing cap casting process which specifically comprises the following steps:
s1, manufacturing a wood pattern according to a casting process diagram, flatly laying and connecting the two main bearing cover blanks to form an X shape, forming an octave inclination angle with the horizontal direction to manufacture an integral wood pattern, fixing the obtained wood pattern on a template in the middle, wherein the wood pattern is integrally in a frame type and is in a falling type at the periphery for facilitating pattern drawing, and the distance between the two main bearing cover blanks is 42-66 mm.
And S2, filling the prepared molding sand into the manufactured wood mold, tamping, scraping, and after the molding sand in the wood mold is hardened, pulling out the molding sand in the wood mold from the wood mold to form the sand core.
S3, adopting phenolic resin self-hardening sand to mold, using ferrochrome ore sand in the areas of a bearing hole and a riser, arranging a single riser in the center of the upper plane of the joint of two main bearing cover blanks, placing a sprue seat at the position of a sprue when a group of main bearing covers are poured, arranging a filter plate in the sprue seat, wherein the probability of slag inclusion of the sprue seat for 1 time is lower by arranging the filter plate, in the process of solidifying molten iron, because the resin sand is heated, sulfur-containing gas is emitted, the gas is combined with molten iron to form slag inclusion for 2 times, in addition, in the process of rising molten metal, the surface is easy to oxidize to form slag inclusion for 2 times by contacting with air for a long time, the sprue is connected with the bottoms of the two main bearing cover blanks, if a conformal chill is connected to the bearing hole of the two main bearing cover blanks, an exhaust hole is arranged at the upper plane of the two main bearing cover blanks, and the molding of an upper box and a lower, the upper box and the lower box of the casting are fastened by a mechanical method, the 24-hour tensile strength of the sand mold is 2.5-2.8MPa, and the box clamping time is 15-22 hours;
and S4, hot air drying the casting mold, and then finishing the casting work.
S5, smelting the molten metal by using an induction furnace, wherein the tapping temperature of the molten metal is controlled to be 1400-1500 ℃, the carbon equivalent in the molten iron is controlled to be 3.3-5.5%, and the pouring temperature is 1300-1350 ℃.
And S6, performing shakeout, riser cutting, artificial aging, body performance sample extraction according to batches, shot blasting, grinding and heat treatment on the cast main bearing cap.
And S7, carrying out magnetic powder inspection on the surface of the casting, and then inspecting the body performance and appearance of the main bearing cap according to the pouring batch.
The small-batch trial production is carried out by the process, the process yield is about 90%, the rejection rate of the casting blank is less than 3%, the processing qualification rate of the blank casting is more than 98.2%, the average time for cleaning each main bearing cap is 0.5h, and the production of the high-efficiency and high-quality main bearing caps is realized.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (6)
1. The utility model provides a novel main bearing cap casting process which characterized in that: the casting method comprises the following specific steps:
s1, manufacturing a wood pattern according to a casting process diagram, flatly laying and connecting two main bearing cover blanks to form an X shape, forming an octave inclination angle with the horizontal direction to manufacture an integral wood pattern, fixing the center of the obtained wood pattern on a template, wherein the wood pattern is integrally frame-type and is separated from the periphery in order to facilitate pattern stripping;
s2, filling configured molding sand into the manufactured wood mold, tamping, scraping, and after the molding sand in the wood mold is hardened, pulling out the molding sand in the wood mold from the wood mold to form a sand core;
s3, adopting phenolic resin self-hardening sand for molding, wherein chromite sand is used in areas of a bearing hole and a riser, a single riser is arranged in the center of an upper plane at the joint of two main bearing cover blanks, a sprue seat is placed at a sprue gate when a group of main bearing covers are poured, the sprue gate is connected with the bottoms of the two main bearing cover blanks, a plurality of shape-following chills are connected with the bearing hole positions of the two main bearing cover blanks, and an exhaust hole is formed in the upper plane of the two main bearing cover blanks to complete the molding of an upper box and a lower box of a casting;
s4, drying the casting mould by hot air, and then finishing the pouring work;
s5, smelting molten metal by using an induction furnace, wherein the tapping temperature of the molten metal is controlled to be 1400-1500 ℃, the carbon equivalent in the molten iron is controlled to be 3.3-5.5%, and the pouring temperature is 1300-1350 ℃;
s6, performing shakeout, riser cutting, artificial aging, body performance sample extraction according to batches, shot blasting, grinding and heat treatment on the poured main bearing cap;
and S7, carrying out magnetic powder inspection on the surface of the casting, and then inspecting the body performance and appearance of the main bearing cap according to the pouring batch.
2. The novel main bearing cap casting process according to claim 1, wherein: and the upper casting box and the lower casting box are fastened by a mechanical method.
3. The novel main bearing cap casting process according to claim 1, wherein: the 24-hour tensile strength of the sand mold in the S3 is 2.5-2.8 MPa.
4. The novel main bearing cap casting process according to claim 1, wherein: and the time of the card box in the S3 is 15-22 h.
5. The novel main bearing cap casting process according to claim 1, wherein: and a filter plate is arranged in the sprue seat in the S3 process.
6. The novel main bearing cap casting process according to claim 1, wherein: the spacing between the two main bearing cap blanks in S1 is 42-66 mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911012848.5A CN110788276A (en) | 2019-10-23 | 2019-10-23 | Novel casting process for main bearing cap |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201911012848.5A CN110788276A (en) | 2019-10-23 | 2019-10-23 | Novel casting process for main bearing cap |
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| Publication Number | Publication Date |
|---|---|
| CN110788276A true CN110788276A (en) | 2020-02-14 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201911012848.5A Pending CN110788276A (en) | 2019-10-23 | 2019-10-23 | Novel casting process for main bearing cap |
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1386951A (en) * | 1971-01-16 | 1975-03-12 | British Leyland Austin Morris | Motor vehicle internal combustion engines |
| CN202192211U (en) * | 2011-09-21 | 2012-04-18 | 金坛市鑫特机械有限公司 | Wood mould of anti-cracking bearing seat |
| DE102012023950A1 (en) * | 2012-12-06 | 2014-06-12 | Daimler Ag | Internal combustion engine i.e. lifting cylinder internal combustion engine, for motor vehicle, has valve element integrated into core bearing cap for partial closing of aperture of engine, where aperture is represented by casting kernel |
| CN107127316A (en) * | 2017-06-22 | 2017-09-05 | 营口经济技术开发区爱维尔铸业有限公司 | The device and method of full mold centrifugal casting double plate flange straight tube and flange straight tube through walls |
| CN109396337A (en) * | 2018-11-09 | 2019-03-01 | 中船海洋动力部件有限公司 | A kind of casting method of marine diesel main beating cap |
| CN109396336A (en) * | 2018-11-07 | 2019-03-01 | 河南柴油机重工有限责任公司 | A kind of casting method of middle and high fast high-power diesel engine main beating cap |
-
2019
- 2019-10-23 CN CN201911012848.5A patent/CN110788276A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1386951A (en) * | 1971-01-16 | 1975-03-12 | British Leyland Austin Morris | Motor vehicle internal combustion engines |
| CN202192211U (en) * | 2011-09-21 | 2012-04-18 | 金坛市鑫特机械有限公司 | Wood mould of anti-cracking bearing seat |
| DE102012023950A1 (en) * | 2012-12-06 | 2014-06-12 | Daimler Ag | Internal combustion engine i.e. lifting cylinder internal combustion engine, for motor vehicle, has valve element integrated into core bearing cap for partial closing of aperture of engine, where aperture is represented by casting kernel |
| CN107127316A (en) * | 2017-06-22 | 2017-09-05 | 营口经济技术开发区爱维尔铸业有限公司 | The device and method of full mold centrifugal casting double plate flange straight tube and flange straight tube through walls |
| CN109396336A (en) * | 2018-11-07 | 2019-03-01 | 河南柴油机重工有限责任公司 | A kind of casting method of middle and high fast high-power diesel engine main beating cap |
| CN109396337A (en) * | 2018-11-09 | 2019-03-01 | 中船海洋动力部件有限公司 | A kind of casting method of marine diesel main beating cap |
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Application publication date: 20200214 |
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