CN110842150B - Assembled frog casting system and method - Google Patents
Assembled frog casting system and method Download PDFInfo
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- CN110842150B CN110842150B CN201911234410.1A CN201911234410A CN110842150B CN 110842150 B CN110842150 B CN 110842150B CN 201911234410 A CN201911234410 A CN 201911234410A CN 110842150 B CN110842150 B CN 110842150B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/088—Feeder heads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses an assembled frog casting system and a casting method, wherein the system comprises a pouring system, the pouring system is communicated with frog toe ends of frog cavities formed in a casting mold; the pouring system comprises a pouring gate assembly and a pouring feeding open riser assembly. According to the assembled frog casting system, the toe end pouring system is provided with a pouring feeding open riser; a casting adopts necking blind risers which are heated and insulated, and the risers are all arranged among the holes; strip-shaped open chill is matched with the top surface of the rail between the risers; pouring in an inclined manner; after pouring, a cold box opening process is adopted, and the casting is hammered to remove a riser at room temperature. Under the condition of inclined pouring, sequential solidification is realized, the cooperation of the heating and heat-insulating riser and the chill is added, the rail surface of the frog is fully fed, the riser is removed in a hammering mode after the box is opened, cracks caused by flame cutting are avoided, and casting defects such as shrinkage cavity and shrinkage porosity are completely eliminated through radiographic inspection.
Description
Technical Field
The invention relates to the technical field of manufacturing of high manganese steel frog castings, in particular to an assembled frog casting system.
Background
Cast manganese-steel frog refers to a frog cast in one piece from high manganese steel. The high manganese steel has higher strength and impact toughness. The whole casting can be randomly shaped, and the size and the appearance of each part of the frog are made to meet the requirements of stable driving as much as possible.
In the prior art, all the split mounting type high manganese steel frog castings are cast in a common industrial frog casting mode, and cast products have the casting defects of shrinkage cavity, shrinkage porosity and the like, and cannot meet the requirements of radiographic inspection quality levels specified by the American AREMA standard, so that the split mounting type high manganese steel frog castings cannot enter North America first-level lines, and the overseas market expansion is limited.
Disclosure of Invention
The invention provides a system and a method for casting an assembled frog. The quality of the casting completely meets the radiographic inspection quality standard level specified in AREMA standard specification, the casting defects of shrinkage cavity, shrinkage porosity and the like are eliminated, the internal quality of the casting is greatly improved, the market competitiveness is enhanced, and the method has great significance for stabilizing and expanding overseas markets.
The invention provides the following scheme:
a spliced frog casting system comprising:
the pouring system is communicated with a frog toe end of a frog cavity formed in the casting mold; the pouring system comprises a pouring gate assembly and a pouring feeding open riser assembly, and the pouring feeding open riser assembly is positioned between the pouring gate assembly and the casting mold;
a plurality of riser assemblies each positioned above the casting mold and in communication with the frog cavity, each riser assembly positioned horizontally between two adjacent casting holes; the riser assembly comprises a necking type heating and heat-insulating blind riser part and a heating and heat-insulating riser part connected with the necking type heating and heat-insulating blind riser part;
and a plurality of open chills are all positioned at the bottom of the casting mold, and each open chill is positioned between two adjacent riser assemblies in the horizontal direction.
Preferably: the pouring feeding open riser assembly comprises a conical riser cavity with a large upper part and a small lower part, and the inclination of the riser cavity is 1: 1.5.
Preferably: the size of a riser of the riser assembly is determined according to the modulus of the riser and the amount of liquid metal required to be fed to the casting.
Preferably: the diameter of the feeding neck of the neck type heating and heat-preserving hidden riser is 100 mm, and the wall thickness of the riser sleeve is 25 mm.
Preferably: the inner dimension of the heating and heat-insulating top opening part between the frog toe end of the frog cavity and the frog middle rail bottom is 170 mm multiplied by 200 mm, the inner dimension of the heating and heat-insulating top opening part at the heel end opening wide section of the frog cavity is 190 mm multiplied by 200 mm, and the inner dimension of the heating and heat-insulating top opening part at the heel end interval iron of the frog cavity is 150 mm multiplied by 160 mm.
Preferably: the bright chill is a strip bright chill with the thickness of 50 mm.
A casting method using the spliced frog casting system, the method comprising:
pouring by adopting an inclined pouring process; the casting temperature of the molten steel is 1450 +/-10 ℃;
and (4) performing shakeout by adopting a cold box opening process 22-24 hours after the pouring is finished, and hammering by using a pneumatic hammer to remove a riser assembly when the casting is placed to room temperature.
Preferably: the inclination angle of the inclined pouring process is 6 degrees.
Preferably: the inclined pouring process further comprises the step of performing the secondary pouring for 2 times when the surface liquid descends 1/3 after the molten steel is fully poured on the pouring feeding open riser assembly.
Preferably: the cold box opening process comprises a vibration shakeout method.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
in one implementation mode, the system can comprise a pouring system which is communicated with frog toe ends of frog cavities formed in a casting mold; the pouring system comprises a pouring gate assembly and a pouring feeding open riser assembly, and the pouring feeding open riser assembly is positioned between the pouring gate assembly and the casting mold; a plurality of riser assemblies each positioned above the casting mold and in communication with the frog cavity, each riser assembly positioned horizontally between two adjacent casting holes; the riser assembly comprises a necking type heating and heat-insulating blind riser part and a heating and heat-insulating riser part connected with the necking type heating and heat-insulating blind riser part; and a plurality of open chills are all positioned at the bottom of the casting mold, and each open chill is positioned between two adjacent riser assemblies in the horizontal direction. According to the assembled frog casting system, the toe end pouring system is provided with a pouring feeding open riser; a casting adopts necking blind risers which are heated and insulated, and the risers are all arranged among the holes; strip-shaped open chill is matched with the top surface of the rail between the risers; pouring in an inclined manner; after pouring, a cold box opening process is adopted, and the casting is hammered to remove a riser at room temperature. Under the condition of inclined pouring, sequential solidification is realized, the cooperation of the heating and heat-insulating riser and the chill is added, the rail surface of the frog is fully fed, the riser is removed in a hammering mode after the box is opened, cracks caused by flame cutting are avoided, and casting defects such as shrinkage cavity and shrinkage porosity are completely eliminated through radiographic inspection.
Of course, it is not necessary for any product in which the invention is practiced to achieve all of the above-described advantages at the same time.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
Fig. 1 is a schematic structural diagram of a spliced frog casting system according to an embodiment of the present invention;
fig. 2 is a schematic view of a prior art casting system for a spliced frog assembly provided in accordance with an embodiment of the present invention;
fig. 3 is a schematic diagram of the position of a ray during ray detection.
In the figure: the casting device comprises a pouring gate component 1, a pouring and feeding open riser component 2, a necking type heating and heat-insulating blind riser part 3, heating and heat-insulating riser parts 4a-4c, open chills 5, a casting mold 6, a casting hole 7 and an exhaust hole 8.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.
Examples
Referring to fig. 1, a spliced frog casting system according to an embodiment of the present invention is shown in fig. 1, and includes a gating system, which is communicated with frog toe ends of frog cavities formed inside a casting mold 6; the pouring system comprises a pouring gate component 1 and a pouring feeding open riser component 2, wherein the pouring feeding open riser component 2 is positioned between the pouring gate component 1 and the casting mold 6; further, the pouring feeding open riser assembly 2 comprises a conical riser cavity with a large upper part and a small lower part, and the inclination of the riser cavity is 1: 1.5. The assembled frog casting system in the prior art adopts inclined pouring, the pouring system at the toe end is only provided with an exhaust hole without a feeding head, and because the pouring end is cooled slowly, if the subsequent molten steel is not supplied enough, the feeding amount is insufficient, and the end face of the pouring end has the defect of shrinkage cavity. According to the scheme provided by the application, a pouring feeding open riser is arranged on a pouring system at the toe end of the frog to replace an original exhaust hole; the sprue gate passes through a gating system of the riser, so that the feeding effect of the riser is enhanced. The open riser is made of a wood mold, the upper part of the open riser is large and the lower part of the open riser is small, the bottom of the open riser is phi 150 multiplied by 300mm, the inclination is 1:15, a riser cavity is formed by a sand mold in the molding process, after the open riser is fully cast with molten steel, the top-view liquid is poured for 2 times when descending 1/3, so that the subsequent molten steel supply in the high-temperature molten steel shrinkage process is ensured, and the shrinkage cavity and shrinkage porosity defect of the end face caused by insufficient feeding amount is prevented.
A plurality of riser assemblies each located above the casting mold 6 and in communication with the frog cavity, each riser assembly being located horizontally between two adjacent casting holes 7; the riser assembly comprises a necking type heating and heat-insulating blind riser part 3 and a heating and heat-insulating riser part connected with the necking type heating and heat-insulating blind riser part; further, the size of a riser of the riser assembly is determined according to the modulus of the riser and the amount of metal liquid required for feeding the casting. The diameter of the neck type heating and heat-insulating blind riser part 3 is 100 mm, and the wall thickness of the riser sleeve is 25 mm. In practical application, when setting up the rising head subassembly, can set up according to the needs of part casting, this application embodiment can provide and be located between frog toe end to the frog middle part rail bottom of frog cavity the internal dimension of fever heat preservation fag end portion 4a is 170 millimeters x 200 millimeters, is located the heel end opening wide section department of frog cavity the internal dimension of fever heat preservation fag end portion 4b is 190 millimeters x 200 millimeters, is located the heel end interval iron department of frog cavity the internal dimension of fever heat preservation fag end portion 4c is 150 millimeters x 160 millimeters.
The assembly frog casting system in the prior art adopts a straight-through type common easy-cutting riser, an easy-cutting piece is made of resin olivine sand with the thickness of 30mm, and a necking part is solidified firstly to block a feeding channel, so that shrinkage cavity and shrinkage porosity at the root of the riser are caused. Important parts such as a center rail, throats and openings are selected at the positions of the risers, the distance is 450mm, feeding efficiency of common risers is low, cold iron is placed in a small amount, and the influence of 13 cast hole sand cores on feeding is ignored, so that shrinkage porosity is generated near holes. In the scheme provided by the application, the risers are arranged between every 2 holes, so that the feeding channel is smooth. Because the high manganese steel has poor processability, 14 holes in the casting are cast, the 14 holes are positioned on the feeding channel of the central axis to obstruct feeding, and the area near the sand core is cooled more quickly, which brings certain difficulty to feeding, therefore, in order to eliminate shrinkage porosity, the risers are reasonably placed, the feeding channel cannot be interrupted by the sand core, and therefore, the risers are all selected to be arranged between every 2 holes. The high manganese steel has large body shrinkage value and large tendency of forming porosity, and various technological measures are required to strengthen feeding, so that a riser with large heat productivity, good heat insulation effect and high feeding efficiency is adopted, external chill is matched with the riser, and the riser is subjected to casting during pouring. Taking an American assembled high manganese steel frog casting as an example, according to the structure and the wall thickness of the casting, the size of a dead head is determined by calculating the modulus of the dead head and the amount of liquid metal required for feeding the casting as follows: the neck-type heating and heat-insulating blind riser with a repaired neck of phi 100 has the wall thickness of 25mm, the end head of a toe end to the middle rail bottom is provided with 4a, the inner dimension phi is 170 multiplied by 200, the wide section of a heel end opening is provided with 4b, the inner dimension phi is 190 multiplied by 200, the heel end spacer iron is provided with 4c, and the inner dimension phi is 150 multiplied by 160.
A plurality of open chilling blocks 5, wherein a plurality of open chilling blocks 5 are all positioned at the bottom of the casting mold 6, and each open chilling block 5 is positioned between two adjacent riser assemblies in the horizontal direction. Further, the bright chill 5 is a strip bright chill with a thickness of 50 mm. The top surface of the rail between the risers is matched with a strip-shaped open chill with the thickness of 50mm, so that the sequential solidification of the casting is enhanced, the effective feeding distance of the risers is enlarged, and the defect of shrinkage cavity and shrinkage porosity of the casting is prevented. In this application embodiment, correspond every cast hole and all set up an open chill at frog toe end to heel end opening wide section department, set up an open chill with end interval iron department. The chill placed on the surface of the pattern during molding is called the bright chill (external chill). The external chill is used as a part of the casting mould, is not fused with the casting and can be repeatedly used. The shape of the external chill is generally designed or selected based on the shape of the portion of the casting that needs to be chilled.
The embodiment of the present application may further provide a casting method using the assembled frog casting system, where the method includes:
pouring by adopting an inclined pouring process; the casting temperature of the molten steel is 1450 +/-10 ℃; specifically, the inclination angle of the inclined pouring process is 6 degrees. The inclined pouring process further comprises the step of performing the secondary pouring for 2 times when the surface liquid descends 1/3 after the molten steel is fully poured on the pouring feeding open riser assembly.
And (4) performing shakeout by adopting a cold box opening process 22-24 hours after the pouring is finished, and hammering by using a pneumatic hammer to remove a riser assembly when the casting is placed to room temperature. Specifically, the cold box opening process comprises a vibration shakeout method. In the prior art, a high-temperature water explosion sand cleaning method is adopted for sand cleaning during casting of the assembled frog, and an oxygen flame is used for cutting and removing a riser after the high-temperature water explosion sand cleaning. This application adopts the cold good solution above-mentioned problem of case method of opening.
And opening the box 22-24 hours after pouring, measuring that the temperature of the casting body is between 200 and 300 ℃, vibrating for shakeout, and hammering and removing the riser by using a pneumatic hammer at room temperature. In the prior art, the pouring temperature is 1470 +/-10 ℃ and is controlled to be higher during casting of the assembled frog, the tendency of forming shrinkage cavity and shrinkage porosity is higher, a coarse dendritic crystal structure is easily formed, feeding conditions are worsened, more serious micro shrinkage porosity among dendrites is caused, and the density is reduced. In order to ensure the quality of the frog, the pouring temperature is strictly controlled to 1450 +/-10 ℃ in the operation in the scheme provided by the application, and the re-pouring during pouring is enhanced.
The method can effectively solve the problem of the inherent quality of the spliced high manganese steel frog casting, is simple and convenient to operate, improves the casting quality, reduces the waste loss and enhances the market competitiveness.
The high manganese steel frog core formed by casting by the casting method provided by the application is inspected by adopting a ray inspection method, and the technical indexes and inspection results of the inspection items are shown in the following table.
The above table shows that the scheme provided by the application effectively solves the quality problem of the assembled high manganese steel frog casting, so that the assembled high manganese steel frog casting completely meets the radiographic inspection quality standard level specified in AREMA standard specification, and the product competitiveness is greatly enhanced.
In a word, the toe end pouring system of the assembled frog casting system is provided with a pouring feeding open riser; a casting adopts necking blind risers which are heated and insulated, and the risers are all arranged among the holes; strip-shaped open chill is matched with the top surface of the rail between the risers; pouring in an inclined manner; after pouring, a cold box opening process is adopted, and the casting is hammered to remove a riser at room temperature. Under the condition of inclined pouring, sequential solidification is realized, the cooperation of the heating and heat-insulating riser and the chill is added, the rail surface of the frog is fully fed, the riser is removed in a hammering mode after the box is opened, cracks caused by flame cutting are avoided, and casting defects such as shrinkage cavity and shrinkage porosity are completely eliminated through radiographic inspection.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.
The above description is only for the preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention shall fall within the protection scope of the present invention.
Claims (6)
1. A sectional frog casting system, comprising:
the pouring system is communicated with a frog toe end of a frog cavity formed in the casting mold; the pouring system comprises a pouring gate assembly and a pouring feeding open riser assembly, and the pouring feeding open riser assembly is positioned between the pouring gate assembly and the casting mold; the pouring feeding open riser assembly comprises a conical riser cavity with a large upper part and a small lower part, and the inclination of the riser cavity is 1: 1.5;
a plurality of riser assemblies each positioned above the casting mold and in communication with the frog cavity, each riser assembly positioned horizontally between two adjacent casting holes, each casting hole positioned on a central axis feeding channel; the riser assembly comprises a necking type heating and heat-insulating blind riser part and a heating and heat-insulating riser part connected with the necking type heating and heat-insulating blind riser part; the size of a riser of the riser assembly is determined according to the modulus of the riser and the amount of liquid metal required to be fed to the casting; the diameter of a feeding neck of the neck type heating and heat-insulating hidden riser part is 100 mm, and the wall thickness of the riser sleeve is 25 mm; the inner dimension of the heating and heat-insulating top opening part between the frog toe end of the frog cavity and the frog middle rail bottom is 170 mm multiplied by 200 mm, the inner dimension of the heating and heat-insulating top opening part at the heel end opening wide section of the frog cavity is 190 mm multiplied by 200 mm, and the inner dimension of the heating and heat-insulating top opening part at the heel end interval iron of the frog cavity is 150 mm multiplied by 160 mm;
and a plurality of open chills are all positioned at the bottom of the casting mold, and each open chill is positioned between two adjacent riser assemblies in the horizontal direction.
2. The spliced frog casting system of claim 1 wherein said bright chill is a strip bright chill having a thickness of 50 mm.
3. A casting method using the split frog casting system of any of claims 1 to 2, wherein the method comprises:
pouring by adopting an inclined pouring process; the casting temperature of the molten steel is 1450 +/-10 ℃;
and (4) performing shakeout by adopting a cold box opening process 22-24 hours after the pouring is finished, and hammering by using a pneumatic hammer to remove a riser assembly when the casting is placed to room temperature.
4. The method of claim 3, wherein the angle of inclination of the angle-pouring process is 6 °.
5. The method of claim 3, wherein the tilt-casting process further comprises topping-up 2 times with surface liquid descending 1/3 after the molten steel has filled the feeding open riser assembly.
6. The method of claim 3, wherein the cold box-opening process comprises a shake-out method.
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| Application Number | Priority Date | Filing Date | Title |
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| CN201911234410.1A CN110842150B (en) | 2019-12-05 | 2019-12-05 | Assembled frog casting system and method |
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| CN201911234410.1A CN110842150B (en) | 2019-12-05 | 2019-12-05 | Assembled frog casting system and method |
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| CN110842150A CN110842150A (en) | 2020-02-28 |
| CN110842150B true CN110842150B (en) | 2021-11-19 |
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| CN112024821B (en) * | 2020-08-07 | 2022-04-01 | 中国铁建重工集团股份有限公司道岔分公司 | Frog mould, frog pouring method and frog casting |
| CN113231605B (en) * | 2021-05-13 | 2022-11-11 | 中国铁建重工集团股份有限公司道岔分公司 | Manufacturing method of super-long high manganese steel frog casting sand mold |
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