CN111496185A - Production process of lost foam casting - Google Patents
Production process of lost foam casting Download PDFInfo
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- CN111496185A CN111496185A CN202010342350.1A CN202010342350A CN111496185A CN 111496185 A CN111496185 A CN 111496185A CN 202010342350 A CN202010342350 A CN 202010342350A CN 111496185 A CN111496185 A CN 111496185A
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- sand
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- beads
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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
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C15/00—Moulding machines characterised by the compacting mechanism; Accessories therefor
- B22C15/10—Compacting by jarring devices only
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
- B22C7/023—Patterns made from expanded plastic materials
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/08—Shaking, vibrating, or turning of moulds
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/15—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using vacuum
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention discloses a production process of a lost foam casting, which comprises the following steps: s1, pre-foaming, namely adding an expandable polystyrene raw material into a vacuum pre-foaming machine for foaming, so that the expandable polystyrene raw material is foamed and expanded into beads with a certain volume; s2, molding the model, namely filling the metal mold cavity with the pre-expanded polystyrene foam beads, heating to soften the beads in the mold cavity for further expansion, fusing gaps among the beads, cooling the mold to stop foaming, and opening the mold to take out the foam plastic model; s3, bonding and combining the model produced by the parts and the pouring system into a whole by using a bonding agent; s4, preparing a coating; s5, hanging paint on the model; s6, drying the coating; s7, sand filling and molding; s8, pouring; and S9, casting cleaning and sand treatment. The invention has the advantages that the negative pressure airflow lost foam casting process can effectively avoid surface carburization and volume carburization of the steel casting, and can also accelerate the solidification of molten metal and refine casting grains.
Description
Technical Field
The invention relates to the technical field of casting production, in particular to a lost foam casting production process.
Background
In mechanical casting production, the most basic method is sand casting, which accounts for more than 90% of the total yield of castings, but sand casting still has many problems, such as large casting structure, and defects of shrinkage cavities, shrinkage porosity, air holes, sand holes and the like in the interior, so that the product quality is not stable enough, the rejection rate is high, and particularly in single-piece, complex and small-batch production, the quality problems of uneven non-processed surface, flash and the like of castings are difficult to solve, so that the product appearance is ugly, and the labor conditions of workers are very hard due to more sand consumption and larger dust. Therefore, the lost foam casting process is introduced, has wide application range, is suitable for casting steel and cast iron, and is more suitable for casting copper and aluminum; the method is not only suitable for castings with simple geometric shapes, but also more suitable for castings which are difficult to finish by common casting. The process can be finished slightly and loosely, can realize pouring in a slight shock state, promotes the formation of a metallographic structure with special requirements, is favorable for improving the internal quality of the casting, is combined pouring in dry sand, and is easy to desalt the casting. The temperature is synchronous, so the heat treatment can be carried out by utilizing the waste heat. Particularly, the water edge treatment of the high manganese steel casting and the solid melting treatment of the heat-resistant steel casting have ideal effects, save a large amount of energy and shorten the processing period. The method has the advantages of obvious economic benefit, simple process and suitability for industrial production, the investment is 30-60% of that of sand casting, and the cost is lower than that of common casting, so that high-precision castings comparable to wax molds can be produced. The process can finish any large precision casting according to the melting capacity, is easy to master, cancels the molding process procedure, and can train workers with little casting knowledge into skilled technicians within 5 days. Therefore, the method is particularly suitable for enterprises and areas lacking of modeling workers, the labor intensity of the workers is greatly reduced, the number of the workers is greatly reduced, the industry mainly for men can be changed into the industry mainly for women, and the occupied working area is small. No matter how many tons of the product are produced in year, the occupied area of the main operation procedures is 300-400 m enough. The production capacity is not limited by the area of a factory building, the yield can be increased by the melting capacity, and the working environment is obviously improved. The sand circulation is realized, the pipeline is completely, dust is not generated in the air, the ground is free of sand, and workers can wear white coats to finish the previous dirty and tired work. The lost foam adopts a foam plastic solid model, when in pouring, the foam plastic is deeply cracked under the heat action of molten metal to generate a large amount of solid carbon particles with high activity, so that irregular volume recarburization and surface recarburization of a casting occur in three stages of mold filling, solidification and cooling, and further the mechanical property of the casting is influenced. The crystal grains of the casting are coarse, and the mechanical property of the casting is finally influenced.
Disclosure of Invention
The invention aims to provide a lost foam casting production process, which has the advantages that the lost foam casting process adopting negative pressure airflow can effectively avoid surface recarburization and volume recarburization of a steel casting, can also accelerate the solidification of molten metal and refine casting grains, and solves the problem that the mechanical property of the casting is influenced by the fact that the lost foam adopts a foam plastic solid model and the foam plastic is deeply cracked under the thermal action of the molten metal during casting to generate a large amount of high-activity solid carbon particles, so that the casting is subjected to irregular volume recarburization and surface recarburization in three stages of mold filling, solidification and cooling. The crystal grains of the casting are coarse, and the mechanical property of the casting is finally influenced.
In order to achieve the purpose, the invention provides the following technical scheme: a production process of a lost foam casting comprises the following steps:
s1, pre-foaming, namely adding an expandable polystyrene raw material into a vacuum pre-foaming machine for foaming, so that the expandable polystyrene raw material is foamed and expanded into beads with a certain volume;
s2, molding the model, namely filling the metal mold cavity with the pre-expanded polystyrene foam beads, heating to soften the beads in the mold cavity for further expansion, fusing gaps among the beads, cooling the mold to stop foaming, and opening the mold to take out the foam plastic model;
s3, bonding and combining the model produced by the parts and the pouring system into a whole by using a bonding agent;
s4, preparing a coating, and adding a refractory material, a binder, a suspending agent and water in a stirrer according to a certain proportion to stir;
s5, hanging a layer of coating on the inner surface and the outer surface of the assembled model before pouring, wherein the layer of coating plays a role in supporting dry sand, isolating molding sand and molten metal;
s6, drying the coating, and drying the coating in a drying furnace or a drying chamber;
s7, filling sand, namely, adopting a sand burying mode of firstly adding bottom sand and then compacting, placing the dried disappearance module in a sand box, placing the sand box on a vibration table, vibrating while filling sand, and vibrating in a high-frequency and low-amplitude mode, when the sand box is to be filled with the sand, placing a sprue cup on a sprue, and continuously vibrating for a period of time after most of the sprue cup is buried in dry sand to finish the sand filling molding process;
s8, pouring, namely pouring molten metal into a sand box through a pouring cup and a sprue, wherein during pouring, a plastic model is in contact with the molten metal and is combusted and gasified, gas is transmitted into sand through a coating layer, the top of the sand box is not sealed by a plastic film but leaks by a special damping plate, the sand box adopts a bottom-pumping type, air or gas with specific chemical components and thermodynamic properties is introduced into the sand box from the upper surface of the damping plate, and meanwhile, the vibration of the sand box is maintained;
s9, cleaning the casting and carrying out sand treatment, cooling for 1-4 hours after pouring to realize sand shakeout, turning over the sand box, pouring the sand and the casting onto a fence, taking out the casting, and screening and cooling the sand to recycle the sand.
Preferably, in S4, the raw materials comprise 28-37% of refractory material, 15-25% of binder, 7-13% of suspending agent and 40-50% of water.
Preferably, in S4, the refractory material is quartz powder or bauxite, the particle diameter is less than 0.075mm, the binder is water-soluble resin or white latex, and the suspending agent is bentonite slurry or CMC slurry.
Preferably, in S6, the dry explosion temperature is controlled at 40-60 ℃ and the drying time is 2-4 hours.
Preferably, in S7, the molding sand is 25-30 AFS silica sand with air permeability of 13.5-16.5 cmZ/Pa & rain, the sand temperature is less than or equal to 45 ℃, and the water content is less than or equal to 3%.
Preferably, in S7, the tap time is controlled to be 20S, the tap frequency is controlled to be 45-50 HZ, and the amplitude is controlled to be l-1.5 mm.
Preferably, in S8, the tapping temperature of the molten metal is increased to 1560 ℃, the pouring temperature is not lower than 1420 ℃, the operation principle of rapid pouring is adopted, and the negative pressure is selected according to different metal materials, and the negative pressure is 40.0-59.0 kPa for cast steel, 26.7-53.3 kPa for cast iron and 0-26.7 kPa for aluminum alloy.
Compared with the prior art, the invention has the beneficial effects that: by using a vacuum pump for vacuum pumping, when air or gas with specific chemical components and thermodynamic properties rapidly flows through a metal liquid-molding sand interface or a casting molding sand surface, the carbon near a metal liquid and a high-temperature casting is inevitably taken away, so that the concentration of the carbon is reduced, the recarburization driving force of the casting is reduced or eliminated, meanwhile, negative pressure airflow has a cooling effect on the metal liquid, the solidification of the metal liquid can be accelerated, crystal grains are refined, vibration is maintained in the metal solidification process, the crystal grains can be effectively refined by applying vibration in the metal solidification process, the influence of the vibration on the structure comprises increasing nucleation, reducing the size of the crystal grains, providing a homogeneous structure and the like, the performance of the alloy can be improved, a sand burying mode of firstly adding bottom sand and then compacting is adopted, sand filling is carried out twice after a foam mold sample is placed, and in order to ensure that the molding sand is filled and compacted in a position where sand is difficult to enter through a manual auxiliary, the molding sand at the dead corner is ensured to have high compactness, and the height of the first sand filling is equal to or slightly higher than that of the box body; the secondary sand filling is covering sand, the covering sand has enough thickness, enough sand eating amount is ensured, and the defect of the iron-coated sand can be effectively overcome.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to 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, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "front", "rear", "both ends", "one end", "the other end", and the like indicate orientations or positional relationships only for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, it is to be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "disposed," "connected," and the like are to be construed broadly, such as "connected," which may be fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
The embodiment provided by the invention comprises the following steps: a production process of a lost foam casting comprises the following steps:
s1, pre-foaming, namely adding an expandable polystyrene raw material into a vacuum pre-foaming machine for foaming, so that the expandable polystyrene raw material is foamed and expanded into beads with a certain volume;
s2, molding the model, namely filling the metal mold cavity with the pre-expanded polystyrene foam beads, heating to soften the beads in the mold cavity for further expansion, fusing gaps among the beads, cooling the mold to stop foaming, and opening the mold to take out the foam plastic model;
s3, bonding and combining the model produced by the parts and the pouring system into a whole by using a bonding agent;
s4, preparing a coating, namely adding a refractory material, a binder, a suspending agent and water in a stirrer according to a certain proportion, stirring, wherein in S4, the raw materials comprise 28-37% of the refractory material, 15-25% of the binder, 7-13% of the suspending agent and 40-50% of water, in S4, the refractory material is quartz powder or bauxite, the particle diameter of the quartz powder or bauxite is smaller than 0.075mm, the binder is water-soluble resin or white latex, and the suspending agent is bentonite slurry or CMC slurry;
s5, hanging a layer of coating on the inner surface and the outer surface of the assembled model before pouring, wherein the layer of coating plays a role in supporting dry sand, isolating molding sand and molten metal;
s6, drying the coating, and drying the coating by using a drying furnace or a drying chamber, wherein in S6, the dry explosion temperature is controlled at 40-60 ℃, and the drying time is 2-4 hours;
s7, filling sand for molding, namely, adopting a sand burying mode of firstly adding bottom sand and then compacting, placing a dried disappearance mould group in a sand box, placing the sand box on a vibration table, vibrating while filling sand, adopting a high-frequency and low-amplitude mode for vibration, placing a sprue cup on a sprue when the sand box is to be filled with the sand, embedding most of the sprue cup in dry sand, continuously vibrating for a period of time to complete the sand filling molding process, S7, using 25-30 AFS for molding sand, silica sand with the air permeability of 13.5-16.5 cmZ/Pa.rain, controlling the sand temperature to be less than or equal to 45 ℃ and the water content to be less than or equal to 3 percent, controlling the compacting time to be 20S in S7, controlling the compacting frequency to be 45-50 HZ and the amplitude to be l-1.5 mm, adopting a sand burying mode of firstly adding bottom sand and then compacting, placing a foam mould sample, then filling sand twice, and ensuring that the position where the sand is difficult to enter is filled with the molding sand and the sand has high compacting degree by a manual auxiliary sand burying means, the height of the first sand filling is equal to or slightly higher than that of the box body; the secondary sand filling is covering sand, and the covering sand has enough thickness to ensure enough sand eating amount and effectively solve the defects of the iron-coated sand;
s8, pouring, namely, pouring molten metal into a sand box through a pouring cup and a sprue, wherein when pouring, a plastic model is in contact with the molten metal and is combusted and gasified, gas is transmitted into sand through a coating layer, the top of the sand box is not sealed by a plastic film, but leaks gas by a special damping plate, the sand box adopts a bottom-pumping type, air or gas with specific chemical components and thermodynamic properties is introduced into the sand box from the upper surface of the damping plate, simultaneously vibration of the sand box is maintained, S8, the tapping temperature of the molten metal is increased to 1560 ℃, the pouring temperature is not lower than 1420 ℃, an operation principle of quick pouring is adopted, the negative pressure is selected according to different metal materials, 40.0-59.0 kPa of cast steel, 26.7-53.3 kPa of cast iron and 0-26.7 kPa of aluminum alloy are cast, when air or gas with specific chemical components and thermodynamic properties rapidly flows through an interface of the molten metal or the surface of a casting sand by using a vacuum pump for vacuum pumping, the carbon near the molten metal and the high-temperature casting is taken away certainly, so that the concentration of the carbon is reduced, the recarburization driving force of the casting is reduced or eliminated, meanwhile, the negative pressure airflow has a cooling effect on the molten metal, the solidification of the molten metal can be accelerated, crystal grains are refined, the vibration is maintained in the metal solidification process, the crystal grains can be effectively refined by applying the vibration in the metal solidification process, the influence of the vibration on the structure comprises the increase of nucleation, the reduction of the size of the crystal grains, the provision of a homogeneous structure and the like, and the performance of the alloy can be improved;
s9, cleaning the casting and carrying out sand treatment, cooling for 1-4 hours after pouring to realize sand shakeout, turning over the sand box, pouring the sand and the casting onto a fence, taking out the casting, and screening and cooling the sand to recycle the sand.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
Claims (7)
1. The production process of the lost foam casting is characterized by comprising the following steps of:
s1, pre-foaming, namely adding an expandable polystyrene raw material into a vacuum pre-foaming machine for foaming, so that the expandable polystyrene raw material is foamed and expanded into beads with a certain volume;
s2, molding the model, namely filling the metal mold cavity with the pre-expanded polystyrene foam beads, heating to soften the beads in the mold cavity for further expansion, fusing gaps among the beads, cooling the mold to stop foaming, and opening the mold to take out the foam plastic model;
s3, bonding and combining the model produced by the parts and the pouring system into a whole by using a bonding agent;
s4, preparing a coating, and adding a refractory material, a binder, a suspending agent and water in a stirrer according to a certain proportion to stir;
s5, hanging a layer of coating on the inner surface and the outer surface of the assembled model before pouring, wherein the layer of coating plays a role in supporting dry sand, isolating molding sand and molten metal;
s6, drying the coating, and drying the coating in a drying furnace or a drying chamber;
s7, filling sand, namely, adopting a sand burying mode of firstly adding bottom sand and then compacting, placing the dried disappearance module in a sand box, placing the sand box on a vibration table, vibrating while filling sand, and vibrating in a high-frequency and low-amplitude mode, when the sand box is to be filled with the sand, placing a sprue cup on a sprue, and continuously vibrating for a period of time after most of the sprue cup is buried in dry sand to finish the sand filling molding process;
s8, pouring, namely pouring molten metal into a sand box through a pouring cup and a sprue, wherein during pouring, a plastic model is in contact with the molten metal and is combusted and gasified, gas is transmitted into sand through a coating layer, the top of the sand box is not sealed by a plastic film but leaks by a special damping plate, the sand box adopts a bottom-pumping type, air or gas with specific chemical components and thermodynamic properties is introduced into the sand box from the upper surface of the damping plate, and meanwhile, the vibration of the sand box is maintained;
s9, cleaning the casting and carrying out sand treatment, cooling for 1-4 hours after pouring to realize sand shakeout, turning over the sand box, pouring the sand and the casting onto a fence, taking out the casting, and screening and cooling the sand to recycle the sand.
2. A lost foam casting production process according to claim 1, wherein: in S4, the raw materials include 28-37% of refractory material, 15-25% of binder, 7-13% of suspending agent and 40-50% of water.
3. A lost foam casting production process according to claim 1, wherein: in S4, the refractory material is quartz powder or bauxite, the particle diameters of the quartz powder or bauxite are smaller than 0.075mm, the adhesive is water-soluble resin or white latex, and the suspending agent is bentonite slurry or CMC slurry.
4. A lost foam casting production process according to claim 1, wherein: in S6, the dry explosion temperature is controlled at 40-60 ℃ and the drying time is 2-4 hours.
5. A lost foam casting production process according to claim 1, wherein: in S7, the molding sand is 25-30 AFS silica sand with air permeability of 13.5-16.5 cmZ/Pa & rain, the sand temperature is less than or equal to 45 ℃, and the water content is less than or equal to 3%.
6. A lost foam casting production process according to claim 1, wherein: in S7, the tap time is controlled at 20S, the tap frequency is controlled at 45-50 HZ, and the amplitude is controlled at l-1.5 mm.
7. A lost foam casting production process according to claim 1, wherein: and S8, increasing the tapping temperature of molten metal to 1560 ℃, the pouring temperature to not less than 1420 ℃, adopting the operation principle of quick pouring, and selecting proper negative pressure according to different metal materials, wherein the negative pressure is 40.0-59.0 kPa for cast steel, 26.7-53.3 kPa for cast iron, and 0-26.7 kPa for aluminum alloy.
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| CN202010342350.1A CN111496185A (en) | 2020-04-27 | 2020-04-27 | Production process of lost foam casting |
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| CN202010342350.1A CN111496185A (en) | 2020-04-27 | 2020-04-27 | Production process of lost foam casting |
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| CN114147178A (en) * | 2021-12-15 | 2022-03-08 | 广州市荣泽模具有限公司 | Aluminum alloy lost foam casting method |
| CN114260423A (en) * | 2020-12-01 | 2022-04-01 | 安阳市凯创科技有限公司 | Casting heat section treatment method for medium and large precision castings |
| CN114346165A (en) * | 2021-12-29 | 2022-04-15 | 凯里市富安鸿达精密铸造有限公司 | Lost foam casting process of low-carbon steel |
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| CN114147178A (en) * | 2021-12-15 | 2022-03-08 | 广州市荣泽模具有限公司 | Aluminum alloy lost foam casting method |
| CN114346165A (en) * | 2021-12-29 | 2022-04-15 | 凯里市富安鸿达精密铸造有限公司 | Lost foam casting process of low-carbon steel |
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Application publication date: 20200807 |