CN111940686B - Casting method of large ring steel casting - Google Patents
Casting method of large ring steel casting Download PDFInfo
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- CN111940686B CN111940686B CN202010734313.5A CN202010734313A CN111940686B CN 111940686 B CN111940686 B CN 111940686B CN 202010734313 A CN202010734313 A CN 202010734313A CN 111940686 B CN111940686 B CN 111940686B
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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
- B22C9/08—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
- B22C9/10—Cores; Manufacture or installation of cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/20—Stack moulds, i.e. arrangement of multiple moulds or flasks
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- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention belongs to the technical field of casting, and particularly relates to a method for casting a large ring steel casting, which comprises the following steps: uniformly modeling the ring castings in sections, casting a plurality of sections of sheet ring castings, and welding the plurality of sections of sheet ring castings into an integral ring casting; manufacturing a sheet ring sand core and a bed plate sand core, wherein a positioning table is arranged on the bed plate sand core, matched sand cores are respectively installed and clamped on two sides of the positioning table, a sheet ring casting cavity is formed between the adjacent sheet ring sand cores, and a plurality of sheet ring casting cavities are respectively formed after the sheet ring sand cores are sequentially installed and clamped with the bed plate sand core; the integral method is simple and easy to operate, safe and reliable, and the problems of large deformation and difficult size control of large castings are solved; large corrective aids are also avoided. Meanwhile, the casting method greatly reduces the size welding repair amount of the large ring casting caused by deformation, saves the welding cost and shortens the production period of the casting.
Description
Technical Field
The invention belongs to the technical field of casting, and particularly relates to a method for casting a large ring steel casting.
Background
The large ring steel castings are large in diameter, for example, the outline dimension of a certain large ring steel casting is phi 7000mm multiplied by 1530mm, the net weight is 30t, the gross weight is 42t, the maximum wall thickness is 140mm, and the minimum wall thickness is 83mm, and the large ring steel castings cannot be cast in a full circle due to size limitations of a modeling pit, a sand box, shot blasting equipment, heat treatment furnace equipment and the like in the casting process, can be cast in a full circle immediately, and cannot be transported on land after delivery and the like. Because the castings have large profile size and large wall thickness difference, deformation in the elliptical diameter direction and deflection in the height direction often exist in the casting, riser cutting and quality heat treatment processes, the deformation amount is generally 10-40 mm and exceeds the machining allowance of the castings, and the local position is machined to be black or not machined; the deviation correction is difficult, the welding repair can be carried out on the deficient part of the casting only after the line is drawn according to the size of the casting, the air gouging removal is carried out on the fleshy part of the casting, and finally the casting is processed in place. The method not only increases the welding amount, but also increases the production cost of gouging, relief grinding, NDT detection and the like, and has the risk of secondary deformation after welding. How to adopt reasonable casting method to cast large-scale ring steel casting to prevent to adopt above-mentioned method to cause a series of casting defects, show improvement large-scale ring steel casting's casting quality prime is waited for to solve.
Disclosure of Invention
Therefore, a new method for casting large ring-shaped steel castings is needed, which can prevent casting defects from being generated during the casting process and improve the casting quality of the ring-shaped steel castings.
A casting method of large ring steel castings comprises the following steps:
the method comprises the following steps of (1) designing a model, namely uniformly modeling ring castings in sections to cast a plurality of sections of sheet ring castings, and then welding the plurality of sections of sheet ring castings into an integral ring casting; because the diameters of the large ring steel castings are all larger, if the large ring steel castings are integrally cast, the subsequent processes of shot blasting, heat treatment, lifting and the like cannot be realized, and the integral transportation is inconvenient, so that the large ring steel castings are uniformly molded in a segmented mode and then welded into integral castings.
Manufacturing a sheet ring sand core and a bed plate sand core, wherein a positioning table is arranged on the bed plate sand core, and the molded line of the positioning table is matched with the molded line of the sheet ring sand core; and the combined sand core is used for respectively clamping matched sand cores on two sides of the positioning table according to the molded line of the positioning table of the molding bed and the molded line of the sand core, a sheet-ring casting cavity is formed between the adjacent sheet-ring sand cores, each sheet-ring sand core is sequentially combined with the molding bed sand core in a clamping way to form a plurality of sheet-ring casting cavities, wherein the outline of the sheet-ring sand core at the edge position and the matched sheet-ring sand core form a complete sheet-ring casting cavity, the outline of two sides of the sheet-ring sand core at the middle position form two side outlines of the sheet-ring casting respectively, namely the space between the adjacent sheet-ring sand cores forms the sheet-ring casting cavity. The bed plate sand core is mainly used for positioning the sheet ring sand core, and if the bed plate sand core is not manufactured, all the lower cores of the sheet ring sand core are positioned on one plane, so that accurate positioning cannot be realized; by manufacturing the tire plate sand core, the molded line of the positioning table matched with the sheet ring sand core is preset to be used as the reference of core setting, so that the accurate core setting position of the sheet ring sand core is realized.
As a further scheme of the invention, an inner sprue is arranged on a positioning table of the tire plate sand core; in order to ensure that the inner pouring gate can be accurately aligned with the die cavity of the sheet ring casting and avoid sand washing in the pouring process, the inner pouring gate is designed on the positioning table when the tire plate sand core is manufactured, so that the position accuracy of the inner pouring gate can be obviously improved.
As a further scheme of the invention, the ring sand core is divided into a plurality of ring sand core blocks; in order to prevent the problems of lower strength and inconvenient lifting caused by excessively slender piece-ring sand cores, the piece-ring sand cores can be divided into a plurality of piece-ring sand core blocks, and the core blocks are placed one by one according to a preset sequence.
As a further scheme of the invention, the thickness of the sheet-ring sand core is 950-1000 mm; this ensures that the sand core of the segment ring has sufficient strength.
As a further scheme of the invention, in the modeling design process, a plurality of first lacing wires are arranged between adjacent sheet ring castings; the diameter of the first lacing wire is preferably 100mm, and two layers of lacing wires can be arranged up and down, so that the rigidity of each ring casting can be effectively enhanced; the first lacing wire can be directly poured out.
As a further scheme of the invention, a second lacing wire is arranged at the inner side of the radian of the sheet ring casting close to the joint surface; the curvature of the second lacing wire is less than or equal to 50mm, and the diameter of the second lacing wire is preferably 120 mm; therefore, the rigidity of the sheet ring casting can be improved, and the casting deformation of the sheet ring casting is prevented.
As a further aspect of the present invention, the casting method further includes the steps of: and after the combined sand core is finished, pouring is carried out, a bottom-returning type pouring process is adopted for pouring, the speed is controlled to be 0.45-0.60 m/s during pouring, and the inflow speed of each ingate is uniform, so that the stable rising of the pouring liquid level can be effectively ensured.
As a further aspect of the present invention, the casting method further includes the steps of: after the casting is finished, a cutting casting system is carried out, after the cast piece ring casting is subjected to boxing and shakeout, all the lacing wires on the piece ring casting are reserved, and vertical supporting lacing wires are arranged between the second lacing wires, so that all the lacing wires and the piece ring casting are subjected to heat treatment as a whole; the diameter of the vertical tie bar is 80-100 mm, so that the second tie bar can be prevented from deforming to drive the sheet ring casting to deform; after the heat treatment is finished, cutting off each lacing wire when the integral temperature of the sheet ring casting is lower than 60 ℃, and cleaning the surface of the sheet ring casting; if the temperature is higher than 60 ℃, the size of the sheet ring casting can be changed or deformed during the cooling shrinkage process, so that all the lacing wires can be cut off only if the temperature is lower than 60 ℃.
As a further aspect of the present invention, the casting method further includes the steps of: after the surface of the sheet ring casting is cleaned, if defect welding is needed, before welding, welding at least two deformation-preventing tie bars at the joint surface of the sheet ring casting, wherein the deformation-preventing tie bars are straight, the maximum bending degree is less than or equal to 50mm, and the deformation-preventing tie bars are additionally arranged to prevent the deformation of the sheet ring casting when welding defects occur; and then uniformly and slowly preheating the casting to a preheating temperature by adopting a preheating pipe in a shape of a following ring, wherein the preheating speed is less than or equal to 50 ℃/h, and the flame length during preheating is controlled within a range of less than or equal to 200 mm. And the area to be welded is divided into 100 × 50mm squares, the welding is carried out in a block symmetric welding mode, the distance between the two squares required to be welded is larger than 800mm, so that the welding deformation caused by over concentration of heat is reduced, and the sheet ring is immediately subjected to postweld heat treatment after the integral welding is finished, so that the purpose of reducing the welding stress and stabilizing the size of the sheet ring is achieved, the probability of secondary deformation of the sheet ring is reduced, and the repair times are reduced.
By adopting the casting method of the large ring steel casting, the production of the large ring casting by small and medium-sized casting enterprises becomes possible, the production bottleneck is reduced, the whole method is simple and easy to operate, safe and reliable, and the problems of large deformation and difficult size control of the large casting are avoided; large corrective aids are also avoided. Meanwhile, the casting method greatly reduces the size welding repair amount of the large ring casting caused by deformation, saves the welding cost and shortens the production period of the casting.
Drawings
FIG. 1 is a schematic diagram of a segment-ring sand core structure in an embodiment;
FIG. 2 is a schematic diagram of a sand core structure of a tire plate in the embodiment;
FIG. 3 is a schematic diagram of a combined structure of a plurality of sheet ring sand cores in the embodiment;
FIG. 4 is a schematic diagram of a structure of a plurality of sand core blocks for dividing the segment ring sand core in the embodiment;
FIG. 5 is a schematic diagram of a structure of a tie bar in the embodiment;
100-piece ring sand core; 200-bed plate sand core; 300-a first lacing wire; 400-a second lacing wire; 101-sand core one; 102-core two; 103-sand core III; 104-sand core four; 1000-molded lines of the ring sand cores; 201-a positioning table; 202-inner gate; 2010-profile of positioning table.
Detailed Description
To facilitate an understanding of the invention, the invention will now be described more fully with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
In the embodiment, a large ring steel casting is taken as an example, the outline dimension is phi 7000mm multiplied by 1530mm, the net weight is 30t, the gross weight is 42t, the maximum wall thickness is 140mm, and the minimum wall thickness is 83 mm; the casting method comprises the following steps:
and (3) modeling design, namely uniformly dividing the ring casting into 3 sections for modeling, casting 3 sections of sheet ring castings, and welding the 3 sections of sheet ring castings into an integral casting.
Manufacturing a sheet-ring sand core 100 and a tire plate sand core 200, and referring to the attached drawings 1 to 3, wherein the thickness of the sheet-ring sand core 100 is preferably 950 mm-1000 mm, a positioning table 201 is arranged on the tire plate sand core 200, the molded line 2010 of the positioning table is matched with the molded line 1000 of the sheet-ring sand core, and the number of the molded lines is equal to the number of sheet-ring castings, namely the number of the positioning tables 201 is 3; the combined sand core comprises a first sand core 101, a second sand core 102, a third sand core 103 and a fourth sand core 104, wherein the first sand core 101, the second sand core 102, the third sand core 103 and the fourth sand core 104 are respectively and sequentially clamped on two sides of a positioning table 201 according to a molded line 2010 of the positioning table of a molding bed and a molded line of the sand core, a sheet ring casting cavity is formed between the adjacent first sand core 101, the second sand core 102, the third sand core 103 and the fourth sand core 104, 3 sheet ring casting cavities are formed in total, the profiles of the first sand core 101 and the fourth sand core 104 and the matched second sand core 102 and the matched third sand core 103 form a complete sheet ring casting cavity, the profiles of two sides of the sheet ring casting are respectively formed by the profiles of the two sand cores 102 and the three sand cores 103, namely, a space between the adjacent second sand core 102 and the third sand core 103 forms the sheet ring casting.
Specifically, in order to ensure that the ingate 202 can be accurately aligned with the die cavity of the sheet ring casting and avoid sand washing in the casting process, the ingate 202 is designed on the positioning table 201 when the molding bed sand core 200 is manufactured.
In order to prevent the problems of low strength and inconvenient lifting caused by the fact that the piece-and-ring sand core 100 is too long and thin, the piece-and-ring sand core 100 is divided into 3 pieces of the piece-and-ring sand core 100, and cores are sequentially placed according to a preset sequence, please refer to fig. 4.
And after the combined sand core is finished, pouring is carried out, in the pouring process, a bottom-returning type pouring process is adopted, the speed is controlled to be 0.45-0.60 m/s during pouring, the inflow speed of each ingate 202 is ensured to be uniform, and thus the stable rising of the pouring liquid level can be effectively ensured.
In the modeling design process, the method also comprises the following steps: a plurality of first lacing wires 300 are arranged between adjacent sheet ring castings; the diameter of the first lacing wire 300 is preferably 100mm, and two layers can be arranged up and down, so that the rigidity of each piece of ring casting can be effectively enhanced; the first tie bar 300 may be poured directly. Further, a second lacing wire 400 is arranged at the inner side of the radian of the sheet ring casting close to the joint surface; the curvature of the second lacing wire 400 is less than or equal to 50mm, and the diameter of the second lacing wire is preferably 120 mm; this increases the rigidity of the sheet and ring casting and prevents casting distortion of the sheet and ring casting, as shown in fig. 5.
After the pouring is finished, a cutting pouring system is carried out, in the process of the cutting pouring system, after the poured sheet ring castings are subjected to boxing and shakeout, all the tie bars on a plurality of sheet ring castings are reserved, and vertical supporting tie bars are arranged between the second tie bars 400, so that all the tie bars and the sheet ring castings are subjected to heat treatment as a whole; the diameter of the vertical tie bar is 80-100 mm, so that the second tie bar 400 can be prevented from deforming to drive the sheet ring casting to deform; after the heat treatment is finished, cutting off each lacing wire when the integral temperature of the sheet ring casting is lower than 60 ℃, and cleaning the surface of the sheet ring casting; if the temperature is higher than 60 ℃, the size of the sheet ring casting can be changed or deformed during the cooling shrinkage process, so that all the lacing wires can be cut off only if the temperature is lower than 60 ℃.
After the surface of the sheet-ring casting is cleaned, if defect welding is needed, before welding, welding at least two anti-deformation tie bars at the joint surface of the sheet-ring casting, wherein the anti-deformation tie bars are straight, the maximum bending degree is less than or equal to 50mm, and the anti-deformation tie bars are additionally arranged to prevent the deformation of the sheet-ring casting when the welding defect occurs; and then uniformly and slowly preheating the casting to a preheating temperature by adopting a preheating pipe in a shape of a following ring, wherein the preheating speed is less than or equal to 50 ℃/h, and the flame length during preheating is controlled within a range of less than or equal to 200 mm. And the area to be welded is divided into 100 × 50mm squares, the welding is carried out in a block symmetric welding mode, the distance between the two squares required to be welded is larger than 800mm, so that the welding deformation caused by over concentration of heat is reduced, and the sheet ring is immediately subjected to postweld heat treatment after the integral welding is finished, so that the purpose of reducing the welding stress and stabilizing the size of the sheet ring is achieved, the probability of secondary deformation of the sheet ring is reduced, and the repair times are reduced.
By adopting the casting method of the large ring steel casting, 1 piece of ring casting can be cast singly, and a plurality of pieces of ring castings can be cast simultaneously, namely a plurality of pieces of ring castings which can form an integral ring casting can be cast simultaneously, then the piece ring castings are welded into an integral ring casting, and in the molding process, the cutting and pouring system process and the defect repair welding process, the operation steps provided by the invention are carried out, the operation process is safe and reliable, and the problems of large casting deformation and difficult size control of the large ring casting can be effectively avoided.
The above-mentioned embodiments only express the specific embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (7)
1. A casting method of large ring steel castings is characterized by comprising the following steps:
the method comprises the following steps of (1) designing a model, namely uniformly modeling ring castings in sections to cast a plurality of sections of sheet ring castings, and then welding the plurality of sections of sheet ring castings into an integral ring casting; during modeling, a plurality of first lacing wires are arranged between adjacent sheet ring castings, and second lacing wires are arranged on the inner side of the radian of the sheet ring casting close to the joint surface;
manufacturing a sheet ring sand core and a bed plate sand core, wherein a positioning table is arranged on the bed plate sand core, and the molded line of the positioning table is matched with the molded line of the sheet ring sand core;
the combined sand core is used for respectively clamping the matched piece ring sand cores on two sides of the positioning table according to the molded line of the positioning table of the bed plate sand core and the molded line of the piece ring sand core, the piece ring casting cavities are formed between the adjacent piece ring sand cores, and the piece ring sand cores are sequentially clamped and combined with the bed plate sand core to respectively form a plurality of piece ring casting cavities;
after the casting is finished, a cutting casting system is carried out, after the cast piece ring casting is subjected to boxing and shakeout, the first tie bars and the second tie bars are reserved, vertical supporting tie bars are arranged between the second tie bars, the first tie bars, the second tie bars, the vertical supporting tie bars and the piece ring casting are subjected to heat treatment as a whole, after the heat treatment is finished, the first tie bars, the second tie bars and the vertical supporting tie bars are cut off after the integral temperature of the piece ring casting is lower than 60 ℃, and the surface of the piece ring casting is cleaned.
2. The method for casting a large ring-type steel casting according to claim 1, wherein an ingate is provided on the positioning table of the core of the bed plate.
3. The method of casting a large ring-type steel casting according to claim 1, wherein the ring core is divided into a plurality of ring core pieces.
4. The method of casting a large ring-type steel casting according to claim 1, wherein the thickness of the sheet-ring core is 950mm to 1000 mm.
5. The method of casting a large ring-type steel casting according to claim 1, wherein the degree of bending of the second tie bar is 50mm or less.
6. The casting method of a large-ring type steel casting according to any one of claims 1 to 5, further comprising the steps of: and after the combined sand core is finished, pouring, wherein a bottom-returning pouring process is adopted for pouring, and the speed is controlled to be 0.45-0.60 m/s during pouring.
7. The casting method of large ring-type steel casting according to claim 1, further comprising the steps of: after the surface of the sheet ring casting is cleaned, if defective welding is needed, at least two deformation-preventing tie bars are welded at the joint surface of the sheet ring casting before welding.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010734313.5A CN111940686B (en) | 2020-07-28 | 2020-07-28 | Casting method of large ring steel casting |
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| CN202010734313.5A CN111940686B (en) | 2020-07-28 | 2020-07-28 | Casting method of large ring steel casting |
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| CN111940686A CN111940686A (en) | 2020-11-17 |
| CN111940686B true CN111940686B (en) | 2022-05-13 |
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| CN114850784B (en) * | 2022-03-28 | 2023-06-02 | 洛阳双瑞精铸钛业有限公司 | Preparation method of titanium and titanium alloy H-shaped material |
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| CN107931990A (en) * | 2017-11-21 | 2018-04-20 | 中船黄埔文冲船舶有限公司 | A kind of manufacture method of shipping stempost structure |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN105665643B (en) * | 2016-04-08 | 2017-12-19 | 宁夏共享模具有限公司 | A kind of manufacture method of the oblique bed casting of 3D printing |
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- 2020-07-28 CN CN202010734313.5A patent/CN111940686B/en active Active
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| CN103639649A (en) * | 2013-11-19 | 2014-03-19 | 西安航天动力机械厂 | Manufacturing method of engine inlet |
| CN204265799U (en) * | 2014-10-11 | 2015-04-15 | 宁夏共享铸钢有限公司 | Large thin-wall rotary type steel casting heat treatment tooling |
| CN105033176A (en) * | 2015-08-27 | 2015-11-11 | 哈尔滨电机厂有限责任公司 | Technology method for casting flexible tie bar through circular ring type steel casting in halving manner |
| CN106636598A (en) * | 2016-11-30 | 2017-05-10 | 共享铸钢有限公司 | Anti-deformation process for large low-strength conical ring-shaped plate type steel casting |
| CN107138683A (en) * | 2017-06-26 | 2017-09-08 | 共享铸钢有限公司 | A kind of sand core structure of turbine blade steel-casting |
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