CN111992671A - Shell mould and manufacturing method and casting method thereof - Google Patents
Shell mould and manufacturing method and casting method thereof Download PDFInfo
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- CN111992671A CN111992671A CN202010723928.8A CN202010723928A CN111992671A CN 111992671 A CN111992671 A CN 111992671A CN 202010723928 A CN202010723928 A CN 202010723928A CN 111992671 A CN111992671 A CN 111992671A
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Images
Classifications
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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
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- 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
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/18—Finishing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Ceramic Engineering (AREA)
- Civil Engineering (AREA)
- Composite Materials (AREA)
- Structural Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention relates to a mold used in the casting field, in particular to a shell mold, which comprises a pouring gate, a pouring gate and at least one shell, wherein the pouring gate and the pouring gate are made of high-temperature-resistant heat-insulating materials, and the shell is made of high-temperature-resistant materials. The shell mold provided by the invention has the advantages of high material yield, low cost, high production efficiency and environmental protection.
Description
Technical Field
The invention relates to a mold used in the casting field, in particular to a shell mold and a manufacturing method and a casting method thereof.
Background
The traditional dewaxing casting process method is adopted, and the manufacturing process flow is as follows:
1. traditional dewaxing casting: developing a mould, and injecting wax by a wax injection machine for molding;
2. polishing the surface of the wax mould: removing redundant supports and corners of the wax mould, and manually trimming wax;
3. the wax pattern forms a wax tree: the wax mould is arranged on a wax frame mould head manufactured by a traditional mould, so that a plurality of products can be cast at one time, and the working efficiency can be improved;
4. preparing a shell: carrying out slurry coating and sand dipping treatment on the wax tree, and continuously repeating the process according to different raw materials of the product until the thickness of the shell mold reaches the expected effect;
5. shell mold dewaxing: the traditional dewaxing furnace is used, water vapor is used for pressurizing and heating, so that the wax mold is liquefied and flows out from a pouring channel of the shell mold, and the wax liquid can be recycled;
6. combustion dewaxing: and (3) heating the shell mold, completely gasifying the wax mold in the shell mold when the temperature in the kiln reaches over 1000 ℃, then removing the shell mold from the kiln, and naturally cooling.
7. Smelting and casting: heating the shell mold, injecting molten metal ingots from a pouring channel, and cooling and molding;
8. and (3) post-treatment: and (3) breaking the outer shell by using a pneumatic jack to separate the casting piece from the shell mold, and performing sand blasting, shot blasting, cutting, gate grinding and other treatments on the casting piece to obtain a blank of the part.
In order to obtain a good casting, the casting is well formed after casting, and surface and internal shrinkage cavities are reduced. Large gates and pouring channels are designed according to the shape of a cast part so as to meet the casting molding of molten metal with different flowability; in addition, for some large-scale shell molds, a layer of heat-insulating cotton needs to be coated outside the shell mold to reduce the cooling speed of molten metal, so that the casting can be supplemented with the molten metal in time during the cold contraction period; by the operation, the metal yield (the volume of the part occupying the whole shell mold) is reduced, the cost of shell-making raw materials is increased, more energy and manpower are wasted to recover the metal die head during aftertreatment, and the operation is neither economical nor environment-friendly.
Disclosure of Invention
In order to solve the problems, the invention provides a shell mold which has high material yield, low cost, high production efficiency and environmental protection, and the specific technical scheme is as follows:
a shell mold comprises a pouring gate, a pouring gate and at least one shell, wherein the pouring gate and the pouring gate are made of high-temperature-resistant heat-insulating materials, and the shell is made of high-temperature-resistant materials.
By adopting the technical scheme, the pouring gate and the pouring gate are made of the high-temperature-resistant heat-insulating material, so that the cooling speed of the pouring gate and the pouring gate can be effectively reduced, the fluidity of molten metal liquid during casting is improved, and the complete molding of parts can be ensured.
The pouring gate and the pouring gate have good heat preservation, so the size of the pouring gate and the pouring gate can be smaller, the casting amount is saved, the metal yield is improved, and the recovery workload is reduced.
The pouring gate and the pouring gate have the heat preservation function, so that the process of coating heat preservation cotton can be omitted, and the casting efficiency is improved.
Further, the high-temperature resistant material is ceramic slurry or photocuring ceramic resin slurry.
Further, the high-temperature-resistant heat-insulating material is a mixture of ceramic slurry or light-cured ceramic resin slurry and a heat-insulating material.
By adopting the technical scheme, the material with the heat preservation performance is added into the ceramic slurry or the light-cured ceramic resin slurry, so that the heat preservation performance is effectively improved, the cooling rate is reduced during casting, and the heat preservation effect is good.
Further, the heat insulation material is heat insulation cotton.
Further, the shell mold is of an integrated structure manufactured by 3D printing.
Through adopting above-mentioned technical scheme, adopt 3D to print and can omit the loaded down with trivial details step of traditional wax matrix to pollute for a short time, adopt 3D to print simultaneously and can let runner and shell form good contact, for overall structure, convenient manufacturing, and the shell mould of an organic whole structure that two kinds of different materials were made is difficult to accomplish to traditional approach.
Another object of the present invention is to provide a method for manufacturing a shell mold, comprising the steps of:
designing a shell mold, wherein the shell mold comprises a pouring gate, a pouring gate and a shell;
preparing a printing raw material, wherein the pouring gate and the pouring gate are made of high-temperature-resistant heat-insulating materials, and the shell is made of high-temperature-resistant materials;
printing a shell mold, and printing the shell mold by using a 3D printer;
drying or degreasing, namely drying the shell mold printed by the ceramic slurry until the moisture in the shell mold is completely gasified, and degreasing the shell mold printed by the photocuring ceramic resin slurry until the resin in the shell mold is combusted and gasified;
and surface treatment, namely polishing the inner surface of the shell mold to improve the smoothness of the inner surface of the shell mold, wherein the polishing treatment comprises grinding or chemical polishing.
By adopting the technical scheme, the shell mold manufacturing efficiency is high, the time is short, the overwhelming advantages of rapidness, elasticity and lower cost are achieved under the condition that a relatively small number of products are produced, and the prior art can be directly replaced on large-scale production.
Furthermore, the temperature rise speed during drying treatment is 25-35 ℃/h, and the drying temperature is 50-150 ℃.
The heating rate during degreasing treatment is 50-100 ℃/h, and the gasification temperature is 500-800 ℃.
The temperature rise rate is beneficial to uniformly gasifying and removing the moisture and the resin in the shell mold, and cracks on the inner surface and the outer surface can not be caused by drying or degreasing the shell mold too fast;
it is another object of the present invention to provide a casting method of a shell mold, comprising the steps of:
heating the finished shell mold to 800-1200 ℃;
taking out the shell mold and casting;
and after the casting is finished, vibrating and breaking the shell mold to obtain a die head and a casting.
By adopting the technical scheme, the shell mold is heated and then cast, so that the temperature difference can be reduced, the quality of cast parts is ensured, and the flowability is improved.
Further, after the heating is finished, the shell mold is taken out and placed in a sand box, and the shell mold is fixed and then cast.
Through adopting above-mentioned technical scheme, fix the shell mould in the sandbox and cast, when making the shell mould pour, be difficult for inclining, also can not break.
Compared with the prior art, the invention has the following beneficial effects:
the shell mold provided by the invention has the advantages of high material yield, low cost, high production efficiency and environmental protection.
Drawings
FIG. 1 is a schematic structural view of a shell mold of the present invention;
FIG. 2 is a schematic view of the structure of the die and casting after casting and crushing of the shell mold.
Detailed Description
The invention will now be further described with reference to the accompanying drawings.
Example one
As shown in figure 1, the shell mold comprises a pouring gate 1, a pouring gate 2 and at least one shell 3, wherein the pouring gate 1 and the pouring gate 2 are made of high-temperature-resistant heat-insulating materials, and the shell 3 is made of high-temperature-resistant materials.
The pouring gate 1 and the pouring gate 2 are made of high-temperature-resistant heat-insulating materials, so that the cooling speed of the pouring gate 1 and the cooling speed of the pouring gate 2 can be effectively reduced, the fluidity during casting is improved, and the complete molding of parts can be ensured.
The pouring gate 1 and the pouring gate 2 have good heat preservation, so the sizes of the pouring gate 1 and the pouring gate 2 can be smaller, the casting amount is saved, the metal yield is improved, and the recovery workload is reduced.
The pouring gate 1 and the pouring gate 2 have the heat preservation function, so that the process of coating heat preservation cotton can be omitted, and the casting efficiency is improved.
The high-temperature resistant material is ceramic slurry or photocuring ceramic resin slurry.
The high-temperature-resistant heat-insulating material is a mixture of ceramic slurry or photocuring ceramic resin slurry and a heat-insulating material, and the heat-insulating material is heat-insulating cotton.
The high-temperature resistant heat-insulating material is a mixture of ceramic slurry and heat-insulating cotton or a mixture of light-cured ceramic resin slurry and heat-insulating cotton
The heat-insulating cotton is formed by melting high-purity clay clinker, alumina powder, silica powder, chrome quartz sand and other raw materials in an industrial electric furnace at high temperature to form fluid. Then blowing compressed air or throwing the silk into fiber shape by a silk throwing machine, and collecting cotton by a cotton collector to form the heat preservation cotton. The heat preservation cotton can be further processed into powder and mixed with ceramic slurry to be used as a 3D printing material. The new material has the characteristics of light weight, high strength, oxidation resistance, low thermal conductivity, good flexibility, corrosion resistance, small heat capacity and the like.
The material with heat preservation performance is added in the ceramic slurry, so that the heat preservation performance is effectively improved, the cooling rate is reduced during casting, and the heat preservation effect is good.
The high-temperature resistant material is ceramic slurry or light-cured ceramic resin slurry.
The shell mould is an integrated structure made by 3D printing.
Adopt 3D to print can omit the loaded down with trivial details step of traditional wax matrix to pollute for a short time, adopt 3D to print simultaneously and can let runner 2 and shell 3 form good contact, for overall structure, convenient manufacturing, and the shell mould of an organic whole structure that two kinds of different materials were made is difficult to accomplish to traditional approach.
In order to reduce cooling rate among the prior art, it is great to water 1 and runner 2, and like this with water 1 and runner 2 and contact the metal cooling earlier, form the heat preservation, do not influence subsequent casting, if water 1 and runner 2 less cause the part shaping incomplete easily, produce the defective products.
The disadvantages in the prior art are: the traditional shell mold design needs to design a larger pouring channel 1 and a pouring gate 2; the shell mold is wrapped with heat insulation cotton before casting after sintering, so that the heat insulation effect of molten metal is achieved; during post-treatment, the energy consumption of a machine and the waste of a shell mold are increased, so that the raw materials for making the shell are wasted, and the environment is polluted; the metal die head 4 is recycled, so that the material yield of the cast metal is low, and the recycling workload is increased.
The material of 3D printer adopts ceramic thick liquids and the cotton heat preservation material that mixes of heat preservation, does not have the high problem of material cost, and it is very cheap to say.
The shell 3 of the part is printed by adopting a high-temperature-resistant material, and the pouring gate 1 and the pouring gate 2 are printed by adopting a high-temperature-resistant heat-insulating material, so that the fluidity of molten metal liquid can be ensured in the pouring process, heat-insulating cotton does not need to be wrapped, the sizes of the pouring gate 1 and the pouring gate 2 can be properly reduced, and the material yield of the poured metal is improved; after the pouring is finished, the workload of the recovery die head 4 is reduced, the energy consumption and manpower are reduced, the environmental pollution is reduced, and the production efficiency is improved; the shell mold printed by 3D can be directly cast into a product without opening the mold, injecting wax, repairing wax, assembling wax trees, soaking the pulp to make the shell, burning, dewaxing and other post-treatment.
When the shell mold is used in the casting field, the pouring gate 1 and the pouring gate 2 have good heat insulation performance, so that molten metal is not easy to solidify, good fluidity of the molten metal can be maintained, and the diameters of the pouring gate 1 and the pouring gate 2 can be effectively reduced, for example, in the prior art, the weight of a part is only 300 g, but 1000 g of metal is needed for casting the part, the rest 700 g of metal is distributed in the pouring gate 1 and the pouring gate 2, the material yield is low, and the shell mold can be used for casting only 800 g, so that the material yield is greatly improved.
Example two
A method of manufacturing a shell mold comprising the steps of:
s10, designing a shell mold, wherein the shell mold comprises a pouring gate 1, a pouring gate 2 and a shell 3;
s11, preparing a printing raw material, wherein the pouring gate 1 and the pouring gate 2 are made of high-temperature-resistant heat-insulating materials, and the shell 3 is made of high-temperature-resistant materials;
s12, printing a shell mold, and printing the shell mold by using ceramic slurry and ceramic slurry mixed with a heat insulation material through a 3D printer;
s13, drying, namely drying the shell mold until the moisture in the shell mold is completely gasified;
and S14, performing surface treatment, namely polishing the inner surface of the shell mold to improve the smoothness of the inner surface of the shell mold, wherein the polishing treatment comprises grinding or chemical polishing.
The shell mold is efficient and short in time, has the overwhelming advantages of being faster, more flexible and lower in cost under the condition of producing a relatively small number of products, and can directly replace the prior art in mass production.
The temperature rise speed is 25-35 ℃/h during drying treatment, and the drying temperature is 50-150 ℃.
The temperature rise rate is beneficial to uniform gasification and removal of moisture in the shell mold, and cracks on the inner surface and the outer surface cannot occur due to too fast drying of the shell mold;
drying the printed whole casting shell mold, namely putting the whole casting shell mold into a drying box, raising the temperature to about 30 ℃ per hour, and when the temperature in the kiln reaches more than 100 ℃, separating water in the shell mold and gasifying the water until the water is completely gasified; and then polishing treatment is carried out, such as manual or electric tool is used for slowly grinding the protruded edges and corners inside the shell mold, or chemical agents are used for fading the fine lines on the inner surface of the shell mold and improving the internal smoothness.
During 3D printing, materials which are high-temperature resistant, heat-insulating and heat-preserving are used for the pouring channel 1 and the pouring gate 2, such as heat-insulating and heat-preserving materials like ceramic slurry mixed heat-preserving cotton; high temperature resistant ceramic slurry is used when printing the shell 3; the whole shell mold is printed layer by layer, each layer of material can be quickly solidified and formed, and finally the shell mold for the whole high-temperature-resistant casting is printed.
The high-temperature-resistant casting shell mold is printed out through 3D, the steps of mold opening, wax injection and wax repair are not needed, and meanwhile, the steps of wax tree grouping, slurry soaking and shell making and combustion dewaxing are skipped, so that the production period of products is greatly shortened, the equipment and labor cost is reduced, the environment is free from pollution, and the transformation and upgrading of the industry are promoted.
3D prints fashioned printing material cost very cheap, can realize bulk production, and the shell mould of printing still can reach the standardization, and later stage automated processing is simpler, swift, green, environmental protection.
EXAMPLE III
A method of manufacturing a shell mold comprising the steps of:
s20, designing a shell mold, wherein the shell mold comprises a pouring gate 1, a pouring gate 2 and a shell 3;
s21, preparing a printing raw material, wherein the pouring gate 1 and the pouring gate 2 are made of high-temperature-resistant heat-insulating materials, and the shell 3 is made of high-temperature-resistant materials;
s22, printing a shell mold, and printing the shell mold by using the photocuring ceramic resin slurry and the photocuring ceramic resin slurry mixed with the heat insulation material by using a 3D printer;
s23, degreasing, wherein degreasing is carried out on the shell mold printed by the light-cured ceramic resin slurry by using a sintering furnace until the resin in the shell mold is burnt and gasified;
and S24, performing surface treatment, namely polishing the inner surface of the shell mold to improve the smoothness of the inner surface of the shell mold, wherein the polishing treatment comprises grinding or chemical polishing.
The temperature rise rate is 50-100 ℃/h during degreasing treatment, and the gasification temperature is 500-800 ℃.
Degreasing the printed whole photo-cured ceramic resin cast shell mold, namely putting the whole photo-cured ceramic resin cast shell mold into a sintering furnace, raising the temperature to about 80 ℃ per hour, and when the temperature in the furnace reaches over 500 ℃, gasifying the resin in the shell mold until the resin is completely gasified; the temperature rise rate is beneficial to uniform gasification and removal of the resin in the shell mold, and cracks on the inner surface and the outer surface cannot be caused by excessively fast degreasing of the shell mold.
The 3D printing forming printing technology is mature, mass production can be achieved, printed shell molds can also achieve standardization, the yield of products is very high, and later-stage automatic processing is simpler, quicker, green and environment-friendly.
Example four
A method of casting a shell mold comprising the steps of:
s30, heating the finished shell mold to 800-1200 ℃;
s31, taking out the shell mold and fixing the shell mold in a sand box;
s32, casting;
and S33, vibrating and breaking the shell mold after the casting is finished to obtain a die head 4 and a casting 5.
The shell mold is heated and then cast, so that the temperature difference can be reduced, the quality of the casting 5 is ensured, and the fluidity of the molten metal is improved.
As the pouring gate 1 and the pouring gate 2 are made of heat insulation materials, heat insulation cotton does not need to be added to small parts, heat insulation cotton can be added to parts with large volumes according to conditions, and the cooling speed of the pouring gate 1 and the pouring gate 2 is reduced.
After the shell mold is taken out, the shell mold can be fixed in a sand box for casting, so that the strength of the shell mold is enhanced, and the shell mold is not easy to incline and not easy to break during casting.
As shown in figure 2, the die head 4 and the casting 5 are crushed after the shell die is shaken after the casting forming, then the casting 5 is cut off, and the die head 4 is recycled.
Claims (9)
1. A shell mould comprises a pouring gate, a pouring gate and at least one shell, and is characterized in that the pouring gate and the pouring gate are made of high-temperature-resistant heat-insulating materials, and the shell is made of high-temperature-resistant materials.
2. A shell mould according to claim 1, characterised in that the refractory material is a ceramic paste or a photocurable ceramic resin paste.
3. The shell mold according to claim 1, wherein the high temperature resistant insulating material is a mixture of a ceramic slurry or a photo-curable ceramic resin slurry and an insulating material.
4. A shell mould as claimed in claim 3, wherein the insulating material is insulating cotton.
5. A shell mould according to claim 1, characterised in that the shell mould is a 3D printed integral structure.
6. A method of manufacturing a shell mold, comprising the steps of:
designing a shell mold, wherein the shell mold comprises a pouring gate, a pouring gate and a shell;
preparing a printing raw material, wherein the pouring gate and the pouring gate are made of high-temperature-resistant heat-insulating materials, and the shell is made of high-temperature-resistant materials;
printing a shell mold, and printing the shell mold by using a 3D printer;
drying or degreasing, namely drying the shell mold printed by the ceramic slurry until the moisture in the shell mold is completely gasified, and degreasing the shell mold printed by the photocuring ceramic resin slurry until the resin in the shell mold is combusted and gasified;
and surface treatment, namely polishing the inner surface of the shell mold to improve the smoothness of the inner surface of the shell mold, wherein the polishing treatment comprises grinding or chemical polishing.
7. The method for manufacturing a shell mold according to claim 6, wherein the temperature rise rate during the drying treatment is 25-35 ℃/h, and the drying temperature is 50-150 ℃;
the heating rate during degreasing treatment is 50-100 ℃/h, and the gasification temperature is 500-800 ℃.
8. A method of casting a shell mold, comprising the steps of:
heating the shell mold completed in claim 6 to 800-1200 ℃;
taking out the shell mold and casting;
and after the casting is finished, vibrating and breaking the shell mold to obtain a die head and a casting.
9. The method of casting a shell mold according to claim 8, wherein the shell mold is taken out after the heating is completed and placed in a flask, and the shell mold is fixed and then cast.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010723928.8A CN111992671A (en) | 2020-07-24 | 2020-07-24 | Shell mould and manufacturing method and casting method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
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