CN112427608A - Large magnesium alloy special-shaped structural part casting die and process - Google Patents
Large magnesium alloy special-shaped structural part casting die and process Download PDFInfo
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- CN112427608A CN112427608A CN202011377611.XA CN202011377611A CN112427608A CN 112427608 A CN112427608 A CN 112427608A CN 202011377611 A CN202011377611 A CN 202011377611A CN 112427608 A CN112427608 A CN 112427608A
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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
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
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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
Abstract
The invention provides a casting die and a casting process for a large magnesium alloy special-shaped structural part. The mold comprises a melt distributor, mud cores and a core box, wherein a mold cavity is arranged in the core box, the upper end and the lower end of the mold cavity are open, the mud cores are arranged in the mold cavity, an annular mold cavity is arranged between the mud cores and the core box, the melt distributor is arranged below the mud cores and the core box, the melt distributor is communicated with the mold cavity, and the mud cores are molded by phenolic polyurethane self-hardening sand. The process comprises the following steps: a vertical modeling and assembling die; low-pressure casting, wherein in the casting process, the alloy melt uniformly rises along the cavity, and is pressurized, kept for a certain time and solidified and formed after the cavity is filled with the alloy melt; and (6) demolding. The invention can be used for casting hollow thin-wall structural members with irregular shapes, and realizes the molding of the transverse rib structure; the problem of sand falling of the die is avoided, the uniformity of flowing and cooling temperature of the alloy melt is improved, disturbance factors in the distribution process are reduced, and the casting quality is improved.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a casting mold and a casting process for a large magnesium alloy special-shaped structural part.
Background
With the continuous improvement of the requirements of advanced aerospace product equipment on comprehensive performance, higher requirements are provided for the performances of bearing strength, light weight, high temperature resistance and the like of the structural member. An important structural member 11 of a certain type of aerospace product shell is shown in fig. 6, wherein the periphery of the structural member 11 is an annular closed curved side wall, the upper end and the lower end of the structural member are open, and a plurality of transverse ribs are arranged inside the closed curved surface and connected with the side wall. The dimension of the structural member 11 in at least one direction exceeds 1m, and the overall dimension is usually 1-2 m.
Currently, the casting of the structural member 11 has the following problems: (1) the casting system has large design difficulty due to large external dimension, irregular shape, complex inner cavity with multiple ribs; (2) the casting system has longer flow due to the shape and the size, and the technical parameters such as cooling uniformity, molding quality and the like are difficult to control, so that casting defects are easy to occur; (3) the casting 10 is of a hollow structure, the inner cavity is provided with a plurality of ribs, the combination difficulty of mud cores is high, sand is easy to fall, the inner surface of the structural part 11 is a non-processing surface, and the casting defects of the inner cavity cannot be removed through post-processing.
Disclosure of Invention
In order to solve the technical problems, the invention provides a casting mold and a casting process for a large magnesium alloy special-shaped structural part.
The invention is realized by the following technical scheme.
The invention provides a large-scale magnesium alloy special-shaped structural member casting die which comprises a melt distributor, a mud core and a core box, wherein a die cavity is arranged in the core box, the upper end and the lower end of the die cavity are open, the mud core is arranged in the die cavity, an annular die cavity is arranged between the mud core and the core box, the melt distributor is arranged below the mud core and the core box and is communicated with the die cavity, and the mud core is molded by phenolic polyurethane self-hardening sand.
The distributor comprises a first-layer distribution cavity and a second-layer distribution cavity, the first-layer distribution cavity is of a fork-shaped structure, the middle of the lower end of the first-layer distribution cavity is provided with a casting connecting pipe, the second-layer distribution cavity is of an annular structure, and a communicating pipe is connected between each fork-shaped part of the first-layer distribution cavity and the second-layer distribution cavity.
The mud core comprises a plurality of sub-cores which are stacked up and down, the end faces of the sub-cores are provided with transverse groove structures, and the end face between every two adjacent sub-cores is provided with a positioning structure.
The positioning structure is characterized in that a protrusion is arranged on the end face of one sub-core, and a groove is arranged on the corresponding end face of the other sub-core.
The core box comprises an outer die I and an outer die II, wherein notches of the outer die I and the outer die II are mutually buckled to form a die cavity with openings at the upper end and the lower end.
And a plurality of columnar runners are arranged on the first outer die and the second outer die around the die cavity, and gaps are arranged on the runners and communicated with the die cavity. The pouring channel (6) is preferably circular or oval.
The edge of the notch of the first outer die is provided with a first rib, the edge of the notch of the second outer die is provided with a second rib, the first rib is clamped with the second rib, and the first rib is contacted with the groove surface of the second outer die.
The invention also provides a casting method of the large magnesium alloy special-shaped structural part, which comprises the following steps:
(1) assembling a mould, namely assembling the mould by adopting a vertical molding manner, wherein the mould is provided with an annular cavity corresponding to the side wall of the structural part, and a transverse molten metal flow channel is arranged corresponding to the transverse rib;
(2) low-pressure casting, namely casting according to the following process parameters, wherein in the casting process, the alloy melt uniformly rises along the cavity, is pressurized and maintained for a certain time after the cavity is filled with the alloy melt, and is solidified and formed;
the technological parameters are as follows: the liquid rising speed is 10-11 mpa/s, the mold filling speed is 9-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-260 s, and the casting temperature is 740-765 ℃;
(3) and (5) demolding, cutting the outer surface of the casting and removing the casting burl.
The step (1) of assembling the mold specifically comprises the steps of taking a plane where a transverse rib of a structural part is located as a parting surface, firstly manufacturing a plurality of sub-cores, arranging grooves on the end surfaces of the sub-cores corresponding to the transverse rib, stacking the sub-cores up and down to manufacture mud cores, then sleeving a core box on the mud cores, reserving a certain gap between the core box and the mud cores corresponding to the thickness of the side wall of the structural part, and communicating the gap with a pouring channel on the core box.
The invention has the beneficial effects that:
the invention has the following advantages: (1) the casting mould can be used for casting hollow thin-wall structural members with irregular shapes, and the forming of a transverse rib structure is realized; (2) the casting process of the casting is vertical casting, the alloy melt gradually rises from the lower part of the cavity to uniformly fill the cavity, sand is not easy to fall off, and casting defects are reduced; (3) the mud core is molded by phenolic polyurethane self-hardening sand, so that the smoothness and the dimensional accuracy of the surface of the casting are ensured; (4) the uniformity of the flowing and cooling temperature of the alloy melt is improved, the disturbance factor in the distribution process is reduced, the quality of the casting is improved, and the later-period processing amount is small; (5) the problem of sand falling of the mold is avoided, the probability of casting defects is reduced, and the forming precision of the inner cavity of the structural member is improved.
Drawings
FIG. 1 is a schematic exterior view of the mold assembly of the present invention;
FIG. 2 is a schematic structural view of the melt distributor of the present invention;
FIG. 3 is a schematic view of the construction of the mud core of the present invention;
FIG. 4 is a schematic structural diagram of a first outer mold of the invention;
FIG. 5 is a schematic structural view of a second outer mold of the present invention;
figure 6 is a schematic structural view of a structural member made using the present invention.
In the figure: 1-covering the box; 2-a melt distributor; 201-one layer of distribution cavity; 202-two-layer distribution chamber; 203-casting connecting pipe; 204-communicating tube; 3-mud core; 301-a daughter core; 302-lateral trenches; 303-bulge; 4-external mold one; 5-outer mold two; 6-pouring channel; 7-a gap; 8, forming a first rib; and 9-rib II.
Detailed Description
The technical solution of the present invention is further described below, but the scope of the claimed invention is not limited to the described.
As shown in FIGS. 1 to 5, the structure of the present invention is schematically illustrated:
the invention provides a large-scale magnesium alloy special-shaped structural member casting die which comprises a melt distributor 2, a mud core 3 and a core box, wherein a die cavity is arranged in the core box, the upper end and the lower end of the die cavity are open, the mud core 3 is arranged in the die cavity, an annular die cavity is arranged between the mud core 3 and the core box, the melt distributor 2 is arranged below the mud core 3 and the core box, the melt distributor 2 is communicated with the die cavity, and the mud core 3 is molded by phenolic polyurethane self-hardening sand.
When the sand core casting machine is used, the melt distributor 2, the sand core 3 and the core box are assembled, then the cover box 1 covers the core box, the upper part of a cavity is closed, the lower part of the cavity is communicated with the melt distributor 2, then the melt distributor 2 is connected with a casting system, casting is carried out by adopting a low-pressure casting process or a differential pressure casting process, a casting 10 shown in the figure 2 is formed, and the structural part 11 is obtained after machining and cutting.
The casting method can be used for casting the hollow thin-wall structural part 11 with an irregular shape, the casting process of the casting 10 is vertical casting, the alloy melt gradually rises from the lower part of the cavity to uniformly fill the cavity, sand is not easy to fall, and the casting defects are reduced; the mud core 3 is molded by adopting phenolic polyurethane self-hardening sand, so that the smoothness and the dimensional accuracy of the surface of the casting 10 are ensured.
As shown in fig. 2: the distributor comprises a first-layer distribution cavity 201 and a second-layer distribution cavity 202, wherein the first-layer distribution cavity 201 is of a fork-shaped structure, a casting connecting pipe 203 is arranged in the middle of the lower end of the first-layer distribution cavity 201, the second-layer distribution cavity 202 is of an annular structure, and communicating pipes 204 are connected between the branched parts of the first-layer distribution cavity 201 and the second-layer distribution cavity 202.
During casting, after the alloy melt enters the first-layer distribution cavity 201 from the casting connecting pipe 203, the alloy melt uniformly rises to the second-layer distribution cavity 202 along each branched part and uniformly rises to the cavity along the second-layer distribution cavity 202, so that each part of the alloy melt uniformly flows, and the distribution time in the forming process is reduced.
As shown in fig. 3: the mud core 3 comprises a plurality of sub-cores 301 which are stacked up and down, the end surfaces of the sub-cores 301 are provided with transverse groove 302 structures, and the end surface between two adjacent sub-cores 301 is provided with a positioning structure. The transverse ribs of the structural member 11 are used as parting surfaces to arrange the plurality of sub-cores 301, so that the forming of the transverse rib structure is realized.
The positioning structure is specifically that a protrusion 303 is arranged on the end face of one sub-core 301, and a groove is arranged on the corresponding end face of the other sub-core 301. The connecting surfaces between the adjacent sub-cores 301 form a male and female mold positioning structure, so that the mud cores 3 can be accurately assembled, sand falling in the assembling process is avoided, and the forming precision of the inner cavity of the structural member 11 is improved.
As shown in FIGS. 4-5: the core box comprises an outer die I4 and an outer die II 5, wherein notches of the outer die I4 and the outer die II 5 are mutually buckled to form a die cavity with openings at the upper end and the lower end. The core box is subjected to die splitting design, so that the core box and the mud cores 3 are convenient to assemble, sand falling in the assembling process is avoided, and the probability of casting defects is reduced.
And a plurality of columnar pouring channels 6 are arranged on the first outer die 4 and the second outer die 5 around the die cavity, and gaps 7 are arranged on the pouring channels 6 and communicated with the die cavity. The pouring channel (6) is preferably circular or oval. The pouring gate 6 is communicated with the melt distributor 2, the alloy melt uniformly rises along the pouring gate 6 and simultaneously flows into the cavity from the gap 7, so that the scouring of the alloy melt in the cavity to the mud core 3 and the core box is reduced, the sand falling and casting defects are prevented, and the surface smoothness of the casting 10 is improved.
The edge of the notch of the first outer die 4 is provided with a first rib 8, the edge of the notch of the second outer die 5 is provided with a second rib 9, the first rib 8 is clamped with the second rib 9, and the first rib 8 is in contact with the groove surface of the second outer die 5. The core box is conveniently and accurately assembled by positioning the first rib 8 and the second rib 9, and the contact parts of the first outer die 4 and the second outer die 5 are isolated from the cavity in the assembling process, so that the position does not need to be repeatedly adjusted after the assembling process, and the quality of a casting 10 cannot be influenced even if sand falls due to mutual friction of the first outer die 4 and the second outer die 5 in the assembling process.
The invention also provides a casting method of the large magnesium alloy special-shaped structural part, which comprises the following steps:
(1) assembling a mould, namely assembling the mould by adopting a vertical modeling, wherein the mould is provided with an annular cavity corresponding to the side wall of the structural part 11, and a transverse molten metal flow channel is arranged corresponding to the transverse rib;
(2) low-pressure casting, namely casting according to the following process parameters, wherein in the casting process, the alloy melt uniformly rises along the cavity, is pressurized and maintained for a certain time after the cavity is filled with the alloy melt, and is solidified and formed;
the technological parameters are as follows: the liquid rising speed is 10-11 mpa/s, the mold filling speed is 9-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-260 s, and the casting temperature is 740-765 ℃;
(3) and (4) demolding, cutting the outer surface of the casting 10 and removing the casting burls.
The step (1) of assembling the mold specifically comprises the steps of taking the plane where the transverse ribs of the structural member 11 are located as a parting surface, firstly manufacturing a plurality of sub-cores 301, arranging grooves on the end surfaces of the sub-cores 301 corresponding to the transverse ribs, stacking the sub-cores 301 up and down to manufacture mud cores 3, then sleeving a core box on the mud cores 3, reserving a certain gap between the core box and the mud cores 3 corresponding to the thickness of the side wall of the structural member 11, and communicating the gap with a pouring gate 6 on the core box.
When low-pressure casting or differential pressure casting is adopted, the mud core 3 and the core box are assembled on the melt distributor 2, the pouring gate 6 on the core box is aligned with the alloy melt outlet on the melt distributor 2, and the assembled mould is wholly sealed by the bottom box and the cover box 1, so that casting can be carried out.
The step (2) is casting according to the following process parameters, wherein the liquid raising speed is 10-11 mpa/s, the mold filling speed is 9-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-220 s, and the casting temperature is 755-765 ℃;
the step (2) is casting according to the following process parameters, wherein the liquid rising speed is 10-11 mpa/s, the mold filling speed is 11-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-220 s, and the casting temperature is 760-765 ℃;
the step (2) is casting according to the following process parameters, wherein the liquid rising speed is 11mpa/s, the mold filling speed is 13mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-220 s, and the casting temperature is 765 ℃;
the step (2) is cast according to the following process parameters, wherein the liquid rising speed is 11mpa/s, the mold filling speed is 13mpa/s, the pressurization speed is 7mpa/s, the pressurization time is 14s, the dwell time is 210s, and the casting temperature is 765 ℃;
the step (2) further comprises the following steps: the core box is additionally provided with a vent needle with the diameter of phi 3-phi 4, the mud core 3 is additionally provided with an air rope and a lightening hole, and the exhaust effect in the casting process is improved.
In the first embodiment of the invention, the step (2) of the casting method of the large magnesium alloy special-shaped structural part is carried out according to the following process parameters:
the technological parameters are as follows: the liquid rising speed is 11mpa/s, the mold filling speed is 13mpa/s, the pressurization speed is 7mpa/s, the pressurization time is 14s, the dwell time is 210s, and the casting temperature is 765 ℃;
the core box is additionally provided with a vent needle with the diameter of phi 3-phi 4, the mud core 3 is additionally provided with an air rope and a lightening hole, and the exhaust effect in the casting process is improved.
Casting quality: after the box is opened, no obvious undercasting exists, a crack defect appears on the edge of the large end face or the small end face or the transverse rib part of a part of the casting 10, and after the defect is repaired, the fluorescence detection is qualified.
In the second embodiment, according to the casting method of the large magnesium alloy special-shaped structural part provided by the invention, the step (2) is performed according to the following process parameters:
the technological parameters are as follows: the liquid-lifting speed is 10mpa/s, the filling speed is 11mpa/s, the pressurizing speed is 7mpa/s, the pressurizing time is 14s, the pressure-maintaining time is 210s, and the casting temperature is 760 ℃.
Casting quality: after the box is opened, 4-8 parts of the part of the casting 10 are under-cast, and part of the casting is qualified after being repaired and is scrapped.
In the third embodiment, according to the casting method of the large magnesium alloy special-shaped structural part, in the step (2), casting is performed according to the following process parameters:
the technological parameters are as follows: the liquid rising speed is 10mpa/s, the filling speed is 9mpa/s, the pressurizing speed is 7mpa/s, the pressurizing time is 14s, the pressure maintaining time is 210s, and the casting temperature is 755-760 ℃.
Casting quality: after the box is opened, a part of the casting 10 has a plurality of cold shut and is lack of casting, and after the part is repaired, the casting 10 is qualified and more castings are scrapped.
In the fourth embodiment, according to the casting method of the large magnesium alloy special-shaped structural part provided by the invention, the step (2) is carried out according to the following process parameters:
the technological parameters are as follows: the liquid rising speed is 10mpa/s, the filling speed is 9mpa/s, the pressurizing speed is 7mpa/s, the pressurizing time is 14s, the pressure maintaining time is 210s, and the casting temperature is 750-755 ℃.
Casting quality: the temperature is difficult to control in the casting process, the casting 10 has a plurality of cold partitions and under-casting after the casting is opened, the casting is qualified after only a small amount of repair, and the yield is low.
Claims (10)
1. A casting process of a large magnesium alloy special-shaped structural part is characterized in that: comprises the following steps of (a) carrying out,
(1) assembling a mould, namely assembling the mould by adopting a vertical molding manner, wherein the mould is provided with an annular cavity corresponding to the side wall of the structural part, and a transverse molten metal flow channel is arranged corresponding to the transverse rib;
(2) low-pressure casting, namely casting according to the following process parameters, wherein in the casting process, the alloy melt uniformly rises along the cavity, is pressurized and maintained for a certain time after the cavity is filled with the alloy melt, and is solidified and formed;
the technological parameters are as follows: the liquid rising speed is 10-11 mpa/s, the mold filling speed is 9-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-260 s, and the casting temperature is 740-765 ℃;
(3) and (4) demolding, cutting the outer surface of the casting (10) and removing the casting burl.
2. The casting process of the large magnesium alloy special-shaped structural part according to claim 1, wherein the casting process comprises the following steps: step (1) mould equipment specifically includes, regard the horizontal muscle place plane of structure as the parting surface, make a plurality of child cores (301) earlier, set up the slot at the terminal surface of child core (301) corresponding horizontal muscle, stack up the child core (301) from top to bottom and place, make mud core (3), then locate mud core (3) with the core box cover on, certain clearance is reserved to the lateral wall thickness of corresponding structure between core box and mud core (3), and the clearance communicates with watering (6) on the core box.
3. The casting process of the large magnesium alloy special-shaped structural part according to claim 1, wherein the casting process comprises the following steps: the step (2) is cast according to the following process parameters, wherein the liquid rising speed is 10-11 mpa/s, the mold filling speed is 9-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-220 s, and the casting temperature is 755-765 ℃.
4. The casting process of the large magnesium alloy special-shaped structural part according to claim 3, wherein the casting process comprises the following steps: the step (2) is cast according to the following process parameters, wherein the liquid rising speed is 10-11 mpa/s, the mold filling speed is 11-13 mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-220 s, and the casting temperature is 760-765 ℃.
5. The casting process of the large magnesium alloy special-shaped structural part according to claim 4, wherein the casting process comprises the following steps: the step (2) is cast according to the following process parameters, wherein the liquid rising speed is 11mpa/s, the mold filling speed is 13mpa/s, the pressurization speed is 6-8 mpa/s, the pressurization time is 12-17 s, the pressure maintaining time is 200-220 s, and the casting temperature is 765 ℃.
6. The casting process of the large magnesium alloy special-shaped structural part according to claim 5, wherein the casting process comprises the following steps: the step (2) is cast according to the following process parameters, wherein the liquid rising speed is 11mpa/s, the filling speed is 13mpa/s, the pressurizing speed is 7mpa/s, the pressurizing time is 14s, the pressure maintaining time is 210s, and the casting temperature is 765 ℃.
7. A large-scale magnesium alloy special-shaped structural member casting mold used for the large-scale magnesium alloy special-shaped structural member casting method according to any one of claims 1 to 6, characterized in that: including melt distributor (2), mud core (3), core box, be equipped with the die cavity in the core box, both ends opening about the die cavity, mud core (3) are located in the die cavity, are equipped with annular die cavity between mud core (3) and the core box, and melt distributor (2) are located the below of mud core (3), core box, and melt distributor (2) and die cavity intercommunication, mud core (3) adopt phenolic aldehyde polyurethane from the hard sand molding.
8. The large magnesium alloy special-shaped structural member casting mold according to claim 7, wherein: the distributor (2) comprises a first-layer distribution cavity (201) and a second-layer distribution cavity (202), the first-layer distribution cavity (201) is of a fork-shaped structure, a casting connecting pipe (203) is arranged in the middle of the lower end of the first-layer distribution cavity (201), the second-layer distribution cavity (202) is of an annular structure, and communicating pipes (204) are connected between each branch part of the first-layer distribution cavity (201) and the second-layer distribution cavity (202).
9. The large magnesium alloy special-shaped structural member casting mold according to claim 7, wherein: the mud core (3) comprises a plurality of sub-cores (301) which are stacked up and down, the end faces of the sub-cores (301) are provided with transverse groove (302) structures, and the end face between every two adjacent sub-cores (301) is provided with a positioning structure.
10. The large magnesium alloy special-shaped structural member casting mold according to claim 7, wherein: the core box comprises a first outer die (4) and a second outer die (5), notches of the first outer die (4) and the second outer die (5) are mutually buckled to form a die cavity with openings at the upper end and the lower end, a plurality of columnar pouring channels (6) are arranged on the first outer die (4) and the second outer die (5) around the die cavity, and gaps (7) are formed in the pouring channels (6) and communicated with the die cavity.
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| CN113560494A (en) * | 2021-07-21 | 2021-10-29 | 贵州航天风华精密设备有限公司 | Deformation-reducing casting method and structure for large aluminum-magnesium alloy thin-wall cabin |
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| CN113560494A (en) * | 2021-07-21 | 2021-10-29 | 贵州航天风华精密设备有限公司 | Deformation-reducing casting method and structure for large aluminum-magnesium alloy thin-wall cabin |
| CN113560494B (en) * | 2021-07-21 | 2023-03-14 | 贵州航天风华精密设备有限公司 | Deformation-reducing casting method and structure for large aluminum-magnesium alloy thin-wall cabin |
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