CN112548036A - Production process for lost foam centrifugal casting - Google Patents
Production process for lost foam centrifugal casting Download PDFInfo
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- CN112548036A CN112548036A CN202110013058.XA CN202110013058A CN112548036A CN 112548036 A CN112548036 A CN 112548036A CN 202110013058 A CN202110013058 A CN 202110013058A CN 112548036 A CN112548036 A CN 112548036A
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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
- B22C9/046—Use of patterns which are eliminated by the liquid metal in the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/088—Feeder heads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
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- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention discloses a production process for lost foam centrifugal casting, which comprises the following steps: s1, designing a pouring channel; s2, designing a riser; s3, a box filling (making) process; and S4, casting. Meanwhile, the molten metal fills the space with reduced volume due to solidification under the action of centrifugal force, the feeding effect is good, the regrown dendritic crystals are broken under the action of centrifugal force and exciting force to generate a large amount of crystal nuclei, crystal grains are refined, the density of the product is further improved, and the molten metal in a pouring gate and in a riser (a slag collecting riser or a feeding riser) moves towards a casting model under the action of centrifugal force, so that the utilization rate of the molten metal is improved, the yield of centrifugal casting is also improved, and the processing amount of a centrifugal casting machine is reduced.
Description
Technical Field
The invention belongs to the technical field of centrifugal casting, and particularly relates to a production process for lost foam centrifugal casting.
Background
The lost foam casting (also called solid casting) is a new casting method for producing castings by using a new one-step forming casting process, which is formed by using foamed plastic (EPS, STMM or EPMM) high polymer material to make a solid mould with the same structure and size as the parts to be produced and cast, dip-coating refractory paint (having strengthening, cleaning and ventilating functions) and drying, embedding in dry quartz sand, carrying out three-dimensional vibration moulding, pouring a casting moulding box, pouring molten metal in the casting moulding box under a negative pressure state, heating, gasifying and extracting the high polymer material model, and further replacing the liquid metal for cooling and solidifying. Compared with the traditional casting technology, the lost foam casting technology has the advantages of incomparable ratio, and is called as the casting technology of the 21 st century and the green revolution of the casting industry by the casting world at home and abroad.
The lost foam casting has the following characteristics that 1, the casting quality is good, the cost is low, 2, the material is not limited, the size is suitable, 3, the precision is high, the surface is smooth, the cleaning is reduced, the machining cost is saved, 4, the internal defects are greatly reduced, the casting tissue is compact, 5, the large-scale and mass production can be realized, 6, the lost foam casting is suitable for mass production and casting of the same casting, 7, the lost foam casting is suitable for manual operation and automatic assembly line production operation control, 8, the production state of a production line meets the requirement of environmental protection technical parameter indexes, 9, the working environment and the production condition of the casting production line can be greatly improved, the labor intensity is reduced, the energy consumption is reduced, but the existing lost foam: the quality problems of insufficient pouring and the like caused by carburization, shrinkage porosity, slag inclusion, and reduction of the temperature of the metal liquid due to model vaporization are easy to occur.
Disclosure of Invention
The invention aims to provide a production process for lost foam centrifugal casting, which combines lost foam casting and centrifugal casting to exert respective advantages and solves the problems that molding sand is not easy to fill dead corners of a model when a box is filled (manufactured) in the prior art, the product quality problem and the machining amount are not easy, the working efficiency is low and a large amount of labor is wasted.
In order to achieve the purpose, the invention adopts the following technical scheme:
a production process for lost foam centrifugal casting comprises the following steps:
s1, design of pouring channel: the pouring channels are divided according to the flowing direction of molten metal: vertical (straight) pouring channels, horizontal pouring channels and ingate; ratio of cross section of vertical (straight) runner, horizontal runner to cross section of ingate 1.3: (1.2- -1.4): 1;
s1.1, vertical (straight) pouring channel: the runner is connected with a sprue at the upper part and is vertically placed, and a horizontal runner or an ingate are connected at the lower part (the horizontal runner and the ingate are integrated, the cross section of the runner is circular or square, and the appearance is cylindrical or columnar;
s1.2, cross runners: the upper part is connected with a vertical (straight) pouring channel, the lower part is connected with an ingate. The cross section is square or round, when two or more models are poured at one time, the end part of the bottom surface of a horizontal and vertical (straight) pouring gate can be connected with an ingate in a staggered way by 20-50 mm, the horizontal pouring gate and the ingate can be combined into a whole, the bottom is horizontal, the top inclines downwards towards the model, and the cross section gradually becomes smaller;
s1.2.1, slag collection setting of cross runners:
s1.2.1.1, a slag collecting bag installed at the upper end of the slag collecting bag is square or round, the width is the same as or slightly larger than that of the horizontal pouring channel, the height is more than one time of the height of the horizontal pouring channel and not more than 3 times of the height of the horizontal pouring channel, so that the internal scum is collected in the slag collecting bag in the flowing process of molten metal, the end part of the horizontal pouring channel is provided with an extension section which is vertical to the inner pouring channel, and the distance between the tail end and the connecting part of the inner pouring channel is more than 30 mm;
s1.2.1.2, the horizontal pouring gate is divided into one, two or three sections, the ingate is connected with the front lower part of the horizontal pouring gate by dislocation of 20-50 mm in the first section, and the ingate is connected with the front lower part of the horizontal pouring gate by dislocation of the first section, the ingate is connected with the horizontal pouring gate by dislocation of the second section, the ingate is connected with the horizontal pouring gate by dislocation of the first section, the ingate is connected with the horizontal pouring gate, and the;
s1.3, an inner pouring channel is connected with a transverse pouring channel in a large front end, is connected with a model in a small rear end, is rectangular in section and is wedge-shaped in shape. A plurality of ingates can be connected to one mold at the same time. The inner pouring channel is connected with the model and is provided with three types: the method comprises top pouring, bottom pouring and middle pouring, wherein the connecting direction of a pouring gate is consistent with the rotating direction of a casting and is not aligned to the inner wall, so that the inner wall is prevented from being washed by molten metal; if the casting model has larger volume, the ingates can be arranged in layers from two layers (bottom pouring and middle pouring) to three layers (top pouring, bottom pouring and middle pouring) or more. Ratio of cross section of runner to cross section of ingate (1.2-1.4): 1;
s1.3.1 ingate slag collection setting is divided into two conditions:
s1.3.1.1, the ingate is composed of a section, the section is rectangle, the section of the ingate becomes smaller towards the direction of the model, the section of the contact part of the ingate and the model is flat rectangle and is convenient to be taken down when being cleaned, the shape of the ingate can not be square or round, the bottom of the ingate is horizontal as much as possible, the upper surface of the ingate is an inclined plane, and the shape of the ingate is wedge-shaped;
s1.3.1.2, the ingate is divided into two sections, one section is on the top, one end of the other section is connected with the lower part of the front end of the top section in a staggered way by 20-50 mm, the other end is not opposite to the inner wall of the mould wall, so as to avoid the metal liquid from scouring the inner wall, the connection mode with the mould is also flat, and the requirement is the same as the above;
s2, design of a riser: the slag collecting riser and the feeding riser are combined together to form the slag collecting feeding riser or can be used separately in most cases;
s2.1, the diameter of a feeding head is more than 1.5 times of the wall thickness, the feeding head is determined according to actual conditions, an ingate can be directly connected with the feeding head sometimes, high-temperature molten metal is convenient to provide, and feeding is better;
s2.2, the diameter of the slag collecting riser is more than 1.2 times of the wall thickness according to the actual condition;
s2.3, riser placement position: under the action of centrifugal force, molten metal enters the casting mold from the feeding riser, and slag and gas move into the slag collecting riser from the casting; when the vertical (straight) pouring channel is tightly attached to the casting, the vertical (straight) pouring channel can be used as a riser.
S2.3.1 the riser can be connected with the atmosphere via an air duct to be called an exhaust riser.
S3, the box loading (making) process comprises the following steps:
s3.1, installing a rounded deluge sand feeder at the bottom of the sand warehouse, and installing an infrared ray or other light ray indicating marks capable of indicating the center position in the sand box in the middle of the sand feeder; the indicating mark and the self-rotation center of the compaction table are on the same vertical line;
s3.2, placing a special round sand box or a special square sand box on a fixed position of the center position of a special jolt ramming table for centrifugal casting of the lost foam, and fixing the sand box by using a fixing device; the rotation center of the sand box and the rotation center of the jolt ramming table are vertically superposed;
s3.3, paving a layer of sand with proper thickness in a sand box by using a sand feeder for about 200mm, leveling, putting the assembled model, irradiating the indicating light rays such as infrared rays and the like to the center of a pouring cup or a vertical (straight) runner, slowly rotating a jolt ramming table and the sand box to ensure that the center of the pouring cup or the vertical (straight) runner and a light ray indicating point are preferably superposed when rotating, if the center deviates, the distance can be adjusted between 0 and 50mm, and the smaller the distance is, the better the distance is;
and S3.4, opening the deluge sand feeder to uniformly feed sand, and simultaneously opening a vibration motor to feed sand and vibrate. Or in the sand adding process, multiple intermittent vibration is adopted, each time lasts for 5-30 seconds, the rotating speed of the compaction table is adjusted between 1-300 revolutions per minute, the dead angle parts which are not easy to fill sand in the model can be effectively filled under the acting force of centrifugal force and exciting force of the molding sand, but on the premise of ensuring the quality of the box, the rotating speed is gradually increased to the specified rotating speed from slow to fast, and the molding sand does not relatively move in the box under the action of the centrifugal force and the exciting force and is compacted to the end; the vibration motor is a vibration motor with adjustable frequency or a vibration motor with non-adjustable frequency.
S3.5, stopping adding the sand when the sand is added to a preset height, and slowly stopping rotating the compaction table;
and S3.6, paving a layer of plastic film on the sand box, and opening the plastic film at the mouth of the vertical (sprue) or pouring cup, wherein the size of the opening is the same as the outer diameter of the vertical (sprue) or pouring cup (when the pouring cup is arranged, the opening of the plastic film is larger than that of the vertical sprue, and the binding is required to reduce the opening). Exposing the vertical (straight) pouring gate or pouring cup to be more than 150mm in height, adding sand on the surface of the plastic film, flattening the sand with the thickness not less than 80mm, and making the size of the film exceed the edge of the sand box wall by more than 150mm after adding the sand;
s3.7, if a finished pouring cup is installed at the vertical (straight) pouring gate, the center of the pouring cup is placed to be coincident with the center of the vertical (straight) pouring gate or the rotation center of the sand box as much as possible, so that high-temperature molten metal is easily poured into the pouring cup when the pouring cup rotates, and the molten metal is prevented from splashing to hurt people due to the centrifugal force generated by the rotation of the pouring cup;
when the pouring cup is installed, the film connecting part at the vertical (straight) pouring gate at the root part of the pouring cup is surrounded outside after refractory materials such as quartz sand, chrome sand and the like are uniformly mixed with 0.5 to 10 percent of the binder for casting, and the mixture is solidified to prevent molten metal from seeping out;
s3.8, burying the poured empty foam model into the center of a sand box, adding sand, rotating, vibrating and compacting according to the process operation of filling (making) the box;
s4, casting the steel plate;
s4.1, the manufactured sand box is hoisted or mechanically conveyed to a special evaporative pattern centrifugal casting machine, meanwhile, a negative pressure interface on the sand box is connected with a negative pressure outlet on the casting machine in an abutting mode, and the sand box is fixed;
s4.2, placing the runner in place, wherein the outlet is over against the center of the pouring basin;
s4.3, opening a negative pressure machine to start negative pressure pumping 3-5 minutes before metal pouring, and simultaneously opening a negative pressure switch of the sand box to enable the negative pressure in the sand box to reach a specified value of the production technical requirement of 0.1-1.0 Mp;
s4.4, igniting the foam of the model by fire according to the condition of the model and the composition requirement of the casting, introducing oxygen when necessary, fully combusting the foam to the greatest extent, reducing carburetion, simultaneously preheating the cavity wall of the model, reducing the cooling speed of molten metal and facilitating better metal mold filling;
s4.5, when the components of the molten metal in the furnace are qualified, pouring the molten metal into a pouring ladle, lifting the pouring ladle to a pouring station, pouring the molten metal into a launder, and then enabling the molten metal to flow into a pouring cup from an outlet of the launder; according to the current situation, the casting machine can be started in advance or at the beginning of casting, the rotating speed is slowly increased from slow to fast to the required rotating speed, the rotating speed can also be gradually increased to the required rotating speed along with the increase of the amount of the metal liquid entering the model, the rotating speed is 1-300 r/min, and the vibrating motor can be started to vibrate when the amount of the metal poured into the model is about 1/5-1/2 of the weight of the casting piece according to the requirement; the vibration motor is a vibration motor with adjustable frequency or a vibration motor with non-adjustable frequency.
S4.6, after pouring is finished, adjusting the negative pressure holding time, the rotation duration time and the vibration duration time of the casting machine according to the casting solidification condition, wherein the adjustment can be carried out within 1-60 minutes; the rotation deceleration stop time of the casting machine is not in the duration range;
s4.7, after the machine is stopped, the launder is recovered to the original position; and (5) conveying the sand box to a box overturning position, and taking out the casting. Preferably, the casting pattern layout in S1 includes a single-piece casting pattern and two or more casting patterns, and the layout principle is as follows:
the arrangement principle of the single casting model is as follows: model with axis of symmetry: the central axis of the vertical (straight) pouring gate is superposed with the symmetric axis of the casting; the model without symmetry axis is that the center axis of the vertical (straight) pouring gate passes through the gravity center of the casting; meanwhile, the placement of the casting model also needs to consider that the main part or the processing part of the casting is placed at the farthest end from the central shaft of the vertical (straight) pouring channel and is placed at the bottom; the feeder head can not be placed at the riser head placing position or the uppermost end, but the pouring channel can be placed on the processing surface. The casting model can be horizontally placed, vertically placed or obliquely placed according to the condition.
The arrangement principle of two or more casting models is as follows: arranging one by one and in multiple layers: the components are assembled and arranged up and down according to a single piece, and are arranged in parallel as much as possible; one layer is formed by multiple layers: the models of each layer are uniformly arranged on a plane of the layer by taking the central axis of the vertical (straight) pouring channel as the center of a circle, the radius of each layer can be the same or different, and meanwhile, the placement of the casting models needs to consider that the main part or the processing part of the casting is placed at the farthest end from the central axis of the vertical (straight) pouring channel and is placed at the bottom. Can not be placed on the mounting surface of the slag collecting riser. But the machined surface may receive runners. The casting model can be horizontally placed, vertically placed or obliquely placed according to the condition.
Preferably, the design of the riser (slag collector or feeding riser) in S2 includes: setting direction and setting position.
Preferably, the arrangement direction of a riser (a slag collecting riser or a feeding riser) is horizontal; the setting position is on the casting side.
Preferably, the arrangement direction of a riser (a slag collecting riser or a feeding riser) is vertical; the setting position is on the top of the casting.
Preferably, the arrangement direction of the risers (slag collecting risers or feeding risers) is inclined; the setting positions are at the upper, middle and lower parts on the side surface of the casting.
Preferably, the vertical (straight) pouring channel is arranged at the side part of the casting close to the rotation center, and can replace a riser (a slag collecting riser or a feeding riser).
The invention has the technical effects and advantages that: compared with the prior art, the production process for lost foam centrifugal casting provided by the invention has the following advantages:
1. the invention has flexible design: the method provides sufficient freedom for the structural design of the casting, and can be used for casting a highly complex casting through the combination of the foam plastic templates; the investment and production cost are reduced: the weight of the casting blank is reduced, and the machining allowance is small; no sand core in traditional casting; the casting precision is high: compared with the traditional sand casting method, the machining time can be reduced by 40 to 50 percent; clean production, no chemical binder in the molding sand, no harm to the environment caused by the foamed plastic at low temperature, and the recovery rate of the used sand is more than 95 percent;
2. the product produced by the lost foam is used for centrifugal casting, so that the sand grinding during boxing (boxing) is improved, and the quality of the sand filling (boxing) can be effectively improved under the action of centrifugal force. The forming quality of the product can be effectively improved, the density of the product is improved, the yield of the product can be improved by using the lost foam for the centrifugally cast product, and the product machining allowance is reduced by using a plurality of lost foam in one box;
3. the sand box is enabled to rotate and vibrate, so that the slag and gas with lighter weight move upwards and towards the direction of the circle center under the action of centrifugal force, exciting force and molten metal buoyancy, and the degassing and deslagging effects are good. Meanwhile, the grown dendrite is broken under the action of centrifugal force and exciting force to generate a large amount of crystal nuclei, crystal grains are refined, and the density of the product is further improved. Molten metal in a pouring gate and in a riser (a slag collecting riser or a feeding riser) moves towards the casting model under the action of centrifugal force, so that the utilization rate of the molten metal is improved, and the feeding effect is good.
Drawings
FIG. 1 is a schematic view showing the position of a runner in example 1 of the present invention;
FIG. 2 is a schematic view showing the connection of a runner in example 1 of the present invention;
FIG. 3 is a schematic view showing the arrangement of a single-piece casting mold in example 1 of the present invention;
FIG. 4 is a schematic view showing the arrangement of two or more casting molds according to example 1 of the present invention;
FIG. 5 is a schematic plan view showing the arrangement of a casting mold in example 1 of the present invention;
FIG. 6 is a schematic diagram showing the position of a riser in example 1 of the present invention;
FIG. 7 is a schematic view showing the position of a riser in example 2 of the present invention;
FIG. 8 is a schematic view showing the position of a runner in example 3 of the present invention;
FIG. 9 is a schematic top view showing the position of a runner in example 1 of the present invention;
FIG. 10 is a schematic front view showing the position of a runner in example 1 of the present invention;
FIG. 11 is a schematic view of the position of the ingate of the present invention;
FIG. 12 is a schematic illustration of the locations of the ingates and runners of the present invention;
FIG. 13 is a schematic view of the position of a slag trap according to the present invention;
FIG. 14 is a schematic view showing the positions of the vertical (sprue), horizontal runner and ingate of the present invention.
In the figure: 1. casting; 2. top pouring; 3. bottom pouring; 4. intermediate pouring; 5. a vertical (straight) pouring channel; 6. a riser; 7. a pouring cup; 8. a cross gate; 9. an inner pouring channel; 10. and (4) collecting a slag ladle.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. The specific embodiments described herein are merely illustrative of the invention and do not delimit the invention. 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.
Example 1
Referring to fig. 1-14, a production process for centrifugal casting of a lost foam includes the following steps:
s1, positioning of pouring channel: the casting mold comprises a cross pouring gate 8, a bottom pouring gate 3 and a middle pouring gate 4, wherein the connecting direction of the pouring gate is consistent with the rotating direction of a casting 1, and a casting mold is arranged;
s1.1, vertical pouring channel 5: the upper part is connected with a sprue and is vertically arranged, and the lower part is connected with a horizontal pouring channel or an ingate (the ingate of the horizontal pouring channel is combined with the ingate of the ingate). The cross section of the pouring gate is round or square, and the appearance is cylindrical or columnar;
s1.2, cross gate 8: the upper part is connected with a vertical pouring channel, the lower part is connected with an ingate. The cross section is square or round, when two or more models are poured at one time, the end part of the bottom surface of the horizontal and vertical pouring channel can be connected with the ingate in a staggered way by 20-50 mm, or the horizontal pouring channel and the ingate can be combined into a whole, the bottom is horizontal, the top inclines downwards to the direction of the model, and the cross section gradually becomes smaller;
s1.2.1, slag collection setting of cross runners:
s1.2.1.1 slag collection bag 10, which is square column or cylinder, with width same as or slightly larger than the horizontal runner and height more than one time of the horizontal runner and not more than 3 times, so that the inner floating slag is collected in the slag collection bag when the molten metal flows, the end of the horizontal runner has an extension section vertical to the inner runner, and the distance between the end and the connection part of the inner runner is more than 30 mm;
s1.2.1.2, 8 the horizontal runner is divided into one, two and three, the ingate is connected with 20-50 mm dislocation from the lower part of the front end of the horizontal runner in a first section, and the ingate is connected with one section up and one section down in sequence in more than two sections, the dislocation of the connecting parts is required to be the same as that of the connecting parts, thus facilitating slag discharge when the molten metal passes through the ingate;
s1.3, an ingate 9, wherein the front end is connected with a horizontal runner, the rear end is connected with a model, and the ingate is connected with the model and is provided with three types: the method comprises top pouring, bottom pouring and middle pouring, wherein the connecting direction of a pouring gate is consistent with the rotating direction of a casting and is not aligned to the inner wall, so that the inner wall is prevented from being washed by molten metal; multiple ingates can be used simultaneously for a single casting. If the casting model is large in volume, the ingates can be arranged in a layered mode, two layers (such as bottom pouring and middle pouring) are more than three layers (such as bottom pouring, middle pouring and top pouring), and the ratio of the cross section of the horizontal pouring channel to the cross section of the ingates is (1.2-1.4): 1;
s1.3.1 the ingate 9 slag collection is arranged in two cases:
s1.3.1.1, the ingate 9 is composed of a section, the section is rectangle, the section of the ingate 9 is gradually reduced towards the model direction, the section of the contact part of the ingate and the model is flat rectangle, and is convenient to be taken down when being cleaned, the ingate can not be square or round, the bottom of the ingate is horizontal as much as possible, and the upper surface is an inclined plane;
s1.3.1.2, the ingate 9 is divided into two sections, one section is on the top, one end of the other section is connected with the lower part of the front end of the top section in a staggered way by 20-50 mm, the other end is not opposite to the inner wall of the mould wall, so as to avoid the metal liquid from scouring the inner wall, the connection mode with the mould is also flat, and the requirement is the same as the above;
s1.4, the arrangement of the casting models comprises a single casting model and two or more casting models, and the arrangement principle is as follows:
the arrangement principle of the single casting model is as follows: model with axis of symmetry: the central axis of the vertical (straight) pouring gate is superposed with the symmetric axis of the casting; the model without symmetry axis is that the center axis of the vertical (straight) pouring gate passes through the gravity center of the casting; meanwhile, the placement of the casting model also needs to consider that the main part or the processing part of the casting is placed at the farthest end from the central shaft of the vertical pouring channel and is placed at the bottom; the casting mold can not be placed on a riser placing surface, but a pouring channel can be placed on a machining surface, and the casting mold can be horizontally placed, vertically placed or obliquely placed according to the situation;
the arrangement principle of two or more casting models is as follows: arranging one by one and in multiple layers: the components are assembled and arranged up and down according to a single piece, and are arranged in parallel as much as possible; one layer is formed by multiple layers: the models of each layer are uniformly arranged on a plane of the layer by taking the central axis of the vertical (straight) pouring gate as the center of a circle, the radius of each layer can be the same or different, and meanwhile, the placement of the casting models needs to consider that the main part or the processing part of the casting is placed at the farthest end or the bottom of the placement from the central axis of the vertical (straight) pouring gate. Can not be placed on the mounting surface or the uppermost end of a riser (a slag collecting riser or a feeding riser). But the processing surface can be provided with a pouring channel, and the casting model can be horizontally placed, vertically placed or obliquely placed according to the situation;
s2, design of a riser: the slag collecting riser and the feeding riser are combined together to form the slag collecting feeding riser or can be used separately in most cases;
s2.1, the diameter of a feeding head is more than 1.5 times of the wall thickness, the feeding head is determined according to actual conditions, an ingate can be directly connected with the feeding head sometimes, high-temperature molten metal is convenient to provide, and feeding is better;
s2.2, the diameter of the slag collecting riser is more than 1.2 times of the wall thickness according to the actual condition;
s2.3, riser placement position: under the action of centrifugal force, molten metal enters the casting mold from the feeding riser, and slag and gas move into the slag collecting riser from the casting; the vertical pouring gate can be used as a riser when clinging to the casting.
S2.3, the riser can be communicated with the atmosphere through a connecting air duct to be an exhaust riser when necessary
S2.4, designing a riser (a slag collecting riser or a feeding riser): risers (slag collecting risers or feeding risers) 6 are arranged at the center and the upper end close to the rotation of the model, so that molten metal in the risers enters the casting model under the action of centrifugal force, slag and gas are moved into the risers (slag collecting risers or feeding risers) 6 from the casting, and the arrangement direction of the risers (slag collecting risers or feeding risers) 6 is horizontal; the arrangement position is on the side surface of the casting;
s3, the box loading (making) process comprises the following steps:
s3.1, installing a rounded deluge sand feeder at the bottom of the sand warehouse, and installing an infrared ray or other light ray indicating marks capable of indicating the center position in the sand box in the middle of the sand feeder; the indication mark coincides with the rotation center of the jolt ramming table.
S3.2, placing the special round sand box or square sand box on a specified position of the center of a special jolt ramming table or pouring table for centrifugal casting of the lost foam, and fixing the round sand box or the square sand box by using a fixing device;
s3.3, opening the rain-drenching sand feeder, paving a layer of sand with proper thickness about 200mm in a sand box, spreading the sand horizontally, putting the assembled model, irradiating the indicating light rays such as infrared rays and the like to the center of the sprue cup 7 or the vertical (straight) runner, slowly rotating the jolt ramming table and the sand box, adjusting the deviation distance between the center of the sprue cup 7 or the vertical (straight) runner 5 and the light indicating point to be 0-50mm, and ensuring that the smaller the distance is, the better the distance is;
s3.4, opening the deluge sand feeder to uniformly feed sand, simultaneously opening a vibration motor to feed the sand and vibrate simultaneously, or adopting multiple intermittent vibration in the sand feeding process, wherein each time lasts for 5-30 seconds, the rotating speed of a jolting platform is adjusted between 1-300 revolutions per minute, but on the premise of ensuring the box loading (making) quality, the rotating speed is gradually increased to a specified rotating speed from slow to fast, and dead corner parts which are not easy to fill sand in the model can be effectively filled by the acting force of centrifugal force and exciting force of the molding sand, so that the relative movement in the box is not carried out under the action of the centrifugal force and the exciting force of the sand; the vibration motor can adopt a frequency modulation vibration motor or a non-frequency modulation vibration motor.
S3.5, stopping adding the sand when the sand is added to a preset height, and slowly stopping rotating the compaction table;
s3.6, paving a layer of plastic film on the sand box, opening a plastic film at the 5-opening of the vertical (straight) pouring gate, wherein the size of the opening is the same as the outer diameter of the vertical (straight) pouring gate, exposing the vertical (straight) pouring gate by about 150mm, adding sand on the surface of the plastic film, flattening the sand with the thickness not less than 100mm, and enabling the size of the film to exceed the edge of the wall of the sand box by more than 150mm after adding the sand;
s3.7, mounting a finished pouring cup 7 or manufacturing a pouring cup at the position of the vertical (straight) pouring gate 5, and placing the center of the pouring cup 7 to be overlapped with the center of the vertical (straight) pouring gate 5 as much as possible so as to facilitate the inflow of high-temperature molten metal when the pouring cup 7 rotates and prevent the molten metal from splashing under the action of centrifugal force;
s4, casting the steel plate;
s4.1, hanging or conveying the manufactured sand box to a specified position of a special evaporative pattern centrifugal casting machine, butting a negative pressure interface on the sand box with a negative pressure outlet on the casting machine, and fixing the sand box;
s4.2, placing the runner in place, wherein the outlet is over against the center of the pouring cup 7;
and S4.3, opening a negative pressure machine to start negative pressure pumping or opening a negative pressure switch of the sand box 3-5 minutes before metal pouring so that the negative pressure in the sand box reaches the production technical requirement of 0.1-1.0 Mp.
S4.4, according to the condition of the model and the component requirements of the casting, igniting the foam of the model by fire, introducing oxygen when necessary, fully combusting the foam as much as possible, and simultaneously preheating the model, so as to facilitate better filling of metal;
s4.5, when the internal components of the molten metal in the furnace are qualified, pouring the molten metal into a pouring ladle, lifting the pouring ladle to the side of a pouring work flow trough, pouring the molten metal into the flow trough, and then enabling the molten metal to flow into a pouring cup 7 from an outlet of the flow trough; the casting machine is started in advance or simultaneously during the pouring, the rotating speed can also be gradually increased along with the increase of the amount of the molten metal entering the model to the required rotating speed, the speed is gradually adjusted to be 1-300 revolutions per minute/fixed rotating speed per minute, and when the amount of the molten metal entering the model is 1/5 of the weight of the casting blank, the vibrating motor is turned on to vibrate; the vibration motor can adopt a frequency modulation vibration motor or a non-frequency modulation vibration motor.
And S4.6, after pouring is finished, determining the time for pumping negative pressure, the vibration time and the rotation time according to the solidification condition of the casting, and gradually reducing the rotation speed of the casting machine after the negative pressure pumping and the vibration are in place.
S4.7, after the machine is stopped, the launder is recovered to the original position; and (5) conveying the sand box to a box overturning position, and taking out the casting.
Example 2
Referring to fig. 7, a technical solution provided by the present invention: the difference from example 1 is: design of feeder (slag collector or feeding feeder) in S2: risers (slag collecting risers or feeding risers) are arranged at the center and the upper end close to the rotation of the model, so that slag and gas are moved into the risers (slag collecting risers or feeding risers) from the casting under the action of centrifugal force, and the arrangement direction of the risers (slag collecting risers or feeding risers) is vertical; the setting position is on the top of the casting.
Example 3
Referring to fig. 8, a technical solution provided by the present invention: the difference from example 1 is: design of feeder (slag collector or feeding feeder) in S2: risers (slag collecting risers or feeding risers) are arranged at the center and the upper end close to the rotation of the model, so that slag and gas are moved into the risers (slag collecting risers or feeding risers) from the casting under the action of centrifugal force, and the arrangement direction of the risers (slag collecting risers or feeding risers) is inclined; the setting positions are at the upper, middle and lower parts on the side surface of the casting.
In fig. 8: riser (slag collecting riser or feeding riser) can be replaced by vertical (straight) pouring channel
In summary, the following steps: the invention has flexible design: the method provides sufficient freedom for the structural design of the casting, and can be used for casting a highly complex casting through the combination of the foam plastic templates; the investment and production cost are reduced: the weight of the casting blank is reduced, and the machining allowance is small; no sand core in traditional casting; the casting precision is high: compared with the traditional sand casting method, the machining time can be reduced by 40 to 50 percent; clean production, no chemical binder in the molding sand, no harm to the environment caused by the foamed plastic at low temperature, and the recovery rate of the used sand is more than 95 percent;
the product produced by the lost foam is used for centrifugal casting, so that the quality of dead angles of a molding sand filling model during box loading (making) can be effectively improved, the product quality can be effectively improved, the product density can be improved, the yield of the product can be improved by using the lost foam for the product subjected to centrifugal casting, and the product processing allowance can be reduced by using more lost foams in one box;
make the rotation of sand box add the vibration, the metal liquid in the mould in the sand box is under the effect of centrifugal force, and the metal liquid internal pressure increases and leads to: the slag and gas with light weight move upwards and towards the direction of the circle center under the action of centrifugal force and exciting force, and the degassing and deslagging effects are good. The growing dendritic crystal is broken under the action of centrifugal force and exciting force to generate a large number of crystal nuclei, crystal grains are refined, the density of the product is further improved, molten metal in a pouring gate and in a riser (a slag collecting riser or a feeding riser) moves towards a casting model under the action of centrifugal force, the utilization rate of the molten metal is improved, and the feeding effect is good.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments or portions thereof without departing from the spirit and scope of the invention.
Claims (7)
1. A production process for lost foam centrifugal casting is characterized in that: the method comprises the following steps:
s1, design of pouring channel: the pouring channels are divided according to the flowing direction of molten metal: vertical (straight) pouring channels, horizontal pouring channels and ingate; ratio of cross section of vertical (straight) runner, horizontal runner to cross section of ingate 1.3: (1.2- -1.4): 1;
s1.1, vertical (straight) pouring channel: the runner is connected with the sprue at the upper part and is vertically placed, and the runner and the ingate are connected at the lower part (the ingate of the sprue are integrated, the cross section of the runner is circular or square, and the appearance is cylindrical or columnar;
s1.2, cross runners: the vertical (straight) pouring gate is connected upwards and horizontally and the ingate is connected downwards, the cross section of the ingate is square or circular, when two or more models are poured at one time, the bottom end of the vertical (straight) pouring gate can be connected with the ingate in a staggered way of 20-50 mm, the horizontal pouring gate and the ingate can be combined into a whole, the bottom of the vertical (straight) pouring gate is horizontal, the top of the vertical (straight) pouring gate inclines downwards towards the model, the cross section of the vertical (straight) pouring gate gradually becomes smaller, the;
s1.2.1, slag collection setting of cross runners:
s1.2.1.1, a slag collection bag installed at the upper end, the width of the slag collection bag is the same as or slightly larger than that of the horizontal pouring channel, the height of the slag collection bag is more than one time of the height of the horizontal pouring channel and not more than 3 times of the height of the horizontal pouring channel, so that the internal floating slag is collected in the slag collection bag in the flowing process of molten metal, the end part of the horizontal pouring channel is provided with an extension section which is vertical to the inner pouring channel, and the distance between the tail end and the connecting part of the inner pouring channel is more than 30 mm;
s1.2.1.2, the horizontal pouring channel is divided into one section, two sections and three sections, wherein the ingate is connected with the front end lower part of the horizontal pouring channel in a staggered way by 20-50 mm in the first section, and the ingate is connected with the front end lower part of the horizontal pouring channel in the second section, the ingate is connected with the horizontal pouring channel in sequence in the first section, and the connecting parts are staggered with each other to meet the requirement of the same, so that the molten metal can be discharged;
s1.3, an inner pouring channel, wherein the front end of the inner pouring channel is connected with a transverse pouring bottom, the rear end of the inner pouring channel is connected with a model, and the number of the pouring channel connected with the model is three: the method comprises top pouring, bottom pouring and middle pouring, wherein the connecting direction of a pouring gate is consistent with the rotating direction of a casting and is not aligned to the inner wall, so that the inner wall is prevented from being washed by molten metal; if the casting model is large in volume, the ingates can be arranged in a layered mode, two layers (such as bottom pouring and middle pouring) to three layers (such as bottom pouring, middle pouring and top pouring) to more than three layers, and the ratio of the cross section of the horizontal pouring channel to the cross section of the ingates is (1.2-1.4): 1;
s1.3.1 ingate slag collection setting is divided into two conditions:
s1.3.1.1, the ingate is composed of a section, the section is rectangle, the section of the ingate becomes smaller towards the direction of the model, the section of the contact part of the ingate and the model is flat rectangle and is convenient to be taken down when being cleaned, the shape of the ingate can not be square or round, the bottom of the ingate is horizontal as much as possible, the upper surface of the ingate is an inclined plane, and the shape of the ingate is wedge-shaped;
s1.3.1.2, the ingate is divided into two sections, one section is on the top, one end of the other section is connected with the lower part of the front end of the top section in a staggered way by 20-50 mm, the other end is not opposite to the inner wall of the mould wall, so as to avoid the metal liquid from scouring the inner wall, the connection mode with the mould is also flat, and the requirement is the same as the above;
s2, design of a riser: the shape is spherical or cylindrical or conical, and the contact part with the model is in inverted cone transition, so that in most cases, the slag collecting riser and the feeding riser are used together to form the slag collecting feeding riser or can be used separately;
s2.1, the diameter of a feeding head is more than 1.5 times of the wall thickness, the feeding head is determined according to actual conditions, an ingate can be directly connected with the feeding head sometimes, high-temperature molten metal is convenient to provide, and feeding is better;
s2.2, the diameter of the slag collecting riser is more than 1.2 times of the wall thickness according to the actual condition;
s2.3, riser placement position: under the action of centrifugal force, molten metal enters the casting mold from the feeding riser, and slag and gas move into the slag collecting riser from the casting; when the vertical (straight) pouring channel is tightly attached to the casting, the vertical (straight) pouring channel can be used as a riser (slag collection and feeding);
s2.3.1 the riser can be connected with the atmosphere through a connecting air duct to be called an exhaust riser,
s3, the box loading (making) process comprises the following steps:
s3.1, installing a rounded deluge sand feeder at the bottom of the sand warehouse, and installing an infrared ray or other light ray indicating marks capable of indicating the center position in the sand box in the middle of the sand feeder; the indicating mark and the self-rotation center of the compaction table are on the same vertical line;
s3.2, placing a special round sand box or a special square sand box on a fixed position of the center position of a special jolt ramming table for centrifugal casting of the lost foam, and fixing the sand box by using a fixing device; the rotation center of the sand box and the rotation center of the jolt ramming table are vertically superposed;
s3.3, paving a layer of sand with proper thickness in a sand box by using a sand feeder for about 200mm, leveling, putting the assembled model, irradiating the indicating light rays such as infrared rays and the like to the center of a pouring cup or a vertical (straight) runner, slowly rotating a jolt ramming table and the sand box to ensure that the center of the pouring cup or the vertical (straight) runner and a light ray indicating point are preferably superposed when rotating, if the center deviates, the distance can be adjusted between 0 and 50mm, and the smaller the distance is, the better the distance is;
s3.4, opening the deluge sand feeder to uniformly feed sand, and simultaneously opening a vibration motor to vibrate while feeding sand, or adopting multiple intermittent vibrations in the sand feeding process, wherein each vibration lasts for 5-30 seconds;
the rotating speed of the compaction table is adjusted between 1 and 300 revolutions per minute, but on the premise of ensuring the quality of a box, the rotating speed is gradually increased from slow to fast to a specified rotating speed, the acting force of the molding sand on the centrifugal force and the exciting force can effectively fill dead angle parts which are not easy to fill sand in the model, and the sand does not relatively move and is compacted under the action of the centrifugal force and the exciting force; the vibration motor is a vibration motor with adjustable frequency or a vibration motor without adjustable frequency;
s3.5, stopping adding the sand when the sand is added to a preset height, and slowly stopping rotating the compaction table;
s3.6, paving a layer of plastic film on the sand box, punching an opening in the plastic film at the position of the vertical (sprue) or the pouring cup, wherein the size of the opening is the same as the outer diameter of the vertical (sprue) or the pouring cup (the plastic film opening is larger than the vertical sprue when the pouring cup exists, binding is required to reduce the opening), the height of the exposed vertical (sprue) or the pouring cup is more than 150mm, adding sand on the surface of the plastic film, flattening molding sand with the thickness not less than 80mm, and enabling the size of the film to exceed the edge of the wall of the sand box by more than 150mm after adding the sand;
s3.7, if a finished pouring cup is installed at the vertical (straight) pouring gate, the center of the pouring cup is placed to be coincident with the center of the vertical (straight) pouring gate or the rotation center of the sand box as much as possible, so that high-temperature molten metal is easily poured into the pouring cup when the pouring cup rotates, and the molten metal is prevented from splashing to hurt people due to the centrifugal force generated by the rotation of the pouring cup;
when the pouring cup is installed, the joint part of the root part of the pouring cup and a vertical (straight) pouring gate is surrounded by refractory materials such as quartz sand, chrome sand and the like and a casting binder with the content of 0.5-10 percent after being uniformly mixed, and the mixture is solidified to prevent molten metal from seeping out;
s3.8, or embedding the empty shell model poured with the empty foam into the center of a sand box, adding sand, rotating, vibrating and compacting according to the process operation of filling (making) the box;
s4, casting the steel plate;
s4.1, the manufactured sand box is hoisted or mechanically conveyed to a special evaporative pattern centrifugal casting machine, meanwhile, a negative pressure interface on the sand box is connected with a negative pressure outlet on the casting machine in an abutting mode, and the sand box is fixed;
s4.2, placing the runner in place, wherein the outlet is over against the center of the pouring basin;
s4.3, opening a negative pressure machine to start negative pressure pumping 3-5 minutes before metal pouring, and simultaneously opening a negative pressure switch of the sand box to enable the negative pressure in the sand box to reach a specified value of the production technical requirement of 0.1-1.0 Mp;
s4.4, igniting the foam of the model by fire according to the condition of the model and the component requirements of the casting, introducing oxygen when necessary, fully combusting the foam to the greatest extent, reducing the recarburization of the casting, simultaneously preheating the cavity wall of the model, reducing the temperature of molten metal, and facilitating the better mold filling of the molten metal;
s4.5, when the components of the molten metal in the furnace are qualified, pouring the molten metal into a pouring ladle, lifting the pouring ladle to a pouring station, pouring the molten metal into a launder, and then enabling the molten metal to flow into a pouring cup from an outlet of the launder; according to the current situation, the casting machine can be started in advance or at the beginning of casting, the rotating speed is slowly increased from slow to fast to the required rotating speed, the rotating speed can also be gradually increased to the required rotating speed along with the increase of the amount of the molten metal entering the mold, the rotating speed is 1-300 r/min, a vibrating motor can be simultaneously turned on according to the requirement, or the vibrating motor is turned on to vibrate when the amount of the molten metal poured into the mold cavity accounts for 1/5-1/2 of the weight of the casting; the vibration motor is a vibration motor with adjustable frequency or a vibration motor without adjustable frequency;
s4.6, after pouring is finished, adjusting the negative pressure holding time, the rotation duration time and the vibration duration time of the casting machine according to the casting solidification condition, wherein the adjustment is carried out within 1-60 minutes; the rotation of the casting machine is decelerated until the stop time is not within the duration range;
s4.7, after the casting machine stops, the launder is recovered to the original position; and (5) conveying the sand box to a box overturning position, and taking out the casting.
2. A production process for centrifugal casting of lost foam according to claim 1, characterized in that: the casting model arrangement in the S1 comprises a single-piece casting model and two or more casting models, and the arrangement principle is as follows:
the arrangement principle of the single casting model is as follows: model with axis of symmetry: the central axis of the vertical (straight) pouring gate is superposed with the symmetric axis of the casting; the model without symmetry axis is that the center axis of the vertical (straight) pouring gate passes through the gravity center of the casting; meanwhile, the placement of the casting model also needs to consider that the main part or the processing part of the casting is placed at the farthest end from the central shaft of the vertical (straight) pouring channel and is placed at the bottom; the casting mold can not be placed at the riser placement position or the uppermost end, but a pouring channel can be placed on the machining surface, and the casting mold can be horizontally placed, vertically placed and obliquely placed according to the condition;
the arrangement principle of two or more casting models is as follows: arranging one by one and in multiple layers: the components are assembled and arranged up and down according to a single piece, and are arranged in parallel as much as possible; one layer is formed by multiple layers: the models of each layer are uniformly arranged on a plane which takes a vertical (straight) pouring gate central shaft as a circle center, the radius of each layer can be the same or different, meanwhile, the placement of the casting models also needs to consider that the main part or the processing part of the casting is placed at the farthest end away from the vertical (straight) pouring gate central shaft and placed at the bottom, and can not be placed on the slag collecting riser placing surface or the uppermost end, and the casting models can be placed horizontally, vertically and obliquely according to the situation.
3. A production process for centrifugal casting of lost foam according to claim 1, characterized in that: the design of the riser in the S2 comprises the following steps: setting direction and setting position.
4. A production process for lost foam centrifugal casting according to claim 3, characterized in that: the setting direction of the dead head is horizontal; the setting position is on the casting side.
5. A production process for lost foam centrifugal casting according to claim 3, characterized in that: the arrangement direction of the dead heads is vertical; the setting position is on the top of the casting.
6. A production process for lost foam centrifugal casting according to claim 3, characterized in that: the arrangement direction of the dead head is inclined; the setting positions are at the upper, middle and lower parts on the side surface of the casting.
7. A production process for centrifugal casting of lost foam according to claim 1, characterized in that: the vertical (straight) pouring gate is arranged at the side part of the casting close to the rotation center and can replace a riser.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113172201A (en) * | 2021-04-28 | 2021-07-27 | 石家庄工业泵厂有限公司 | Model cluster for auxiliary impeller lost foam string casting process and auxiliary impeller lost foam string casting process |
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