CN112548074A - Pressure-regulating filling type high-pressure solidification casting device and casting method - Google Patents
Pressure-regulating filling type high-pressure solidification casting device and casting method Download PDFInfo
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- CN112548074A CN112548074A CN201910915995.7A CN201910915995A CN112548074A CN 112548074 A CN112548074 A CN 112548074A CN 201910915995 A CN201910915995 A CN 201910915995A CN 112548074 A CN112548074 A CN 112548074A
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/06—Vacuum casting, i.e. making use of vacuum to fill the mould
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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
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
- B22D27/11—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of mechanical pressing devices
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Abstract
The invention discloses a pressure-regulating mold-filling high-pressure solidification casting device and a casting method, wherein the device comprises a smelting furnace, an injection rod, a liquid lifting pipe, a hammer head, a charging barrel, a mold, a vacuum pipe and a vacuum stop valve; the device can take high-quality aluminum alloy melt from the center of aluminum liquid in the smelting furnace, and the aluminum liquid is conveyed into the mold cavity through the closed liquid lifting pipe and the charging barrel by controlling the pressure difference between the smelting furnace and the mold cavity through the computer, so that the liquid level of the aluminum liquid stably rises in the whole process, the contact area of the aluminum liquid and air in the conveying and filling stages is greatly reduced, the oxidation slag is reduced, meanwhile, a certain vacuum condition is formed in the mold cavity, the air content of the aluminum liquid is reduced, and the filling capacity of the aluminum liquid in the mold cavity is improved; after the mold filling is finished, the casting is solidified under high pressure, the structure is compact, the crystal grains are refined, the forming probability of casting defects such as shrinkage porosity, shrinkage cavity, pin hole and the like is greatly reduced, and finally the internal quality and the mechanical property of the casting are greatly improved.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a pressure-regulating filling type high-pressure solidification casting device and a casting method, and specifically comprises the following steps: the device and the method utilize the pressure difference between the cavity and the hearth to convey the alloy liquid to complete the mold filling of the mold cavity and then solidify the alloy liquid under the action of the high pressure of the hammer.
Background
The die casting and the extrusion casting are widely applied to the industrialized mass production of the aluminum alloy castings, compared with other casting processes, the aluminum alloy castings produced by the two casting processes have the advantages of stable size, high precision, excellent casting surface quality, high process yield and high production efficiency. In addition, the strength and mechanical properties of the cast produced by adopting the extrusion casting process are higher than those of the cast produced by adopting the traditional sand casting process.
The extrusion modes of die casting and extrusion casting are divided into direct extrusion and indirect extrusion, wherein the direct extrusion directly applies high pressure to the aluminum liquid by using a die, and the indirect extrusion ensures that the aluminum liquid is solidified under the high pressure condition by using a hammer.
The die-casting and extrusion casting technology adopted at present in China has the following defects in the aspects of molten aluminum conveying, mold filling, solidification and the like: pouring aluminum liquid into the charging barrel by adopting a casting ladle, wherein the aluminum liquid is continuously contacted with air in the pouring process to form a large amount of oxidizing slag; during mold filling, aluminum liquid flows at high speed in the mold cavity and is in secondary contact with air, so that air entrainment and oxidation slag are easily formed; the gas content of the melt is large, and the melt is easy to separate out to form pinholes during solidification. The defects seriously reduce the quality of the aluminum liquid and influence the internal quality and the mechanical property of the casting.
The aluminum alloy die-casting and extrusion casting process is currently applied to industrial production on a large scale, and a pressure-regulating, mold-filling and high-pressure-solidifying device and a method are developed, so that high-quality aluminum alloy melt can be taken from the center of aluminum liquid in a smelting furnace, and the pressure difference between a mold cavity 1 and a smelting furnace 3 is controlled by a computer, so that the high-quality aluminum liquid is conveyed into the mold cavity 1 along a closed liquid lifting pipe 31 and a charging barrel 4, the contact area of the aluminum liquid and air in the conveying and mold-filling stages is reduced, the liquid level is ensured to rise stably, oxide skin and oxidation slag are effectively avoided being formed, meanwhile, a certain vacuum condition is formed in the mold cavity 1, the air content of the aluminum liquid is reduced, and the mold; after the mold filling is finished, the casting is solidified under high pressure, the structure is compact, the crystal grains are refined, the forming probability of casting defects such as shrinkage porosity, shrinkage cavity, pin hole and the like is greatly reduced, and finally the internal quality and the mechanical property of the casting are greatly improved. Therefore, the pressure-regulating filling type high-pressure solidification device and the method have great significance for industrial mass production of high-quality die-casting and extrusion castings.
Disclosure of Invention
The invention provides a pressure-regulating mold-filling high-pressure solidification casting device and a casting method, aiming at reducing the oxidation of molten aluminum in the die casting and extrusion casting processes, reducing the gas content of a melt, avoiding gas entrapment in the mold filling process and improving the quality of a casting. The method mainly comprises the steps of vacuumizing a mould 1, introducing compressed air or vacuumizing into a smelting furnace 3 at the same time, changing the air pressure in the furnace, pushing aluminum liquid to enter a mould cavity through a liquid lifting pipe 31 and a charging barrel 4 sequentially by utilizing the pressure difference between the interior of the smelting furnace 3 and the mould cavity of the mould 1, lifting to a set height, plugging a feeding hole by a hammer head 21, pushing the aluminum liquid in the charging barrel 4 to enter the mould cavity of the mould 1 to complete mould filling, starting a mould vacuum stop valve 13, and applying an extrusion force of 60-200 MPa to alloy liquid until the alloy liquid is solidified. According to the scheme, high-quality aluminum alloy melt can be taken from the center of aluminum liquid in the smelting furnace, the aluminum liquid is conveyed into the cavity of the mold 1 through the closed liquid lifting pipe 31 and the charging barrel by controlling the pressure difference between the interior of the smelting furnace 3 and the cavity of the mold 1 through the computer, the liquid level of the aluminum liquid stably rises in the whole process, the contact area of the aluminum liquid and air in the conveying and filling stages is greatly reduced, oxide slag is reduced, meanwhile, a certain vacuum condition is formed in the cavity of the mold 1, the air content of the aluminum liquid is reduced, and the filling capacity of the aluminum liquid in the cavity of the mold; after the mold filling is finished, the casting is solidified under high pressure, the structure is compact, the crystal grains are refined, the forming probability of casting defects such as shrinkage porosity, shrinkage cavity, pin hole and the like is greatly reduced, and finally the internal quality and the mechanical property of the casting are greatly improved.
The specific technical scheme of the invention is as follows:
the invention provides a pressure-regulating mold-filling high-pressure solidification casting device, which comprises a smelting furnace 3, an injection rod 2, a liquid lifting pipe 31, a hammer 21, a charging barrel 4, a mold 1, a vacuum pipe 5 and a vacuum stop valve 13;
wherein the material cylinder 4 is positioned below the die 1, the hammer 21 is arranged above the injection rod 2, and the hammer is pushed by the injection rod 2 to move up and down in the material cylinder 4; the smelting furnace 3 is placed below the side of the mold 1, the sealing performance of the furnace body is good, one end of the liquid lifting pipe 31 extends into a crucible in the furnace, and the other end of the liquid lifting pipe is connected with the charging barrel 4; the mould 1 consists of a movable mould 11 and a fixed mould 12, the upper part of the fixed mould 12 is provided with a hole and is connected with a vacuum stop valve 13, the vacuum stop valve 13 is externally connected with a vacuum pipe 5, the vacuum pipe 5 is connected with a vacuumizing device, and the cavity of the mould 1 is vacuumized.
The charging barrel 4 is provided with a lateral feeding hole 41, and the highest point of the feeding hole 41 is located 10-20 mm below the bottom of the die cavity.
The inner wall of the charging barrel 4 is smooth, the hammer 21 can move up and down in the charging barrel 4, the length of the hammer 21 is 20-40 mm higher than the height of the feeding port in the vertical direction, the feeding port can be completely sealed when the bottom surface of the hammer moves to the lowest point position in the vertical direction of the feeding port in the charging barrel, and molten aluminum does not leak.
The smelting furnace 3 is connected with a compressed air pipeline and a vacuum-pumping pipeline simultaneously, so that the furnace can be vacuumized, and compressed air can be introduced.
The invention also provides a method for completing pressure-regulating filling type high-pressure solidification, which comprises the following steps:
1) setting parameters: adjusting the bottom surface of the hammer head to be flush with the bottom surface of the feeding hole, and to be an initial position of the hammer head, and setting the final stopping height of the liquid level of the aluminum liquid in the charging barrel in the section of height as 5-10 mm below the bottom of the die cavity at the final position, according to the height difference between the initial position and the final position of the hammer head, setting the final stopping height of the liquid level of the aluminum liquid in the pressure-regulating and mold-filling process, and ensuring that the aluminum liquid in the charging barrel enters the die cavity when the hammer head rises from the initial position to the final position, and;
2) pressure regulating and charging: the mould 1 is closed, the air in the cavity of the mould 1 is extracted, meanwhile, compressed air is introduced into the smelting furnace 3 or vacuum pumping is carried out, the pressure difference between the furnace body and the cavity of the mould 1 is controlled by a computer to push the aluminum liquid to enter the cavity of the mould 1 along the liquid lifting pipe 31 through the charging barrel 4 until the liquid level of the aluminum liquid rises to the set height of the cavity of the mould 1 and then stays;
3) sealing the feed inlet: the hammer head 21 is lifted to close the feeding hole, aluminum liquid in the charging barrel 4 is pushed into the cavity of the mold 1 to complete mold filling, the vacuum stop valve 13 is started to stop vacuumizing, meanwhile, the aluminum liquid is prevented from entering a vacuum pipeline, an exhaust valve of the smelting furnace 3 is opened, and the air pressure in the furnace returns to the normal pressure;
4) high-pressure solidification: the hammer 21 continuously applies 60-200 MPa pressure to the alloy liquid until the alloy liquid is completely solidified in the cavity of the die 1.
The invention has the beneficial effects that:
the device and the method can obtain high-quality aluminum liquid from the central part of the aluminum liquid in the smelting furnace, and the high-quality aluminum liquid is sequentially conveyed to the mold cavity through the closed riser tube and the charging barrel, so that the contact surface of the aluminum liquid and air is reduced, and the formation of oxidation slag is reduced;
the device and the method can accurately control the pressure difference change in the smelting furnace and in the mould cavity by using the computer, so that the aluminum liquid can stably enter the mould cavity, the conditions of aluminum liquid oxidation and air entrainment caused by excessively high filling speed of the traditional high-pressure casting are avoided, and the casting can be subjected to heat treatment.
The device and the method can ensure that the upper surface of the aluminum liquid and the mold cavity are in a certain vacuum degree condition, are favorable for reducing the air content of the aluminum liquid, and improve the mold filling capacity of the aluminum liquid.
The device and the method can solidify the aluminum liquid under high pressure, improve the feeding capacity of the alloy liquid, inhibit hydrogen in the aluminum liquid from being separated out, and avoid the defects of shrinkage porosity, shrinkage cavity, pin hole and the like of a casting.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a schematic diagram of the overall structure of a pressure-regulating and filling type high-pressure solidification device;
FIG. 2 is a partial structural sectional view of a pressure-regulating filling type high-pressure solidification device;
the device comprises a die 1, an injection rod 2, a smelting furnace 3, a charging barrel 4, a vacuum tube 5, a riser tube 31, a hammer 21, a vacuum stop valve 13, a movable die 11, a fixed die 12 and a feeding hole 41.
Detailed Description
The results and the effects of the invention are further illustrated below with reference to examples:
example 1
The embodiment is an aluminum liquid conveying process for preparing the automobile hub by extrusion casting, and the casting is made of ZL114A aluminum alloy.
The specific process is as follows:
1) the highest point of an upper feed port of the charging barrel is 20mm below the bottom of a die cavity, the vertical height of the feed port is 40mm, the length of a used hammer is 60mm and is 20mm longer than that of the feed port, the initial position of the hammer is set to be the lowest point of the feed port, the final rising height of the hammer is 10mm below the bottom of the die cavity, and the final staying height of the molten aluminum liquid level is set to be 20mm below the highest point of the die cavity through calculation;
2) after the ZL114A aluminum alloy is refined and modified in the smelting furnace 3, the die 1 is closed, air in a cavity of the die 1 is extracted, compressed air is introduced into the smelting furnace 3, aluminum liquid is pushed to enter the cavity of the die 1 along the riser pipe 31 through the charging barrel 4 by the pressure difference between the furnace body and the cavity of the die 1 until the liquid level of the aluminum liquid is 20mm below the highest point of the cavity, and air intake is stopped;
3) the hammer 21 is lifted to close the feeding hole, the aluminum liquid in the charging barrel 4 is pushed into the cavity of the mould 1 to complete mould filling, the vacuum stop valve is started 13, the cavity of the mould 1 is stopped being vacuumized, and the aluminum liquid is prevented from entering the vacuumizing pipeline. Meanwhile, an exhaust valve of the smelting furnace 3 is opened, and the air pressure in the smelting furnace is recovered;
4) the hammer 21 continuously applies 160MPa pressure to the alloy liquid until the alloy liquid is completely solidified in the die cavity of the die 1.
Example 2
In the embodiment, the aluminum liquid conveying process for preparing the automobile control arm by extrusion casting is carried out, and the material of the casting is ZL101A aluminum alloy.
The specific process is as follows:
1) the highest point of an upper feed port of the charging barrel is 15mm below the bottom of a die cavity, the vertical height of a feed port is 20mm, the length of a used hammer is 40mm and is 20mm longer than that of the feed port, the initial position of the hammer is set to be the lowest point of the feed port, the final rising height of the hammer is 5mm below the bottom of the die cavity, and the final staying height of the molten aluminum liquid level is set to be 40mm below the highest point of the die cavity through calculation;
2) after the ZL101A aluminum alloy is refined and modified in the smelting furnace 3, the die 1 is closed, air in the cavity of the die 1 is extracted, compressed air is introduced into the smelting furnace 3, aluminum liquid is pushed to enter the cavity of the die 1 along the riser tube 31 through the charging barrel 4 by the pressure difference between the furnace body and the cavity of the die 1 until the liquid level of the aluminum liquid is 40mm below the highest point of the cavity, and air intake is stopped; (ii) a
3) The hammer 21 rises to close the feeding hole, the aluminum liquid in the charging barrel 4 is pushed into the cavity of the mould 1 to complete the mould filling, the vacuum stop valve is started 13, the cavity of the mould 1 is stopped being vacuumized, and the aluminum liquid is prevented from entering the vacuumizing pipeline 5. Meanwhile, an exhaust valve of the smelting furnace 3 is opened, and the air pressure in the smelting furnace is recovered;
4) the hammer 21 continuously applies 120MPa pressure to the alloy liquid until the alloy liquid is completely solidified in the die cavity of the die 1.
Example 3
A pressure-regulating mold-filling high-pressure solidification casting device comprises a smelting furnace 3, an injection rod 2, a liquid lifting pipe 31, a hammer 21, a charging barrel 4, a mold 1, a vacuum pipe 5 and a vacuum stop valve 13;
wherein the material cylinder 4 is positioned below the die 1, the hammer 21 is arranged above the injection rod 2, and the hammer is pushed by the injection rod 2 to move up and down in the material cylinder 4; the smelting furnace 3 is placed below the side of the mold 1, the sealing performance of the furnace body is good, one end of the liquid lifting pipe 31 extends into a crucible in the furnace, and the other end of the liquid lifting pipe is connected with the charging barrel 4; the mould 1 consists of a movable mould 11 and a fixed mould 12, the upper part of the fixed mould 12 is provided with a hole and is connected with a vacuum stop valve 13, an external vacuum tube 5 is connected with a vacuumizing device, and a cavity of the mould 1 is vacuumized. The charging barrel 4 is provided with a lateral feeding hole 41, and the highest point of the feeding hole is located 10-20 mm below the bottom of the die cavity. The inner wall of the charging barrel 4 is smooth, the hammer 21 can move up and down in the charging barrel 4, the hammer 21 is 20-40 mm longer than the feeding hole, the feeding hole can be completely sealed when the hammer moves to the position of the feeding hole in the charging barrel, and aluminum liquid does not leak. The smelting furnace 3 is connected with a compressed air pipeline and a vacuum-pumping pipeline simultaneously, so that the furnace can be vacuumized, and compressed air can be introduced.
Although preferred embodiments have been depicted and described in detail herein, it will be apparent to those skilled in the relevant art that various structural modifications and control parameter combinations can be made without departing from the spirit of the invention and these are considered to be within the scope of the invention as defined in the following claims.
Claims (5)
1. The utility model provides a pressure regulating fills type high pressure solidification casting device which characterized in that: the device comprises a smelting furnace (3), a shot rod (2), a liquid lifting pipe (31), a hammer head (21), a charging barrel (4), a die (1), a vacuum pipe (5) and a vacuum stop valve (13);
the charging barrel (4) is positioned below the die (1), the hammer head (21) is installed above the injection rod (2), and the hammer head is pushed by the injection rod (2) to move up and down in the charging barrel (4); the smelting furnace (3) is placed below the side of the mold (1), the sealing performance of the furnace body is good, one end of the liquid lifting pipe (31) extends into the crucible in the furnace, and the other end of the liquid lifting pipe is connected with the charging barrel (4);
the mould (1) consists of a movable mould (11) and a fixed mould (12), an opening is formed in the upper part of the fixed mould (12) and is connected with a vacuum stop valve (13), the vacuum stop valve (13) is externally connected with a vacuum tube (5), and the vacuum tube (5) is connected with vacuumizing equipment to vacuumize a cavity of the mould (1).
2. The pressure-regulating mold-filling high-pressure solidification casting device according to claim 1, characterized in that: the charging barrel (4) is provided with a lateral feeding hole (41), and the highest point of the feeding hole (41) is located 10-20 mm below the bottom of the die cavity.
3. The pressure-regulating mold-filling high-pressure solidification casting device according to claim 1, characterized in that: the inner wall of the charging barrel (4) is smooth, the hammer head (21) can move up and down in the charging barrel (4), the length of the hammer head (21) is 20-40 mm higher than the height of the feeding port in the vertical direction, the feeding port can be completely sealed when the bottom surface of the hammer head moves to the lowest point position in the vertical direction of the feeding port in the charging barrel, and aluminum liquid does not leak.
4. The pressure-regulating mold-filling high-pressure solidification casting device according to claim 1, characterized in that: the smelting furnace (3) is simultaneously connected with a compressed air pipeline and a vacuum-pumping pipeline, so that the furnace can be vacuumized, and compressed air can be introduced.
5. A method for performing pressure-regulating charge-type high-pressure coagulation by using the device of any one of claims 1 to 4, wherein the method comprises the following steps: the method comprises the following specific steps:
1) setting parameters: adjusting the bottom surface of the hammer head to be flush with the bottom surface of the feeding hole, and to be an initial position of the hammer head, and setting the final stopping height of the liquid level of the aluminum liquid in the charging barrel in the section of height as 5-10 mm below the bottom of the die cavity at the final position, according to the height difference between the initial position and the final position of the hammer head, setting the final stopping height of the liquid level of the aluminum liquid in the pressure-regulating and mold-filling process, and ensuring that the aluminum liquid in the charging barrel enters the die cavity when the hammer head rises from the initial position to the final position, and;
2) pressure regulating and charging: the mold (1) is closed, air in the cavity of the mold (1) is extracted, compressed air or vacuum pumping is performed to the smelting furnace (3), the pressure difference between the furnace body and the cavity of the mold (1) is controlled by a computer to push the aluminum liquid to enter the cavity of the mold (1) along a liquid lifting pipe (31) through a charging barrel (4) until the liquid level of the aluminum liquid rises to the set height of the cavity of the mold (1) and then stays;
3) sealing the feed inlet: the hammer head (21) is lifted to close the feeding hole, aluminum liquid in the charging barrel (4) is pushed into a cavity of the mold (1) to complete mold filling, the vacuum stop valve (13) is started, vacuumizing is stopped, the aluminum liquid is prevented from entering a vacuum pipeline, an exhaust valve of the smelting furnace (3) is opened, and the air pressure in the furnace returns to the normal pressure;
4) high-pressure solidification: the hammer head (21) continuously applies 60-200 MPa pressure to the alloy liquid until the alloy liquid is completely solidified in the die cavity of the die (1).
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117884603A (en) * | 2024-03-18 | 2024-04-16 | 北京航空航天大学 | Vacuum pressure-regulating casting method for aluminum-based composite brake disc |
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| CN117884603A (en) * | 2024-03-18 | 2024-04-16 | 北京航空航天大学 | Vacuum pressure-regulating casting method for aluminum-based composite brake disc |
| CN117884603B (en) * | 2024-03-18 | 2024-05-28 | 北京航空航天大学 | Vacuum pressure-regulating casting method for aluminum-based composite brake disc |
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