CN113134570B - Modeling method for large-scale curved surface structure casting - Google Patents
Modeling method for large-scale curved surface structure casting Download PDFInfo
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- CN113134570B CN113134570B CN202110329108.5A CN202110329108A CN113134570B CN 113134570 B CN113134570 B CN 113134570B CN 202110329108 A CN202110329108 A CN 202110329108A CN 113134570 B CN113134570 B CN 113134570B
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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
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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
- B22C9/103—Multipart cores
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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
Abstract
A molding method for a large curved surface structure casting belongs to the technical field of casting and is used for solving the problem that the large curved surface structure casting is difficult to mold. By adopting a three-box molding mode and a mode of sleeving a sand frame outside a drag flask, the problem that the weight of the two-box molding mode exceeds the standard and the problem that the lower casting mold is difficult to turn over are solved; the problems of difficulty and standard exceeding of weight of the upper half part of the casting are solved by arranging the plurality of equal parts of the middle sand core.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a casting method for a large-scale curved surface structure casting.
Background
The diameter of a large hydroelectric crown casting is about 7100mm, the height of the large hydroelectric crown casting is about 3000mm, the wall thickness of the large hydroelectric crown casting is 70-150 mm, the net weight of the casting is about 63t, the large hydroelectric crown casting has a revolving body structure with a simple shape and a gradually-changed thin wall, the casting structure is shown in figure 1, in the prior art, a real model or a revolving body is used for scraping sand, a lower box (2) is firstly manufactured, an upper box (3) is manufactured after the box is turned, a core box is required to be manufactured to form an internal sand core (4), finally the internal sand core (4) is put into the lower box (2), and a box is closed to form a casting mold (5).
The forming method of the real model has the following problems:
1) The sand mold modeling of 8000 × 8000mm is required, the sand mold modeling is divided into two box modeling, the lower box after modeling is overweight, and the turnover operation cannot be performed, even if the model is changed into three box modeling, because a long box belt cannot penetrate through a ring in a model structure, the risk that a lower bed deforms or even is scrapped in the turnover and hoisting process of the sand mold is avoided, and the lower box is overweight at all;
2) The full-sample model is formed by piling wood, the wood consumption is large, in addition, an internal supporting tire needs to be manufactured to prevent the model from collapsing or deforming when molding quicksand, the total volume of the wood is about 60 cubes, and the manufacturing cost is high;
3) The large-scale curved surface model can not be integrally manufactured by a common numerical control machine tool, and needs to be assembled into an integral model after being processed by a plurality of modules, and the assembly precision and the integral strength are lower due to overlarge size;
4) The manufacturing period of the oversized-diameter full-sample model is about 55 days, and the manufacturing period cannot meet the modeling plan;
5) The thin-wall crown with the ultra-large diameter has high model hoisting difficulty and is not convenient for transportation, storage and management.
The molding method of the scraping of the revolving body has the following problems:
1) The sand scraping amount of the large-diameter product is too large, the sand scraping resistance is large, and the scraper is almost not moved, so that the on-site operation is inconvenient;
2) The preparation of the sand scraping tool is complex, and a large-span balance beam, a positioning shaft and a support frame are required for supporting the sand scraping plate;
3) Before scraping, a three-dimensional scriber is needed to confirm the positioning size of the scraping plate;
4) The sand scraping model with the large diameter and the thin wall can be used only once, the sand scraping model with the large diameter and the thin wall can be used for scraping the sand mould for the first time, the lower box turnover has the overweight problem and can not be operated, the sand mould of the upper box needs to be scraped after the box turnover is carried out, and the sand mould of the lower box can be scraped for the first time.
5) The large-diameter and large-sand-amount scraping sand has steep crown taper, relatively low size precision and compactness of the scraping sand and can not meet the casting quality.
That is, the two molding methods of the solid model or the revolving body scraping sand with two boxes can not or inconveniently mold the large-scale curved surface structure type casting.
Disclosure of Invention
In view of the above problem that the two boxes of the large hydropower upcrown are difficult to mold, there is a need to provide a molding method for a large curved surface structure casting, which realizes efficient and weight-reduced molding of the large casting by splitting the large curved surface structure.
A molding method for a large curved surface structure casting adopts three-box molding, wherein the lower half part of the casting is arranged in a lower casting mold, the upper half part of the casting is arranged in a middle casting mold, and the upper casting mold is used as a cover box to form the inner contour of the upper half part of the casting and place a chill, a riser and the like, wherein the lower casting mold and the middle casting mold form the outer contour of the casting, and an inner sand core is matched in the lower casting mold and is used for forming the inner contour of the lower half part of the casting; and assembling and combining the lower casting mold, the middle casting mold and the upper casting mold which are matched with the inner sand cores to form a complete cavity or a whole casting mold of a casting to be cast.
The lower casting mould is formed by placing a lower sand box on a forming platform; placing a lower mold in the drag flask; arranging an inner pouring gate movable material in the drag flask to form an inner pouring gate, and laying a casting system; flowing sand into the drag flask to form a lower casting mold; after the lower casting mold is turned over, arranging a sand frame on the periphery of the lower casting mold; dismantling the lower sand box, and butting a casting system on the lower casting mold; and sand flows into the sand frame to form an expanded lower casting mold. The outer contour of the sand frame and the middle sand box are the same in size, so that the lower box and the middle box are assembled conveniently. The size of the drag flask is just enough to accommodate the mold for the lower mold, so that the weight of the lower mold is the lightest, and the turning of the lower mold is facilitated.
Preferably, a plurality of cavity bodies are arranged in the sand frame, and the cavity bodies are arranged between the lower casting mold and the sand frame. The cavity body occupies the position of the original molding sand, thereby reducing the amount of the molding sand required by the expanded lower mold, and realizing the reduction of the sand-iron ratio of the expanded lower mold.
Preferably, a core print positioning fuse may also be provided within the drag flask to form a core print positioning structure to facilitate positioning of the sand core and/or assembly of the core.
Preferably, a box belt connecting piece can be arranged in the drag flask, so that the integral strength of the lower casting mold is improved, and the lower casting mold is prevented from collapsing.
The molding method of the middle casting mold comprises the steps of dividing the upper half part of the casting contained in a middle sand box into a plurality of equal parts, and manufacturing a corresponding middle sand core through a core box for each equal part; arranging a middle sand box on the expanded lower casting mold, and placing a plurality of middle sand cores in the middle sand box; and casting sand between the middle sand core and the middle sand box to form a middle casting mold.
Preferably, the middle sand core is provided with a core print positioning structure which is matched with the core print positioning structure on the lower casting mold, so that the middle sand cores can be arranged at specified positions, good matching of the middle sand cores is realized, and the outer contour of the upper half part of the casting with a complete shape is formed.
The molding method of the upper casting mold comprises the steps of arranging an inner ring positioning material on the lower casting mold; arranging outer ring positioning active materials at the upper edge of the middle sand core; arranging a plurality of segmented active materials between the inner ring positioning active material and the outer ring positioning active material; sand flowing to the area between the inner ring positioning active material and the outer ring positioning active material to manufacture a sand mold of the upper casting mold; and placing a cope box on the middle sand box, placing a riser, a chilling block and the like on the sand mould, and flowing sand to form an upper casting mould.
Preferably, a core bar is arranged between every two segmented live materials and used for improving the strength of the sand mold.
Preferably, a lifting piece is further arranged between the segmented movable materials so as to facilitate lifting of the sand mold.
As a supplement of the technical scheme, after the upper casting mold is molded, the upper casting mold is opened, and the lower casting mold and the upper casting mold are taken out and coated to improve the high-temperature resistance of the casting mold.
The technical scheme of the invention has the beneficial effects that: by adopting a three-box molding mode and a mode of sleeving a sand frame outside a drag flask, the problem that the weight of the two-box molding mode exceeds the standard and the problem that the lower casting mold is difficult to turn over are solved; the problems of difficulty and excessive weight of the upper half part of the casting are solved by arranging the plurality of equal parts of the middle sand core.
Drawings
FIG. 1 is a schematic view of a large hydroelectric crown;
FIG. 2 is a schematic view of a two-box molding;
FIG. 3 is a schematic view of a three-box molding;
FIG. 4 is a schematic view showing a state where a lower mold is fitted in a drag flask;
FIG. 5 is a schematic view of a lower mold with a sand frame;
FIG. 6 is a schematic view of an expanded lower mold;
FIG. 7 is a schematic view of a sand core box;
FIG. 8 is a schematic illustration of a sand core;
FIG. 9 is a schematic view of a center case core assembly;
FIG. 10 is a schematic view of a middle mold;
FIG. 11 is a schematic view of an upper box block;
FIG. 12 is a schematic view of an upper mold;
wherein, 1-large hydroelectric crowning; 2, discharging the box; 3, loading the box; 4-inner sand core; 5-casting the whole mould; 6-lower mould for casting; 7-drag flask; 8-core print positioning structure; 9-an inner gate; 10-a box strap connector; 11-a sand frame; 12-leveling; 13-extended lower mold; 14-casting in a mould; 15-medium sand core; 16-a core box; 17-a medium sand box; 18-positioning and activating the material by the inner ring; 19-casting on a casting mold; 20-positioning the movable material on the outer ring; 21-a sand scraping plate; 22-segmented live feed; 23-a cavity body; 24-sand mold.
Detailed Description
In order to more clearly illustrate the technical solutions of the present invention, the technical solutions of the present invention are described in detail with reference to the accompanying drawings, and it is obvious that the following descriptions are some exemplary embodiments of the present invention, and it is obvious for those skilled in the art that other solutions can be obtained according to the embodiments without creative efforts.
The invention relates to a molding method for a large curved surface structure casting, which adopts three-box molding, wherein the lower half part of the casting is arranged in a lower casting mould, the upper half part of the casting is arranged in a middle casting mould, and the upper casting mould is used as a cover box to form the inner contour of the upper half part of the casting and place a chill, a riser and the like, wherein the lower casting mould and the middle casting mould form the outer contour of the casting, an inner sand core is matched in the lower casting mould and is used for forming the inner contour of the lower half part of the casting; and assembling and combining the lower casting mold, the middle casting mold and the upper casting mold which are matched with the inner sand cores to form a complete cavity or a whole casting mold of a casting to be cast.
The implementation of the technical solution of the present invention will be described in detail by taking the large hydroelectric crown 1 as an example, as shown in fig. 3 to 12.
The outline dimension of the large hydroelectric crown 1 is phi 7200mm 2940mm, the wall thickness is 75-140 mm, the casting weight is 61t, the gross weight is 72t, the pouring weight is 145t, and the molding needs a sand box of 8000 mm.
1) Typing: dividing the whole casting mold 5 of the large hydroelectric upper crown 1 into a lower casting mold of a lower half part and a middle casting mold 14 of an upper half part, wherein in order to ensure that the weight of the lower casting mold is reasonable, the divided surfaces of the lower half part and the upper half part are arranged at a position which is 1600mm upwards from the bottom of the large hydroelectric upper crown 1, namely the diameter of the upper edge caliber of the lower casting mold is phi 3754mm; the section of the middle casting mold 14 and the section of the upper casting mold 19 are the upper edges of the large hydroelectric crown 1; the lower casting mould is used for forming a casting structure within a range from the bottom to the upper part of the large hydroelectric crown 1 by 1600mm, the middle casting mould 14 is used for forming an external profile from the bottom to the upper edge of the large hydroelectric crown 1 by 1600mm, and the upper casting mould 19 is used for forming an internal profile from the bottom to the upper edge of the large hydroelectric crown 1 by 1600 mm.
2) Molding of a lower casting mold: placing a lower sand box 7 on a molding platform, placing a lower casting mold 6 in the small sand box 7, placing a core head positioning material and an inner sprue material, and laying a casting system; meanwhile, in order to improve the sand hanging capacity of the drag flask 7 and the overall strength of the lower casting mold, a flask belt connecting piece 10 is also arranged on the inner wall of the drag flask 7; and then, flowing sand into the lower sand box 7 until the molding sand is flush with the edge of the lower sand box 7, and compacting, strickling and hardening to form a lower casting mold. The lower flask 7 has a contour of a size that can just accommodate the lower mold 6, thereby realizing the lightest weight of the lower mold and facilitating the turnover of the lower mold to the lowest sand-iron ratio. Preferably, in order to ensure that the lower casting mold can be conveniently and stably matched with the middle sand box 17, a sand frame 11 is arranged on the periphery of the lower casting mold after the mold turning, the peripheral outline of the sand frame 11 is equal to that of the middle sand box 17, sand flows between the lower casting mold and the sand frame 11, and the lower casting mold 13 is compacted, scraped and hardened to form an expanded lower casting mold 13. Preferably, in order to reduce the weight and sand-iron ratio of the expanded lower mold 13, a plurality of cavity bodies 23 are further arranged between the lower mold and the sand frame 11, and the cavity bodies 23 occupy the space position between the lower mold and the sand frame 11, so that the required amount of molding sand is greatly reduced, namely, the weight and sand-iron ratio of the expanded lower mold 13 is reduced.
3) Molding of the medium casting mold: dividing the upper half part of the casting placed in the middle casting mold 14 into a plurality of equal parts, wherein each equal part is an independent middle sand core 15, the plurality of middle sand cores 15 are spliced into the integral upper half part of the casting, and the middle sand cores 15 are formed by casting sand in a core box 16; arranging a middle sand box 17 on the expanded lower casting mold 13, and arranging a plurality of middle sand cores 15 on the lower casting mold, preferably, in order to facilitate the arrangement of the middle sand cores 15, core head positioning structures 8 are arranged on the lower casting mold and the middle sand cores 15, the core head positioning structures 8 exist on the middle sand cores 15 in the form of positioning tables, the core head positioning structures 8 exist on the lower casting mold in the form of positioning grooves, and the core head positioning structures 8 and the lower casting mold are matched with each other to play a role in positioning the middle sand cores 15; the middle mold 14 is formed by flowing, compacting, scraping and hardening between the periphery of the center core 15 and the center flask 17, wherein the highest level of flowing sand is flush with the uppermost edge of the center core 15 but lower than the edge of the center flask 17. The middle casting mold 14 is provided with a plurality of middle sand cores 15, so that the large curved surface of the middle casting mold 14 is divided into a plurality of small fan-shaped structures, and the large curved surface of the spindle box is convenient to manufacture, hoist, store and the like.
4) Molding of an upper casting mold: arranging an inner ring positioning movable material 18 on an interface of the lower casting mold and the middle casting mold 14, arranging an outer ring positioning movable material 20 on the upper edge of the middle casting mold 14, wherein the inner ring positioning movable material 18 is a flat plate structure buckled on the end face of the lower casting mold, the outer ring positioning movable material 20 is an annular structure matched with the upper edge of the middle casting mold 14, arranging a segmented movable material 22 between the inner ring positioning movable material 18 and the outer ring positioning movable material 20, and then performing sand flowing, compacting, scraping and hardening on an area between the inner ring positioning movable material 18 and the outer ring positioning movable material 20 to form a sand mold 24, wherein the sand mold 24 is used for molding the upper casting mold; a cope flask is disposed on the cope flask 17, a riser, a chill, and the like are provided on the sand mold 24, and an upper mold 19 is formed by pouring sand into the cope flask, compacting, strickling, and hardening. Preferably, when the sand mold 24 is manufactured, in order to improve the overall strength of the sand mold 24, a core bar can be arranged between the segmented movable materials 22; lifting lugs can be arranged between the segmented loose materials 22 for facilitating the lifting or the handling of the sand mould 24. The tools adopted for the scraping operation comprise a sand scraping plate 21, a leveling ruler 12 and the like, and different scraping tools are selected and used according to different end surface structures.
The three-box molding adopts a box-assembling mode, namely, a middle casting mold is molded by utilizing the structure of a lower casting mold, and an upper casting mold is molded by utilizing the structure of the lower casting mold and the middle casting mold, so that the need of more molds is avoided, the production cost is saved, and the production efficiency is improved. After all the molds are molded, parting and removing are carried out, namely, in the embodiment, the upper mold 19 is separated from the middle mold 14, the sand mold 24 on the middle mold 14 is removed after the separation, the lower mold 6 on the lower mold is removed, high-temperature-resistant coating is applied to the surface of the sand mold of each mold, and then the lower mold, the middle mold and the upper mold are combined, so that a complete cavity or a whole mold 5 of the large hydropower top crown 1 is formed, and the casting is waited for casting.
The above embodiment is only a description of a typical application of the technical solution of the present invention, and can be reasonably expanded on the basis of reasonable and creative labor-free.
Claims (8)
1. The molding method for the large curved surface structure casting is characterized by adopting three-box molding, wherein the lower half part of the casting is arranged in a lower casting mould, the upper half part of the casting is arranged in a middle casting mould, the upper casting mould is used as a cover box to form the inner contour of the upper half part of the casting, the lower casting mould and the middle casting mould form the outer contour of the casting, an inner sand core is matched in the lower casting mould, and the inner sand core is used for forming the inner contour of the lower half part of the casting; the molding method of the middle casting mold comprises the steps of cutting a sand core for forming the external outline of the upper half part of the casting into a plurality of middle sand cores, and splicing the middle sand cores on the lower casting mold for sand casting to form the middle casting mold;
the method for molding the lower mold comprises the following steps:
placing a drag flask on the molding platform;
placing a lower mold in the drag flask;
arranging movable material of an inner pouring gate in the drag flask to form the inner pouring gate, and paving a casting system;
flowing sand into the drag flask to form a lower casting mold;
after the lower casting mold is turned over, arranging a sand frame at the periphery of the lower casting mold;
dismantling the lower sand box, and butting and expanding the casting system on the lower casting mould;
and sand flows into the sand frame to form an expanded lower casting mold.
2. A molding method for a large curved structure casting according to claim 1, wherein a plurality of cavity bodies are provided in said sand frame, said cavity bodies being provided between the lower mold and the sand frame.
3. A method of molding large curved castings according to claim 1, wherein a core positioning shot is provided in said drag flask.
4. A molding method for a large curved structure casting according to claim 1, wherein the molding method for the middle mold is:
dividing the upper half part of the casting contained in the medium sand box into a plurality of equal parts, and manufacturing a corresponding medium sand core by each equal part through a core box;
disposing a drag flask on the expanded lower mold;
placing a plurality of the medium sand cores in the medium sand box;
and casting sand between the middle sand core and the middle sand box to form a middle casting mold.
5. The molding method for large curved structure castings according to claim 4, wherein core print positioning structures are provided on said sand core.
6. A molding method for a large curved structure casting according to claim 1, wherein the molding method for the upper mold is:
arranging the inner ring positioning material on the lower casting mold;
arranging the outer ring positioning material at the upper edge of the middle sand core;
a plurality of segmented active materials are arranged between the inner ring positioning active material and the outer ring positioning active material;
sand flowing to the area between the inner ring positioning active material and the outer ring positioning active material to manufacture a sand mold of the upper casting mold;
placing a cope box on the middle sand box, and placing a riser, a chill and the like on the sand mould;
and casting sand to form an upper casting mold.
7. A molding process for large curved castings according to claim 6, wherein a core is provided between each two of said segmented shots.
8. A method of moulding large curved castings according to claim 6, wherein there are further provided lifting means between the segmented charges.
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| CN202110329108.5A CN113134570B (en) | 2021-03-30 | 2021-03-30 | Modeling method for large-scale curved surface structure casting |
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| CN202110329108.5A CN113134570B (en) | 2021-03-30 | 2021-03-30 | Modeling method for large-scale curved surface structure casting |
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| CN113134570B true CN113134570B (en) | 2023-01-06 |
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| CN114749625A (en) * | 2022-04-21 | 2022-07-15 | 重庆江增船舶重工有限公司 | 3D printing sand mold and molding method for bearing shell of supercharger |
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| CN111558696A (en) * | 2020-05-22 | 2020-08-21 | 共享铸钢有限公司 | Forming method of ring-shaped steel casting |
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2021
- 2021-03-30 CN CN202110329108.5A patent/CN113134570B/en active Active
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| JPS6483336A (en) * | 1987-09-25 | 1989-03-29 | Suzuki Motor Co | Casting core and its manufacture |
| JP2010524690A (en) * | 2007-04-19 | 2010-07-22 | 南車眉山車輌有限公司 | How to make an integrated core for rail pillows or side frames of rail freight trains |
| CN203459625U (en) * | 2013-09-18 | 2014-03-05 | 苏州市通润机械铸造有限公司 | Sand mould structure with integrally-formed screw compressor shell |
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