CN113145800A - Composite casting process of slurry pump impeller - Google Patents
Composite casting process of slurry pump impeller Download PDFInfo
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- CN113145800A CN113145800A CN202110465486.6A CN202110465486A CN113145800A CN 113145800 A CN113145800 A CN 113145800A CN 202110465486 A CN202110465486 A CN 202110465486A CN 113145800 A CN113145800 A CN 113145800A
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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
- B22C9/03—Sand moulds or like moulds for shaped castings formed by vacuum-sealed moulding
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/28—Moulds for peculiarly-shaped castings for wheels, rolls, or rollers
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Abstract
The invention provides a composite casting process of a slurry pump impeller, which comprises the steps of manufacturing a front cover plate sand mold and a rear cover plate sand mold by adopting a V-method casting process to obtain an upper sand box and a lower sand box; manufacturing an integral core sand mold by adopting a resin sand casting process; assembling the front cover plate sand mold and the integral core sand mold; mould assembling and pouring: combining the cope flask and the drag flask, and pouring under negative pressure; and (5) demolding and shakeout. According to the invention, the front cover plate sand mold and the rear cover plate sand mold are manufactured by adopting a V-method casting process, the integral core sand mold is manufactured by adopting a resin sand casting process, and finally the three are assembled together for box-assembling pouring, so that the slurry pump impeller with a complex sand core is manufactured under the conditions of meeting the requirements of environmental protection and low cost, and the problem that the complex part sand core cannot be manufactured by adopting the V-method casting process in the prior art is solved.
Description
Technical Field
The invention relates to the technical field of impeller casting, in particular to a composite casting process of an impeller of a slurry pump.
Background
A slurry pump belongs to one of centrifugal pumps and is slurry conveying equipment commonly used in the industries of coal washing, chemical engineering, building and the like. The impeller of the slurry pump is a key component of the slurry pump and can be divided into a closed type, a semi-closed type and an open type according to a mechanical structure. The impeller of the slurry pump is used as a core part of a pump product, and the product quality of the impeller plays an intuitive and important role in the service performance of the pump and the reliability and the service life of the whole machine.
Regarding the production process of the slurry pump impeller, the traditional casting process scheme is mainly resin sand casting. The main disadvantages of this process scheme are the high cost of the resin and curing agent, and the volatile substances, which are not environment friendly. The V-method casting process is an advanced casting process developed in recent years, and adopts a negative pressure casting and automatic production mode. Compared with the resin sand casting process, the V-method casting process has the advantages of environmental protection, high efficiency and cost saving, so that the V-method casting process is widely applied to the production of casting parts with large production batch and regular shapes.
However, due to the limitation of the V-process casting process itself, the present process cannot be applied to the manufacture of parts with complicated cavity structures because it cannot manufacture complicated sand cores. The impeller of the large slurry pump mostly adopts a closed structure and consists of a front cover plate, a rear cover plate and a middle twisted blade, and a complex sand core needs to be manufactured for the middle blade part during casting. Therefore, the slurry pump impeller cannot be manufactured by the V-process casting process.
Therefore, the development of a composite casting process capable of manufacturing a slurry pump impeller with a complicated sand core is a problem to be solved by those skilled in the art.
Disclosure of Invention
In view of the above, the present invention is directed to a composite casting process of slurry pump impeller, so as to manufacture slurry pump impeller with complex sand core under the conditions of environmental protection and low cost.
In order to achieve the purpose, the technical scheme of the invention is realized as follows:
the composite casting process of slurry pump impeller includes the following steps
And a step a, manufacturing a front cover plate sand mold and a rear cover plate sand mold. In this embodiment, a front cover plate sand mold and a rear cover plate sand mold are manufactured by a V-process casting process to obtain a cope flask and a drag flask.
Step b, manufacturing an integral core sand mold: manufacturing an integral core sand mold by adopting a resin sand casting process;
step c, assembling the front cover plate sand mold and the integral core sand mold: designing a core print, and positioning the integral core sand mold on the front cover plate sand mold through the core print;
step d, mould assembling and pouring: combining the upper sand box and the lower sand box to form a casting mold with a pouring cup and a cavity, and then pouring under vacuum-pumping treatment;
step e, demolding and shakeout: and cooling after the pouring is finished, and relieving the negative pressure to obtain the slurry pump impeller.
Further, step a comprises
Step a1, designing a mould: designing a front cover plate mold and a rear cover plate mold, and respectively manufacturing a front cover plate sand mold and a rear cover plate sand mold by a V-method casting process;
step a2, coating film: covering and clinging the film to the surfaces of the front cover plate mould and the rear cover plate mould;
step a3, releasing the sand box and adding sand for vibration: respectively placing the two empty sand boxes on a front cover plate mold and a rear cover plate mold which are coated with films; adding sand into the two empty sand boxes, and starting vibration; after the vibration is finished, an upper sand adding box and a lower sand adding box are obtained;
step a4, coating a back film: scraping the sand on the surfaces of the upper sand adding box and the lower sand adding box, and covering and tightly attaching a film to the sand layer surfaces of the upper sand adding box and the lower sand adding box; opening a casting head on the upper sand adding box;
step a5, hardening and molding of sand mold: c, vacuumizing the upper sand adding box and the lower sand adding box in the step a4 until the sand mold is hardened and formed;
step a6, film forming: and c, performing pressure relief treatment on the upper sand adding box and the lower sand adding box in the step a5, and then taking off the film of the front cover plate mold and the film of the rear cover plate mold to obtain a front cover plate sand mold and a rear cover plate sand mold.
Furthermore, the front cover plate die and the rear cover plate die are made of cast aluminum materials.
Further, in the step a5, the negative pressure of the vacuum treatment is not less than 0.06 MPa.
Further, in the step b,
step b1, manufacturing a mould: manufacturing a resin sand core box, wherein the resin sand core box comprises a model main body and a blade;
step b2, adding sand: adding resin sand into the resin sand core box;
step b3, curing and forming: curing and molding the resin sand in the resin sand core box;
step b4, stripping: and taking down the blades to obtain the integral core sand mold.
Further, in the step c, the core print is a wrapping core print, the angle of the core print is 5 degrees, and the gap of the core print is 2 mm.
Further, in the step d, the cavity is cleaned before the cope flask and the drag flask are combined.
Further, in the step d, when the cope flask and the drag flask are combined, the box sealing paste is squeezed on a parting surface, and the distance between the box sealing paste and the cavity is not less than 40 mm.
Further, in the step d, before casting, a layer of thin sand is coated on the back film of the cope box.
Further, in the step d, when pouring is carried out, the negative pressure degree of vacuumizing treatment is not lower than 0.05 MPa; and after the pouring is finished, the vacuum degree of the vacuumizing treatment is 0.035-0.045 MPa.
Compared with the prior art, the invention has the following advantages:
according to the invention, the front cover plate sand mold and the rear cover plate sand mold are manufactured by adopting a V-method casting process, the integral core sand mold is manufactured by adopting a resin sand casting process, and finally the three are assembled together for box-assembling pouring, so that the slurry pump impeller with a complex sand core is manufactured under the conditions of meeting the requirements of environmental protection and low cost, and the problem that the complex part sand core cannot be manufactured by adopting the V-method casting process in the prior art is solved. Meanwhile, in the whole casting process, only the sand core is manufactured by adopting a resin sand casting process, and the rest parts are all manufactured by adopting a V-method casting process, so that the production cost is reduced, and the production efficiency is improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts. In the drawings:
fig. 1 is a schematic perspective view of an impeller of a slurry pump in embodiment 1 of the present invention;
FIG. 2 is a schematic sectional view of a slurry pump impeller in an embodiment 1 of the present invention;
FIG. 3 is a schematic perspective view of an impeller of a front cover plate of an impeller of a slurry pump in embodiment 1 of the present invention;
fig. 4 is a schematic perspective view of a back cover plate impeller of an impeller of a slurry pump in embodiment 1 of the invention;
fig. 5 is a schematic perspective view of a sand mold with an integral core of an impeller of a slurry pump in embodiment 1 of the invention.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. It is to be understood that the described embodiments are merely a few embodiments of the invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the present invention without making any creative effort, shall fall within the protection scope of the present invention.
The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
Example 1
The embodiment relates to a composite casting process of a slurry pump impeller, which comprises the following steps
Step a, manufacturing a front cover plate sand mold and a rear cover plate sand mold: and manufacturing a front cover plate sand mold and a rear cover plate sand mold by adopting a V-method casting process to obtain a cope flask and a drag flask. One of preferred embodiments of the present embodiment is as follows, but is not limited thereto, as long as the front cover sand mold and the back cover sand mold are manufactured using a V-process casting process.
Step a1, designing a mould. The impeller (as shown in fig. 1 and 2) is divided into a front cover plate 1, a rear cover plate 2 and a blade 3. The front cover plate 1 and the rear cover plate 2 are both manufactured into a front cover plate sand mold and a rear cover plate sand mold by adopting a V-method casting process mold. Therefore, in the present embodiment, the mold for the front cover plate 1 is designed as shown in fig. 3, and the mold for the rear cover plate 2 is designed as shown in fig. 4. Preferably, the front cover plate mold and the rear cover plate mold are made of cast aluminum materials. The material has the advantages of high strength, light weight and good machinability, and is suitable for manufacturing V-method casting process dies.
Step a2, coating film: and covering and clinging the film to the surfaces of the front cover plate mould and the back cover plate mould. Specifically, a front cover plate die and a rear cover plate die are respectively placed on an upper film laminating station workbench and a lower film laminating station workbench in an oriented and positioned mode. After the film laminating machine is placed, whether the film laminating station and the film laminating frame can normally operate or not is checked, whether the film cutting wires can normally heat or not is checked, and whether the negative pressure box for the casting process is in butt joint with the negative pressure interface of the film laminating station or not is checked. After the inspection is finished, the film covering process of the front cover plate die and the rear cover plate die is started, firstly, the film covering frame is descended to cover the film, secondly, the vacuum pumping treatment is carried out to enable the film to be tightly attached to the two dies, the negative pressure degree is not lower than 0.06MPa, and finally, the film outside the two dies is cut by the film cutting wire, and the film covering process is finished.
Step a3, releasing the sand box and adding sand for vibration. After the film covering is finished, the front cover plate die and the rear cover plate die are transferred to the compaction table from the film covering station. And after the negative pressure interface of the compaction table is well butted with a negative pressure box for a casting process, vacuumizing, wherein the negative pressure is not lower than 0.06MPa, and after vacuumizing for 10s, loosening the negative pressure interface of the film coating station. And respectively installing the two empty sand boxes on the front cover plate die and the rear cover plate die which are covered with the films through positioning pins. When the empty sand box is lifted, the stable and accurate movement of the empty sand box is ensured.
And respectively moving the compaction tables carrying two empty sand boxes (including a front cover plate mould and a rear cover plate mould inside the empty sand boxes) to a sand adding station. Adding sand into two empty sand boxes, and starting vibration when the sand adding amount reaches 1/3 of the volume of the empty sand box, wherein the vibration frequency is 50Hz, and the vibration time is generally controlled to be about 60 s. And after the vibration is finished, an upper sand adding box and a lower sand adding box are obtained.
Step a4, coating a back film. And after the sand adding vibration is finished, the upper sand adding box and the lower sand adding box are moved to a back film covering station. The surfaces of the cope and drag flasks are scraped, and in particular the drag flask must be completely scraped, to prevent sand mold deformation after falling to the ground. Then starting a back film coating process, namely, firstly, coating and tightly attaching a film on the sand layer surfaces of the upper sand adding box and the lower sand adding box; secondly, the upper sand adding box needs to find out the positions of an exhaust pipe and a casting head, clean nearby dry sand and make a concave pit with a convex middle part on the periphery to prevent sand from flowing into a cavity; thirdly, cleaning floating sand at the box openings of the two sand adding boxes to ensure that the back film is tightly attached to the box openings of the two sand adding boxes; and fourthly, fixing the back film and the two sand adding boxes by using a magnet or an adhesive tape.
Step a5, hardening and molding the sand mold. And moving the upper sand adding box and the lower sand adding box coated with the back film to a box turning station, clamping the handles of the two sand adding boxes by using a box turning manipulator, and butting the negative pressure interface of the box turning station with the two sand adding boxes. Vacuumizing is carried out to harden and mold the sand mold, generally 10 min. Preferably, the negative pressure of the vacuum pumping treatment is not lower than 0.06MPa so as to ensure that the sand mold is hardened and formed.
And step a6, film forming. And c, performing pressure relief treatment on the upper sand adding box and the lower sand adding box in the step a5, and then taking off the film of the front cover plate mold and the film of the rear cover plate mold to obtain a front cover plate sand mold and a rear cover plate sand mold. Before taking off the coating, positive pressure is blown into the two sand adding boxes by using a vacuum pump, the pressure is 0.11Mpa, and stripping is carried out after 30 s. Wherein, when stripping, the negative pressure needs to be strictly controlled, because the friction force of the die needs a higher pressure guarantee coefficient.
Step b, manufacturing an integral core sand mold: and manufacturing the integral core sand mold by adopting a resin sand casting process. What needs to be done first is the manufacture of the mould, i.e. the manufacture of the resin core box. The resin core box comprises a mould main body and blades, wherein the mould main body can be made of wood materials, and the blades can be made of foams (as shown in figure 5). And after the resin sand core box is manufactured, adding resin sand into the resin sand core box, and then curing and molding the resin sand in the resin sand core box. And after forming, taking down the blades to obtain the integral core sand mold. The foam blades are typically scooped out with a blade.
And c, assembling the front cover plate sand mold and the integral core sand mold. The core print is needed when the front cover plate and the rear cover plate are positioned and assembled, and the whole core sand mold is positioned on the front cover plate sand mold through the core print. It is generally desirable to design the core print based on the structural characteristics of the impeller. In the embodiment, the core print is designed to be a wrapping core print, the core print is designed to protrude 70mm of sand eating amount along the maximum excircle of the impeller, the angle of the core print is designed to be 5 degrees, and the gap of the core print is designed to be 2 mm. Meanwhile, the core print is a vertical core print and is divided into an upper core print 4 and a lower core print 5, the length of the upper core print 4 is 30mm, and the length of the lower core print 5 is the same as the width of the flow channel of the impeller 3. The integral core sand mold is accurately placed in the front cover plate sand mold through the core print, the quality of the integral core sand mold is carefully checked during placement, and the defect part is repaired and polished smoothly. And after polishing, spraying the integral core sand mold by adopting the special coating for V-process casting, and polishing after twice spraying until the integral core sand mold is smooth and has no flow mark. Wherein, the core head edges and corners of the integral core sand mold are modified into circular arcs so as to prevent the lower core mold closing box from scratching the film.
Step d, mould assembling and pouring: and (3) combining the upper sand box and the lower sand box to form a casting mold with a pouring cup and a cavity, and then pouring under the vacuum-pumping treatment. Preferably, the cavity is cleaned before the cope flask and the drag flask are combined to ensure that no quartz sand, talcum powder or other impurities are contained in the cavity. More preferably, when the cope flask and the drag flask are combined, the mold sealing paste is squeezed and sealed on a parting surface (namely quality inspection of a joint surface of the cope flask and the drag flask), the thickness of the mold sealing paste is uniform, and the distance between the mold sealing paste and the mold cavity is not less than 40 mm. And finishing the mould assembling preparation work.
And after the mud paste sealing is finished, the lower sand adding box is moved to a mold stripping and box overturning station through a transfer flat car, and the box closing operation is carried out through a manipulator to form a casting mold with a pouring cup and a cavity. The rear cover plate sand mold and the front cover plate sand mold are accurately positioned through a positioning pin between the upper sand adding box and the lower sand adding box. After the mold closing is confirmed, the box clamping hooks of the two sand adding boxes are locked by a sledge hammer. And after the mould assembling is finished, the casting process can be started. Preferably, before pouring, a layer of thin sand is coated on the back film of the cope flask to prevent the pouring molten iron from splashing out to burn the back film and influence the pressure value. Connecting a negative pressure interface of the box turnover station with a vacuum pump, and vacuumizing. Molten metal is prepared and a casting process is started.
When pouring, the ladle nozzle should be as close to the pouring cup as possible, and splashing and vortex cannot be caused. Meanwhile, the pouring is not interrupted to ensure that a certain amount of molten metal is always kept in the pouring cup. In the casting process, the casting speed is controlled all the time, the principle of 'two small strands and one large strand' is followed, namely, the small strand is introduced by casting, then the large-flow casting is carried out, and the small strand is cast again when the molten metal is filled quickly. After the pouring is finished, the negative pressure is reduced and the negative pressure is kept for more than 30 minutes. Preferably, the negative pressure of the vacuumization is not lower than 0.05MPa when the pouring is carried out; and after the pouring is finished, the vacuum degree of the vacuumizing treatment is 0.035-0.045 MPa.
Step e, demolding and shakeout: after the time for keeping the negative pressure reaches the requirement, a vacuum pipeline valve on a vacuum pump pipeline is closed, the normal pressure state is slowly recovered, at the moment, the sand in the two sand adding boxes automatically flows out, and the sand can be reused after being cooled. And (3) waiting for the casting to be cooled under the normal pressure state, and obtaining a clean slurry pump impeller without sand blocks and mechanical bonded sand after cooling.
According to the invention, the front cover plate sand mold and the rear cover plate sand mold are manufactured by adopting a V-method casting process, the integral core sand mold is manufactured by adopting a resin sand casting process, and finally the three are assembled together for box-assembling pouring, so that the slurry pump impeller with a complex sand core is manufactured under the conditions of meeting the requirements of environmental protection and low cost, and the problem that the complex part sand core cannot be manufactured by adopting the V-method casting process in the prior art is solved. Meanwhile, in the whole casting process, only the sand core is manufactured by adopting a resin sand casting process, and the rest parts are all manufactured by adopting a V-method casting process, so that the production cost is reduced, and the production efficiency is improved.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (10)
1. The composite casting process of the slurry pump impeller is characterized in that: comprises the following steps
Step a, manufacturing a front cover plate sand mold and a rear cover plate sand mold: manufacturing a front cover plate sand mold and a rear cover plate sand mold by adopting a V-method casting process to obtain a cope flask and a drag flask;
step b, manufacturing an integral core sand mold: manufacturing an integral core sand mold by adopting a resin sand casting process;
step c, assembling the front cover plate sand mold and the integral core sand mold: manufacturing a core print, and positioning an integral core sand mold on the front cover plate sand mold through the core print;
step d, mould assembling and pouring: combining the upper sand box and the lower sand box to form a casting mold with a pouring cup and a cavity, and then pouring under vacuum-pumping treatment;
step e, demolding and shakeout: and cooling after the pouring is finished, and relieving the negative pressure to obtain the slurry pump impeller.
2. The composite casting process of the slurry pump impeller of claim 1, wherein: step a comprises
Step a1, designing a mould: designing a front cover plate mold and a rear cover plate mold, and respectively manufacturing a front cover plate sand mold and a rear cover plate sand mold by a V-method casting process;
step a2, coating film: covering and clinging the film to the surfaces of the front cover plate mould and the rear cover plate mould;
step a3, releasing the sand box and adding sand for vibration: respectively placing the two empty sand boxes on a front cover plate mold and a rear cover plate mold which are coated with films; adding sand into the two empty sand boxes, and starting vibration; after the vibration is finished, an upper sand adding box and a lower sand adding box are obtained;
step a4, coating a back film: scraping the sand on the surfaces of the upper sand adding box and the lower sand adding box, and covering and tightly attaching a film to the sand layer surfaces of the upper sand adding box and the lower sand adding box; opening a casting head on the upper sand adding box;
step a5, hardening and molding of sand mold: c, vacuumizing the upper sand adding box and the lower sand adding box in the step a4 until the sand mold is hardened and formed;
step a6, film forming: and c, performing pressure relief treatment on the upper sand adding box and the lower sand adding box in the step a5, and then taking off the film of the front cover plate mold and the film of the rear cover plate mold to obtain a front cover plate sand mold and a rear cover plate sand mold.
3. The composite casting process of the slurry pump impeller of claim 2, wherein: the front cover plate die and the rear cover plate die are made of cast aluminum materials.
4. The composite casting process of the slurry pump impeller of claim 2, wherein: in the step a5, the negative pressure degree of the vacuum pumping treatment is not lower than 0.06 MPa.
5. The composite casting process of the slurry pump impeller according to any one of claims 1 to 4, wherein: step b | comprises
Step b1, manufacturing a mould: manufacturing a resin sand core box, wherein the resin sand core box comprises a model main body and a blade;
step b2, adding sand: adding resin sand into the resin sand core box;
step b3, curing and forming: curing and molding the resin sand in the resin sand core box;
step b4, stripping: and taking down the blades to obtain the integral core sand mold.
6. The composite casting process of the slurry pump impeller of claim 5, wherein: in the step c, the core print is a wrapping core print, the angle of the core print is 5 degrees, and the gap of the core print is 2 mm.
7. The composite casting process of the slurry pump impeller of claim 5, wherein: and d, cleaning the cavity before the cope flask and the drag flask are combined.
8. The composite casting process of the slurry pump impeller of claim 5, wherein: and d, extruding and sealing box mud paste on a parting surface when the cope flask and the drag flask are combined, wherein the distance between the box mud paste and the cavity is not less than 40 mm.
9. The composite casting process of the slurry pump impeller of claim 5, wherein: and d, coating a layer of thin sand on the back film of the cope box before casting.
10. The composite casting process of the slurry pump impeller of claim 9, wherein: in the step d, when pouring is carried out, the negative pressure degree of vacuumizing treatment is not lower than 0.05 MPa; and after the pouring is finished, the vacuum degree of the vacuumizing treatment is 0.035-0.045 MPa.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116851651A (en) * | 2023-08-15 | 2023-10-10 | 无锡锡南科技股份有限公司 | Motor casing combined type air passage core and core manufacturing method |
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| CN111774530A (en) * | 2020-07-11 | 2020-10-16 | 青岛盛美机械有限公司 | V-method molding process capable of casting propeller |
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| KR20080017932A (en) * | 2006-08-23 | 2008-02-27 | 현대자동차주식회사 | Method for manufacturing mg cylinder head cover united baffle plate |
| KR100945896B1 (en) * | 2009-09-08 | 2010-03-05 | (주)성신엠테크 | Mold manufacturing method for castings of impeller, mold using thereof and impeller manufactured thereby |
| CN107414026A (en) * | 2017-08-16 | 2017-12-01 | 四川省井研卫东机械制造厂 | Using the vacuo-forming of V methods and the casting sand mold preparation method of phenolic sand molding combination process |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN116851651A (en) * | 2023-08-15 | 2023-10-10 | 无锡锡南科技股份有限公司 | Motor casing combined type air passage core and core manufacturing method |
| CN116851651B (en) * | 2023-08-15 | 2024-02-23 | 无锡锡南科技股份有限公司 | Motor casing combined type air passage core and core manufacturing method |
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| CN113145800B (en) | 2022-11-18 |
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