CN113560494B - Deformation-reducing casting method and structure for large aluminum-magnesium alloy thin-wall cabin - Google Patents
Deformation-reducing casting method and structure for large aluminum-magnesium alloy thin-wall cabin Download PDFInfo
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- CN113560494B CN113560494B CN202110826312.8A CN202110826312A CN113560494B CN 113560494 B CN113560494 B CN 113560494B CN 202110826312 A CN202110826312 A CN 202110826312A CN 113560494 B CN113560494 B CN 113560494B
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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
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
- B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
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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
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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
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
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Abstract
The invention provides a method and a structure for reducing deformation of a large aluminum-magnesium alloy thin-wall cabin, wherein the method comprises the following steps: the structural design is that a mud core, an outer mold, cavity gaps and a pouring channel are designed according to the shape and the size of a cabin body, then a vertical support cavity and a plurality of cross support cavities surrounding the vertical support cavity are additionally arranged in the mud core, and blocking chillers are additionally arranged around the positions, connected with the cavity gaps, of the cross support cavities; manufacturing a sand mold, namely manufacturing a mud core and an outer mold respectively; and (5) closing the die and casting. By adopting the invention, the deformation of the cabin body in the casting and heat treatment processes is effectively reduced, the mechanical correction is not needed, the labor force is saved, the cabin body is prevented from being damaged in the correction process, and the cost is saved; vertical supporting rods and transverse supporting rods are respectively formed through the vertical supporting cavities and the transverse supporting cavities, the blocking chilling blocks ensure the molding quality of castings in the casting process, and the casting precision reaches the tolerance grade requirement of Ct 7-Ct 6.
Description
Technical Field
The invention relates to the technical field of casting of magnesium aluminum alloy thin-wall cabin bodies, in particular to a method for casting a large-sized magnesium aluminum alloy thin-wall cabin body by reducing deformation and a casting structure thereof.
Background
The diameter of the large aluminum-magnesium alloy thin-wall cabin body is more than or equal to 600mm generally, the wall thickness is less than or equal to 4mm, the casting usually has larger deformation in the heat treatment process, and the maximum deformation can reach 4-5 mm or more. Excessive deformation can cause the subsequent cabin casting to be unfinished in the machining process, and parts are scrapped. The deformation is reduced by adopting a mechanical correction method, and the deformation of the casting of the cabin body can be controlled within 2-3 mm through the mechanical correction, so that the machining allowance is usually added on a machining surface and a casting correction process amount is added on a non-machining surface in the casting process, the casting shrinkage rate is controlled, and the cabin casting can be successfully machined after being deformed by heat treatment.
By mechanically aligning the casting, the amount of deformation is reduced, which has a high skill level requirement on the operator and is very labor intensive. In addition, as the cabin castings are subjected to heat treatment, the rigidity of the whole cabin is weak, and the cabin castings are easily subjected to integral damage by adopting mechanical correction, so that cracks, local deformation and the like appear in the cabin.
Disclosure of Invention
In order to solve the technical problems, the invention provides a casting method and a casting structure for reducing deformation of a large aluminum-magnesium alloy thin-wall cabin.
The invention is realized by the following technical scheme.
The invention provides a method for casting a large aluminum-magnesium alloy thin-wall cabin body by reducing deformation, which comprises the following steps:
A. the mud core, the outer mold, the cavity gap and the pouring channel are designed according to the shape and the size of a cabin body, then a vertical support cavity and a plurality of cross-support cavities surrounding the vertical support cavity are additionally arranged in the mud core, two ends of each cross-support cavity are respectively communicated with the vertical support cavity and the cavity gap, and blocking chillers are additionally arranged on the periphery of the cross-support cavity connected with the cavity gap;
B. manufacturing sand moulds, namely manufacturing a mud core and an outer mould respectively, and filling molding sand into positions outside a cavity gap, a pouring channel, a vertical support cavity and a transverse support cavity;
C. and (3) closing the die and casting, wherein molten metal enters a cavity gap, a vertical support cavity and a transverse support cavity, and is cooled to form a casting, and a vertical support rod and a transverse support rod which are integrated with the casting.
And step A, structural design, wherein multiple layers of cross brace cavities are arranged along the height direction of the mud core, and each layer is provided with a plurality of cross brace cavities.
Four transverse supporting cavities are uniformly distributed in the circumferential direction in each layer.
The top surface and the bottom surface of the mud core are respectively provided with a layer of cross brace cavity.
Blocking chills are arranged between two adjacent cross brace cavities on each layer.
Two ends of the blocking chilling block are respectively communicated with two adjacent cross-brace cavities on the same layer, and the outer side face of the blocking chilling block is communicated with a cavity gap.
Under the condition that the cabin body is a revolving body, the blocking chilling block is arc-shaped.
The mud core is of a multilayer laminated structure, and 1-2 layers of cross-brace cavities are arranged on each layer of mud core.
And B, manufacturing a sand mold, namely manufacturing the mud core by adopting sand mold 3D printing or sand casting molding.
The pounding sand molding specifically comprises the following steps: placing the core box on a flat plate, placing the transverse bracing type cavity and the vertical bracing type cavity dies, blocking the chill, pounding sand, placing the second layer of transverse bracing type cavity dies and blocking the chill, making core head positioning grooves after pounding sand, and taking out the transverse bracing type cavity dies and the vertical bracing type cavity dies and blocking the chill when molding is completed; after all the mud cores are manufactured according to the same method, the mud cores are positioned through the core head positioning grooves.
The invention also provides a deformation-reducing casting structure of the large aluminum-magnesium alloy thin-wall cabin, which comprises a mud core and an outer mold, wherein the mud core is positioned in the outer mold, a cavity gap is formed between the mud core and the outer mold, a pouring channel is arranged on the outer mold and is communicated with the cavity gap, a plurality of vertical supporting cavities and cross supporting cavities are arranged on the mud core, the cross supporting cavities surround the vertical supporting cavities, two ends of each cross supporting cavity are respectively communicated with the vertical supporting cavities and the cavity gap, and blocking chills are arranged on the periphery of the positions, connected with the cavity gap, of the cross supporting cavities.
The invention has the beneficial effects that:
by adopting the invention, the deformation of the cabin body in the casting and heat treatment processes is effectively reduced, the mechanical correction is not needed, the labor force is saved, the cabin body is prevented from being damaged in the correction process, and the cost is saved; vertical support rods and transverse support rods are respectively formed through the vertical support cavities and the transverse support cavities, the molding quality of a casting in the casting process is guaranteed by blocking chilling blocks, the deformation amount is reduced to 1mm when casting is finished, the deformation amount after heat treatment is reduced to 1.5mm, the tolerance grade requirement of Ct 7-Ct 6 can be met, the requirement of the original aerospace product is exceeded, and the requirement of an aerospace product is met on some parts; in other words, the invention can finish the manufacturing of some aviation parts by the original casting process, thereby greatly reducing the cost of aviation equipment.
Drawings
Fig. 1 is a schematic structural view of a casting sand mold of the present invention.
FIG. 2 is a schematic view of the casting of the present invention.
FIG. 3 is a perspective view of a casting of the present invention.
In the figure: 1-mud core; 2-external mold; 3-a cavity gap; 4-pouring channel; 5-vertically supporting the cavity; 6-cross brace cavity; 7-blocking chilling block; 8-vertical support rods; 9-transverse supporting rods; 10-casting.
Detailed Description
The technical solution of the present invention is further described below, but the scope of the claimed invention is not limited to the described.
As shown in fig. 1-2, the structure of the invention is schematically illustrated:
the invention provides a method for casting a large aluminum-magnesium alloy thin-wall cabin body by reducing deformation, which comprises the following steps:
A. the mud core 1, the outer mold 2, the cavity gap 3 and the pouring channel 4 are designed according to the shape and the size of a cabin body, then a vertical support cavity 5 and a plurality of cross support cavities 6 surrounding the vertical support cavity 5 are additionally arranged in the mud core 1, two ends of each cross support cavity 6 are respectively communicated with the vertical support cavity 5 and the cavity gap 3, and blocking chills 7 are additionally arranged around the positions, connected with the cavity gap 3, of the cross support cavities 6;
B. manufacturing sand molds, namely manufacturing a mud core 1 and an outer mold 2 respectively, and filling molding sand into parts except a cavity gap 3, a pouring gate 4, a vertical support cavity 5 and a transverse support cavity 6;
C. and (3) closing the die and casting, wherein molten metal enters the cavity gap 3, the vertical support cavity 5 and the transverse support cavity 6, and is cooled to form a casting, and a vertical support rod 8 and a transverse support rod 9 which are integrated with the casting.
The principle is as follows: after molten metal enters the whole sand mold, under the condition that a chilling block 7 is not blocked, the transverse support cavity 6 and the vertical support cavity 5 have certain influence on feeding of a casting system, and specifically, when the molten metal enters the transverse support cavity 6, the molten metal has certain probability to cause shrinkage deformation in a casting, so that defects and influence on quality are caused; the blocking chilling block 7 can prevent the phenomenon from occurring, when the metal liquid enters the cross brace cavity 6 and the vertical brace cavity 5, the blocking chilling block 7 enables the metal liquid to be chilled quickly, and therefore the defect caused by the fact that the metal liquid in the cavity gap 3 at the position is lost too fast is avoided. After the casting 10 is cast and molded, the vertical support rods 8, the transverse support rods 9 and the cabin casting form a whole, in the process of heating to quick cooling through heat treatment, the transverse support rods 9 generate inward traction force, the vertical support rods 8 improve the rigidity of the whole casting, so that the deformation is uniform and the integrity is good, and the deformation of the cabin is reduced. Designing the mud core 1, the outer die 2, the cavity gap 3 and the pouring gate 4 according to the shape and the size of the cabin body, wherein the casting process is a conventional method.
By adopting the invention, the deformation of the cabin body in the casting and heat treatment processes is effectively reduced, the mechanical correction is not needed, the labor force is saved, the cabin body is prevented from being damaged in the correction process, and the cost is saved; vertical supporting rods 8 and transverse supporting rods 9 are respectively formed through the vertical supporting cavities 5 and the transverse supporting cavities 6, the blocking chilling blocks 7 ensure the molding quality of castings in the casting process, the deformation amount is reduced to 1mm when casting is finished, the deformation amount after heat treatment is reduced to 1.5mm, the tolerance grade requirement of Ct 7-Ct 6 can be met, the requirement of original aerospace products is exceeded, and the requirement of aerospace products is met on certain parts; in other words, the invention can finish the manufacturing of some aviation parts by the original casting process, thereby greatly reducing the cost of aviation equipment.
And step A, structural design, wherein multiple layers of cross brace cavities 6 are arranged along the height direction of the mud core 1, and each layer is provided with a plurality of cross brace cavities 6. The supporting device is convenient for supporting different parts of the cabin casting, and ensures that the deformation of each part of the cabin with larger length meets the requirement.
Four cross brace cavities 6 are uniformly distributed in the circumferential direction in each layer. So that the transverse supporting rod 9 formed subsequently has uniform traction force in all directions, the deformation amount is reduced, and the transverse supporting rod 9 is easy to remove.
The top surface and the bottom surface of the mud core 1 are respectively provided with a layer of cross brace cavity 6. The rigidity of the opening part of the cabin body is improved, the deformation is reduced, and the removal difficulty of the transverse stay bar 9 is small.
And a blocking chilling block 7 is arranged between two adjacent cross-brace cavities 6 in each layer. The manufacturing of the mud core 1 is convenient, and the blocking chill 7 can be arranged when the mold of the cross brace cavity 6 is pre-embedded.
Two ends of the blocking chiller 7 are respectively communicated with two adjacent cross-brace cavities 6 on the same layer, and the outer side surface of the blocking chiller 7 is communicated with the cavity gap 3. The blocking chiller 7 has the same circumferential shape with the inner wall of the cabin body, and can form an annular support inside the cabin body in the casting process and the heat treatment process, thereby improving the rigidity and reducing the deformation.
Under the condition that the cabin body is a revolving body, the blocking chilling block 7 is arc-shaped.
The mud core 1 is of a multilayer laminated structure, and 1-2 layers of cross brace cavities 6 are arranged on each layer of mud core 1. The cross brace cavity 6 can be arranged on the top surface or the bottom surface of each layer of mud core 1, and the mud core 1 is manufactured by adopting a split mold, so that the manufacturing difficulty of the mud core 1 is reduced, and the manufacturing efficiency is improved; the scheme is suitable for the condition that the length is large and 3-4 layers of cross-brace cavities 6 are needed.
And B, manufacturing a sand mold, namely manufacturing the mud core 1 by adopting sand mold 3D printing or sand casting molding. When 3D printing is adopted, a transverse supporting cavity 6 mould is not needed, direct modeling and printing are carried out, and the operation is convenient; when the sand pounding molding is adopted, the moulds of the vertical support cavity 5 and the cross support cavity 6 are pre-buried, then the sand pounding is carried out, the mould of the cross support cavity 6 of the next layer is pre-buried, and finally the moulds of the cross support cavity 6 and the vertical support cavity 5 are taken out after the sand pounding is finished.
The sand pounding modeling specifically comprises the following steps: placing a core box on a flat plate, placing a mold of a cross brace cavity 6 and a vertical brace cavity 5, blocking chill 7, pounding, placing a mold of a second layer of cross brace cavity 6 and blocking chill 7, making a core head positioning groove after pounding is finished, and taking out the mold of the cross brace cavity 6 and the vertical brace cavity 5 and blocking chill 7 when molding is finished; after all the mud cores 1 are manufactured according to the same method, the mud cores 1 are positioned by the core head positioning grooves.
The first embodiment is as follows:
ZL114A large thin-wall cabin (phi 970 x phi 720 x 1700) structural casting.
1. Putting the baked ZL114 alloy ingot into a furnace for melting, refining at 720-740 ℃, removing a surface slag layer by using a skimming ladle, preserving heat, standing, hoisting a bottom plate on a flat plate by using a crane for standby, putting casting core boxes on the flat plate according to the number from large to small, then placing a mold for blocking a chill 7, a cross brace cavity 6 and a vertical brace cavity 5 in the core boxes, pre-burying hoisting holes, and then performing sand pounding and tamping;
2. after the casting sand core is completely molded, the molds of the cross-bracing cavity 6 and the vertical-bracing cavity 5 are taken out, the sand cores are combined by a crane, the casting sand core casting is completed after the combination is completed, the sand core casting is baked for 5-10 min by a blowtorch, after the casting is cooled, the outer mold 2 is hoisted for closing, and the casting can be performed after the closing.
3. After casting pouring is finished, the casting is scanned in a three-dimensional mode through a handheld composite three-dimensional scanner, and after three-dimensional comparison, deformation caused by manual box closing is 1mm.
4. After the casting is subjected to heat treatment, the casting is subjected to three-dimensional scanning by using a handheld composite three-dimensional scanner, and after three-dimensional comparison, the deformation caused by adding a manual mould assembling after the heat treatment is 1.5mm.
Compared with the conventional method, the casting method for casting the casting has the advantages that the deformation of the cabin casting produced by the conventional method after heat treatment is 4-4.5 mm, and the deformation is controlled to be 2-2.5 mm after mechanical correction. In addition, the tolerance grade requirement of Ct 7-Ct 6 is met, the requirement of the original aerospace product is exceeded, and the requirement of similar parts of the aerospace product is met; in other words, the manufacturing of some aviation parts can be completed by the invention, and the cost of aviation equipment is greatly reduced.
The invention also provides a deformation-reducing casting structure of the large aluminum-magnesium alloy thin-wall cabin, which comprises a mud core 1 and an outer mold 2, wherein the mud core 1 is positioned in the outer mold 2, a cavity gap 3 is formed between the mud core 1 and the outer mold 2, a pouring gate 4 is arranged on the outer mold 2, the pouring gate 4 is communicated with the cavity gap 3, a plurality of vertical bracing cavities 5 and cross bracing cavities 6 are arranged on the mud core 1, the cross bracing cavities 6 surround the vertical bracing cavities 5, two ends of the cross bracing cavities 6 are respectively communicated with the vertical bracing cavities 5 and the cavity gap 3, and blocking chills 7 are arranged around the positions, connected with the cavity gap 3, of the cross bracing cavities 6.
The cross-brace type cavities 6 are provided with a plurality of layers along the height direction of the mud core 1, and a plurality of cross-brace type cavities 6 are arranged on each layer. The supporting device is convenient for supporting different parts of the cabin casting, and ensures that the deformation of each part of the cabin with larger length meets the requirement.
The number of the cross-brace cavities 6 of each layer is four.
The cross brace cavities 6 are uniformly distributed along the circumferential direction.
So that the transverse supporting rod 9 formed subsequently has uniform traction force in all directions, the deformation amount is reduced, and the transverse supporting rod 9 is easy to remove.
The top surface and the bottom surface of the mud core 1 are respectively provided with a layer of cross brace cavity 6. The rigidity of the opening part of the cabin body is improved, the deformation is reduced, and the removal difficulty of the transverse stay bar 9 is small.
The blocking chiller 7 is arranged between every two adjacent cross brace cavities 6. The manufacturing of the mud core 1 is convenient, and the blocking chill 7 can be arranged when the mold of the cross brace cavity 6 is pre-embedded.
Two ends of the blocking chiller 7 are respectively communicated with two adjacent cross brace cavities 6 on the same layer. The wholeness is good, can improve the intensity of sand mould, makes mud core 1 make the degree of difficulty reduce.
And the outer side surface of the blocking chilling block 7 is communicated with the cavity gap 3. The blocking chilling blocks 7 are consistent with the circumferential shape of the inner wall of the cabin body, and can form an annular support inside the cabin body in the casting process and the heat treatment process, so that the rigidity is improved, and the deformation is reduced.
Under the condition that the cabin body is a revolving body, the blocking chilling block 7 is arc-shaped.
The mud core 1 is of a multilayer laminated structure, and 1-2 layers of cross brace cavities 6 are arranged on each layer of mud core 1. The cross brace cavity 6 can be arranged on the top surface or the bottom surface of each layer of mud core 1, and the mud core 1 is manufactured by adopting a split mold, so that the manufacturing difficulty of the mud core 1 is reduced, and the manufacturing efficiency is improved; the scheme is suitable for the condition that the length is large and 3-4 layers of cross-brace cavities 6 are needed.
Claims (7)
1. A method for reducing deformation of a large aluminum-magnesium alloy thin-wall cabin is characterized by comprising the following steps: comprises the following steps of (a) preparing a solution,
A. the mud core (1), the outer mold (2), the cavity gaps (3) and the pouring channel (4) are designed according to the shape and the size of a cabin, then a vertical support cavity (5) and a plurality of cross-brace cavities (6) surrounding the vertical support cavity (5) are additionally arranged in the mud core (1), two ends of each cross-brace cavity (6) are respectively communicated with the vertical support cavity (5) and the cavity gap (3), and blocking chills (7) are additionally arranged on the periphery of the positions, connected with the cavity gaps (3), of the cross-brace cavities (6);
B. manufacturing sand moulds, namely manufacturing a mud core (1) and an outer mould (2) respectively, and filling molding sand into positions outside a cavity gap (3), a pouring gate (4), a vertical support cavity (5) and a transverse support cavity (6);
C. closing the die and casting, wherein molten metal enters a cavity gap (3), a vertical support cavity (5) and a transverse support cavity (6), and is cooled to form a casting, and a vertical support rod (8) and a transverse support rod (9) which are integrated with the casting;
step A, structural design, wherein multiple layers of cross brace cavities (6) are arranged along the height direction of the mud core (1), and each layer is provided with a plurality of cross brace cavities (6); a blocking chill (7) is arranged between two adjacent cross brace cavities (6) on each layer; two ends of the blocking chiller (7) are respectively communicated with two adjacent cross-brace cavities (6) in the same layer, and the outer side surface of the blocking chiller (7) is communicated with the cavity gap (3); the blocking chiller (7) is consistent with the circumferential shape of the inner wall of the cabin body.
2. The method for casting the large aluminum-magnesium alloy thin-wall cabin with reduced deformation according to claim 1, wherein the method comprises the following steps: four transverse supporting cavities (6) are uniformly distributed in the circumferential direction.
3. The method for casting the large aluminum-magnesium alloy thin-wall cabin with reduced deformation according to claim 1, wherein the method comprises the following steps: the top surface and the bottom surface of the mud core (1) are respectively provided with a layer of cross brace cavity (6).
4. The method for casting the large aluminum-magnesium alloy thin-wall cabin with reduced deformation according to claim 1, wherein the method comprises the following steps: the mud core (1) is of a multilayer laminated structure, and 1-2 layers of cross-brace cavities (6) are arranged on each layer of mud core (1).
5. The method for casting the large aluminum-magnesium alloy thin-wall cabin with reduced deformation according to claim 1, wherein the method comprises the following steps: and B, manufacturing a sand mold, namely manufacturing the mud core (1) by adopting sand mold 3D printing or sand casting.
6. The method for casting the large aluminum-magnesium alloy thin-wall cabin with reduced deformation according to claim 5, wherein the method comprises the following steps: the sand pounding modeling specifically comprises the following steps: placing a core box on a flat plate, placing a mold of a cross brace cavity (6) and a vertical brace cavity (5), blocking a chill (7), pounding sand, placing a mold of a second layer of cross brace cavity (6) and blocking the chill (7), making a core head positioning groove after pounding sand is finished, and taking out the mold of the cross brace cavity (6) and the vertical brace cavity (5) and blocking the chill (7) when molding is finished; after all the mud cores (1) are manufactured according to the same method, the mud cores (1) are positioned through the core head positioning grooves.
7. The casting structure of the deformation-reducing casting method for the large aluminum-magnesium alloy thin-wall cabin according to any one of claims 1 to 6, wherein: including mud core (1), external mold (2), mud core (1) is located external mold (2), forms die cavity gap (3) between mud core (1) and external mold (2), is equipped with on external mold (2) and waters (4), waters (4) and die cavity gap (3) intercommunication, is equipped with stull die cavity (5), stull die cavity (6) on mud core (1), stull die cavity (6) are equipped with a plurality ofly around stull die cavity (5), and the both ends of stull die cavity (6) communicate stull die cavity (5), die cavity gap (3) respectively, and stull die cavity (6) are connected and are equipped with around die cavity gap (3) department and block chill (7).
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| CN102166639A (en) * | 2011-03-26 | 2011-08-31 | 河南理工大学 | Integral precision casting method for large complicated thin-walled aluminum alloy cabin components |
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