CN114101591B - Core assembly molding method of large curved surface shell casting - Google Patents
Core assembly molding method of large curved surface shell casting Download PDFInfo
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- CN114101591B CN114101591B CN202111254070.6A CN202111254070A CN114101591B CN 114101591 B CN114101591 B CN 114101591B CN 202111254070 A CN202111254070 A CN 202111254070A CN 114101591 B CN114101591 B CN 114101591B
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- 238000005266 casting Methods 0.000 title claims abstract description 71
- 238000000465 moulding Methods 0.000 title claims abstract description 43
- 238000000034 method Methods 0.000 title claims abstract description 20
- 230000002093 peripheral effect Effects 0.000 claims abstract description 60
- 239000004576 sand Substances 0.000 claims abstract description 30
- 238000007493 shaping process Methods 0.000 claims description 12
- 238000005498 polishing Methods 0.000 claims description 7
- 239000011347 resin Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 5
- 238000007790 scraping Methods 0.000 claims description 4
- 230000007704 transition Effects 0.000 claims description 4
- 238000003825 pressing Methods 0.000 claims description 3
- 230000001502 supplementing effect Effects 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 14
- 238000010586 diagram Methods 0.000 abstract description 5
- 238000011161 development Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 2
- 238000007667 floating Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000002159 abnormal effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000008676 import Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 238000005272 metallurgy Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
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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
-
- 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
- B22C9/108—Installation of cores
Abstract
The application discloses a core assembly molding method of a large curved surface shell casting in the technical field of casting, which comprises the steps of sand core positioning cavity design, inner cavity sand core design, peripheral sand core design, sand core pre-assembly, sand core formal assembly and the like, wherein a large-size moulding bed, an inner cavity sand core and the peripheral sand core are all divided into small block structures for assembly, so that the size and the quality of a mould and a sand mould are smaller, the manufacturing cost and the operation difficulty of a core box are greatly reduced, the operation safety is improved, and the damaged sand core is also convenient to be independently manufactured again; when the sand core is assembled, the sand core positioning cavity is utilized, the sand core of the inner cavity can be quickly and accurately put into the cavity, the axial dimension of the curved surface shell casting of the shaft and the bearing which is required to be put into the inner cavity is guaranteed not to deviate and cannot be processed to be scrapped, meanwhile, the peripheral sand core is pre-assembled and put into the core according to the model diagram, and is formally assembled after being marked, so that the assembly efficiency and accuracy are improved, and the sand mold quality is guaranteed.
Description
Technical Field
The application relates to the technical field of casting, in particular to a core assembly molding method of a large curved surface shell casting.
Background
The curved surface shell is high-efficiency energy-saving equipment for conveying and raising gas pressure, belonging to the field of technologically-intensive turbine machinery. With the rapid development of various industries and the enlargement of process equipment, the mechanical equipment has larger and larger demand, and is widely applied to industries such as power plants, pharmacy, metallurgy, cracking, blast furnace gas and the like. Before the century, no mature pressure energy-saving equipment for conveying and improving gas exists in China, and the equipment mainly depends on imported Mitsubishi, mitsui, su Er shou, DEMAG and other companies, is high in price, has long spare part purchase and accident handling period, and severely restricts the progress of economy and production. Through continuous efforts and innovations of domestic universities and colleges, the curved-surface shell energy-saving equipment is successfully developed. The application rate of the machine type reaches or exceeds the annual demand of 500, import saves foreign exchange by more than 30 hundred million dollars, and a large number of devices are exported to most countries and regions of Asia, africa, south America and Europe. Therefore, the method has great significance for successful development of the curved shell casting.
The casting technology of curved surface shell castings is high in production difficulty, the castings consist of an upper half shell and a lower half shell, the materials are HT250, the upper and lower shells are cast in a split mode, the maximum single piece weight is 40 tons, and the maximum casting outline size is 6900 multiplied by 3780 multiplied by 2100. Many enterprises cannot adopt conventional template technology for manufacturing due to limited production equipment, technological equipment and technology, and development and production cannot be completed due to potential safety hazards caused in the hoisting process due to overlarge sand molds.
Disclosure of Invention
In order to overcome the defects of large production difficulty, high cost, potential safety hazard and the like of the existing large curved surface shell castings, the application aims to solve the technical problems that: the core assembly molding method of the large curved surface shell casting is easy to realize.
The technical scheme adopted for solving the technical problems is as follows:
a core assembly molding method of a large curved surface shell casting comprises the following steps:
a. sand core positioning cavity design: designing a moulding bed according to the projection profile of the cavity in the casting on a horizontal plane, placing the moulding bed on a horizontal sand mould for sand scraping molding, and taking out the moulding bed after the molding is solidified to form a sand core positioning cavity;
b. designing an inner cavity sand core: designing an inner cavity sand mold according to the overall outline of the inner cavity of the casting, wherein the inner cavity sand core is formed by splicing a plurality of inner cavity sand core blocks;
c. peripheral sand core design: designing a peripheral sand core according to the outer contour of the casting, wherein the peripheral sand core is formed by splicing a plurality of peripheral sand core blocks;
d. pre-assembling a sand core: firstly, drawing a positioning line on the periphery of a sand core positioning cavity serving as a reference, then placing all peripheral sand core blocks according to the positioning line, drawing alignment marks between adjacent peripheral sand core blocks, carrying out smooth polishing transition at a splicing part after the peripheral sand core blocks are spliced, and finally taking down all the peripheral sand core blocks;
e. formally assembling the sand core: firstly, placing inner cavity sand core blocks in a sand core positioning cavity, carrying out sand supplementing and polishing on a spliced part, then placing peripheral sand core blocks according to positioning lines and alignment marks on all peripheral sand core blocks, and finally, sleeving and fixing the assembled sand cores by using a ring box.
Further, the moulding bed is formed by splicing a plurality of shaping plates, and the shaping plates comprise a basic shaping plate and a plurality of replaceable shaping plates with different lengths.
Further, the height of the template is 100-150mm, and the draft angle is 8-15mm.
Further, the inner cavity sand core blocks comprise basic models and a plurality of replaceable models with different lengths, each inner cavity sand core block is divided according to the boundary line of each end face or processing face of the casting, and the mass of each inner cavity sand core block is not more than 10 tons.
Further, the peripheral sand core is divided into an upper layer and a lower layer by taking a waist line in the middle of the casting as a boundary, each layer of sand core is formed by splicing a plurality of peripheral sand core blocks, each peripheral sand core block is divided according to the boundary by taking each end face or processing face of the casting, and the mass of each peripheral sand core block is not more than 10 tons.
When the positioning line is drawn, firstly, an axial central line is drawn on the sand core positioning cavity, then, according to the length of the casting, two datum lines which are coincident with two end faces of the casting and perpendicular to the central line are drawn, finally, the central line is offset towards two sides of the casting, and two side lines are drawn, wherein the positions of the two side lines exceed the edge of the peripheral sand core which is placed later by at least 50mm.
Further, when the inner cavity sand core block and the peripheral sand core block are assembled, the positions of the sand cores are finely adjusted by measuring the distances from the edges of the sand cores to two side lines.
Further, after the sand core is sleeved with the ring box, resin sand is filled in a gap between the ring box and the sand core, and the sand core is pressed by a weight which is 3-5 times of the casting weight.
The beneficial effects of the application are as follows:
1. the sand core is divided into a plurality of sand core blocks, the volume and the mass of the sand core block are smaller, the manufacturing cost and the operation difficulty of the core box are greatly reduced, the number and the weight of core bars placed in the sand core are also smaller and lighter, the operation safety is improved, and in addition, even if a certain sand core is damaged, the damaged sand core can be independently manufactured again;
2. the core head part of the inner cavity sand core is integrally designed into a core head moulding bed, and the moulding bed is used for manufacturing a sand core positioning cavity, so that the inner cavity sand core is conveniently, quickly and accurately put into the cavity, and the axial dimension of a curved surface shell casting of which the inner cavity needs to be put into a shaft and a bearing is ensured not to deviate and cannot be processed to be scrapped;
3. after the peripheral sand core is put down according to the positioning line, the wall thickness of the casting can be conveniently detected, if the dimension is problematic, the problematic sand core can be timely adjusted to meet the drawing dimension requirement, secondly, after the peripheral sand core is put down, the degree of cleanliness of the cavity can be checked by naked eyes or an endoscope, and blowing and sucking treatment can be performed on abnormal points by using compressed air, so that casting defects are avoided.
Drawings
FIG. 1 is a diagram of a molding cavity in an embodiment of the application;
FIG. 2 is a drawing of a division of an inner cavity sand core in an embodiment of the present application;
FIG. 3 is a two-layer peripheral sand core diagram in an embodiment of the present application;
FIG. 4 is a profile diagram in an embodiment of the application;
the figure is marked as a 1-sand core positioning cavity, a 2-sand mold, a 3-axial center line, a 4-datum line, a 5-outlet end standard line and a 6-lower core edge line.
Detailed Description
The application will be further described with reference to the drawings and examples.
The application provides a core assembly modeling method of a large curved surface shell casting, which comprises the following steps:
a. sand core positioning cavity design: designing a moulding bed according to the projection profile of the cavity in the casting on a horizontal plane, placing the moulding bed on a horizontal sand mould for sand scraping molding, and taking out the moulding bed after the molding is solidified to form a sand core positioning cavity;
b. designing an inner cavity sand core: designing an inner cavity sand mold according to the overall outline of the inner cavity of the casting, wherein the inner cavity sand core is formed by splicing a plurality of inner cavity sand core blocks;
c. peripheral sand core design: designing a peripheral sand core according to the outer contour of the casting, wherein the peripheral sand core is formed by splicing a plurality of peripheral sand core blocks;
d. pre-assembling a sand core: firstly, drawing a positioning line on the periphery of a sand core positioning cavity serving as a reference, then placing all peripheral sand core blocks according to the positioning line, drawing alignment marks between adjacent peripheral sand core blocks, carrying out smooth polishing transition at a splicing part after the peripheral sand core blocks are spliced, and finally taking down all the peripheral sand core blocks;
e. formally assembling the sand core: firstly, placing inner cavity sand core blocks in a sand core positioning cavity, carrying out sand supplementing and polishing on a spliced part, then placing peripheral sand core blocks according to positioning lines and alignment marks on all peripheral sand core blocks, and finally, sleeving and fixing the assembled sand cores by using a ring box.
Compared with the existing integral sand mold structure, the application obtains the casting sand mold by dividing the sand mold into a plurality of structural forms of sand cores and combining the sand mold in the specific mode. The mode can greatly reduce the production difficulty of large castings, improve the safety and ensure the quality of castings.
Specifically, when designing the moulding bed, because the casting size is bigger, and the casting of many different models only has the difference in the size of certain length or width, the shape of key position is the uniformity mostly, therefore, the application designs the moulding bed into the structure form that a plurality of shaping plates are spliced, and the shaping plates comprise basic shaping plates and a plurality of replaceable shaping plates with different lengths. The basic template is used for the same position of each model, and the interchangeable template is rationally selected and combined according to the size of different models. Thus, the cost of the die can be greatly reduced, and the applicability of the tire die can be improved.
In order to stably position the core head of the inner cavity sand core block, the height of the template is preferably 100-150mm, and meanwhile, in order to smoothly demould, the draft angle is designed to be 8-15mm of a negative draft.
The inner cavity sand core and the peripheral sand core are in a spliced structure mode with a plurality of sand core structures, so that the inner cavity sand core blocks are designed into basic types and replaceable types with different lengths according to the size differences among castings of various types, and when the inner cavity sand core blocks are specifically divided, the inner cavity sand core blocks are divided according to the requirements of convenience in manufacturing, follow-up processing and the like by taking the end surfaces or the processing surfaces of the castings as boundary lines, the quality of each inner cavity sand core block is not more than 10 tons, the distribution and the assembly are convenient, and the safety is improved.
Similarly, because the height of the casting is generally higher, if the sand core is designed to be too large, the deformation of the core box is easy to cause, the used core bars are more, and potential safety hazards exist, so the preferable scheme is that the peripheral sand core is divided into an upper layer and a lower layer by taking the waist line in the middle of the casting as a boundary, each layer of sand core is formed by splicing a plurality of peripheral sand core blocks, each peripheral sand core block is divided by taking each end face or processing face of the casting as a boundary, and the quality of each peripheral sand core block is not more than 10 tons.
The specific practice when drawing the locating line in the stage of sand core pre-assembly is that firstly, an axial central line is drawn on a sand core locating cavity, then, according to the length of a casting, two datum lines which are coincident with two end faces of the casting and are perpendicular to the central line are drawn, finally, the central line is offset towards two sides of the casting, and two side lines are drawn, wherein the positions of the two side lines exceed the edge of a peripheral sand core which is placed later by at least 50mm. The purpose of drawing the locating line is to facilitate the subsequent positioning during core setting, and improve the assembly efficiency and precision. Particularly, when the inner cavity sand core block and the peripheral sand core block are assembled, the positions of the sand cores are finely adjusted by measuring the distances from the edges of the sand cores to the two side lines, so that the sand cores are free from axial deviation, and the axial concentricity is ensured.
Finally, after the sand core is sleeved by the ring box, a gap is formed between the ring box and the sand core, and is usually larger than 300mm, and resin sand is preferably filled in the gap between the ring box and the sand core for curing to avoid casting deformation caused by sand mold expansion after casting, and a weight 3-5 times of casting weight is used for pressing the sand core to avoid floating of the sand core.
The application is further illustrated by the following specific examples.
Embodiment one:
according to the core assembly molding method, a certain type of compressor shell is cast.
Step one: the sand core positioning cavity is designed, a proper moulding bed plate is selected for assembly according to the size of the sand core positioning cavity, the moulding bed is firstly placed on a sand mould 2 which is prepared in advance and measured by an infrared level meter during operation, then the moulding bed is scraped out along with the shape of the moulding bed by using a sand scraping modeling mode, and finally the moulding bed is taken out after the modeling is solidified, so that a sand core positioning cavity 1 is formed, as shown in figure 1;
step two: the design of the inner cavity sand core is as shown in fig. 2, the inner cavity sand core is divided into 9 blocks according to the basis and the processing surface of the inner cavity of the casting, wherein 1#, 2#, 6#, 7#, 8# and 9# sand cores are taken as basic types, and the 3# sand core, the 4# sand core and the 5# sand core in the middle are replaceable types selected according to the size of the casting;
step three: and the peripheral sand cores are designed and numbered according to the core setting sequence of the sand cores, as shown in fig. 3, wherein the placement positions of the peripheral sand cores are shown in the drawing. Considering that the height of the casting is too high, the casting is divided from the waist part of the casting, and the peripheral sand core consists of two layers. The first layer of sand cores takes the end face of the air inlet flow director as a reference plane and extends to the end face of the small end diffuser as a reference sand core, 1 sand core, namely 12# sand core and 15# sand core, is respectively arranged at the left end and the right end, and 2 sand cores, namely 10# sand core, 11# sand core, 13# sand core and 14# sand core are respectively arranged at the two ends to form the first layer of outer shape. The division of the second layer sand core is based on the center of the large and small tuyere circular flange, the middle section is formed by 1 large sand core, namely 18# sand core, the accuracy of the casting size is ensured, the sand cores at the two ends are the same as the division mode of the first layer, and the sand cores are respectively surrounded by 4 sand cores, namely 16# sand cores, 17# sand cores, 19# sand cores and 20# sand cores. The sand core box is relatively large, is made of miscellaneous wood materials, is reinforced on the surface of the core box by using channel steel, is positioned or fixed at multiple points by using screws, is arranged at intervals of 800-1000mm, and is distributed in the length and height directions of the core box. The inner cavity core with higher requirement on part of precision is fixed by adopting a mode of configuring a bottom plate and assembling a positioning pin. The core box is manufactured according to the longest model, the middle section is adjusted according to different product models, the stop blocks are manufactured at four corners during manufacturing the core box, the perpendicularity of the core box frame is ensured, and the error is controlled within 2 per mill;
step four: the sand core is preassembled, as shown in fig. 4, an axial center line 3 is drawn on a tire membrane, a non-processing surface at the air inlet end is used as a reference surface and a reference line 4 perpendicular to the center line is made, the length of a shell is determined, the distance from the reference line 4 to the outlet end is offset by the length of the shell, an outlet end reference line 5 perpendicular to the center line is drawn, and finally, the distance from the reference line perpendicular to the axial center line 3 is respectively offset by 2m, and a side line 6 is drawn; the sand core assembly is performed in advance before the lower peripheral core, and the sand cores are assembled based on the datum line, as shown in fig. 4, according to the sizes of distance side lines S1 and S2, the sand cores on the two sides of the 12# sand core and the 15# sand core are symmetrically arranged on two sides, the sand cores on the 12# sand core and the 15# sand core which are arranged adjacently are arranged on the two sides of the inlet and the outlet, and the sand cores on the 10# sand core, the 11# sand core, the 13# sand core and the 14# sand core are arranged on the two ends of the inlet and the outlet, so that the pre-assembly of the sand cores on the first layer is completed. After a sand core is put in, an L-shaped alignment mark at any 2-3 surface mark is selected, so that the accuracy of final formal core setting is ensured. When the second layer sand core is arranged, the sand cores of the air inlet 12# and 15# are used as the reference to shift 350mm towards the air outlet according to the drawing requirement, as shown in figure 3, 18# sand cores are arranged on the two cores in a vertical mode, the outer edges of the sand cores close to the outer edges of the 9# sand cores and the 10# sand cores are respectively aligned, and when the 16# sand cores, the 17# sand cores, the 19# sand cores and the 20# sand cores are arranged in a vertical mode, the second layer sand core can be assembled by being attached to the 18# sand cores only by distinguishing the sand cores from the outlet sand cores, and any 2-3 surface marking L line is selected to ensure the accuracy of the final formal sand core. After the two layers of sand cores are pre-assembled, an operator carries out manual smooth polishing transition along with the sand cores, so that dislocation or poor contact is not generated after casting pouring;
step five: and finally, formally assembling sand cores, namely respectively putting into a 1# sand core and a 7# sand core in a sand core positioning cavity according to the diagram 2, measuring the distance between the two sand cores to meet the requirement of the drawing, and sequentially putting into a 2# sand core, a 3# sand core, a 6# sand core, a 5# sand core and a 4# sand core with inner cavities, wherein the dimension distance from the edge of each sand core to the side line can be respectively measured after each sand core is put into, and the requirement of the dimension to be equal is left and right. And checking gaps among each sand core, and filling resin sand for sand filling and coating operation if gaps exist. When the 8# and 9# cores are put down, only the core is put down at the position of the core head of the tire mold at the inlet end and the outlet end, and the space between the two cores is measured by using a tape measure to meet the drawing requirement. And (3) core setting is carried out according to the L line marked before the top peripheral core is formally set. And finally, sleeving all the assembled sand cores by using the ring box, filling resin sand into a gap between the ring box and the sand cores, and pressing a weight which is 3-5 times of the casting weight on the sand cores to avoid floating of the sand cores.
By adopting the core assembly molding method, the manufacturing difficulty of the large casting sand mold can be greatly reduced, the production efficiency and quality are improved, and the core assembly molding method is safe and reliable and has good practicability and application prospect.
Claims (4)
1. The core assembly molding method of the large curved surface shell casting is characterized by comprising the following steps of:
a. sand core positioning cavity design: designing a moulding bed according to the projection profile of the cavity in the casting on a horizontal plane, placing the moulding bed on a horizontal sand mould for sand scraping molding, and taking out the moulding bed after the molding is solidified to form a sand core positioning cavity;
b. designing an inner cavity sand core: designing an inner cavity sand mold according to the overall outline of the inner cavity of the casting, wherein the inner cavity sand core is formed by splicing a plurality of inner cavity sand core blocks;
c. peripheral sand core design: designing a peripheral sand core according to the outer contour of the casting, wherein the peripheral sand core is formed by splicing a plurality of peripheral sand core blocks;
d. pre-assembling a sand core: firstly, drawing a positioning line on the periphery of a sand core positioning cavity serving as a reference, then placing all peripheral sand core blocks according to the positioning line, drawing alignment marks between adjacent peripheral sand core blocks, carrying out smooth polishing transition at a splicing part after the peripheral sand core blocks are spliced, and finally taking down all the peripheral sand core blocks;
e. formally assembling the sand core: firstly, placing inner cavity sand core blocks in a sand core positioning cavity, carrying out sand supplementing and polishing on a spliced part, then placing peripheral sand core blocks according to positioning lines and alignment marks on all peripheral sand core blocks, and finally, sleeving and fixing the assembled sand cores by using a ring box;
the tire mold is formed by splicing a plurality of shaping plates, and the shaping plates comprise a basic shaping plate and a plurality of replaceable shaping plates with different lengths; the inner cavity sand core blocks comprise basic models and a plurality of replaceable models with different lengths, each inner cavity sand core block is divided according to the boundary line of each end face or processing face of the casting, and the mass of each inner cavity sand core block is not more than 10 tons; the peripheral sand cores are divided into an upper layer and a lower layer by taking a waist line in the middle of the casting as a boundary, each layer of sand core is formed by splicing a plurality of peripheral sand core blocks, each peripheral sand core block is divided according to the boundary line by taking each end face or processing face of the casting, and the mass of each peripheral sand core block is not more than 10 tons; when the positioning lines are drawn, an axial central line is drawn on the sand core positioning cavity, then two datum lines which are coincident with two end faces of the casting and perpendicular to the central line are drawn according to the length of the casting, finally the central line is offset towards two sides of the casting, two side lines are drawn, and the positions of the two side lines exceed the edge of the peripheral sand core which is placed later by at least 50mm.
2. The core assembly molding method of the large curved surface shell casting according to claim 1, wherein the core assembly molding method comprises the following steps: the height of the template is 100-150mm, and the draft angle is 8-15mm.
3. The core assembly molding method of the large curved surface shell casting according to claim 1, wherein the core assembly molding method comprises the following steps: when the inner cavity sand core block and the peripheral sand core block are assembled, the positions of the sand cores are finely adjusted by measuring the distances from the edges of the sand cores to two side lines.
4. The core assembly molding method of the large curved surface shell casting according to claim 1, wherein the core assembly molding method comprises the following steps: after the sand core is sleeved by the ring box, filling resin sand into a gap between the ring box and the sand core, and pressing the gap on the sand core by using a weight which is 3-5 times of the casting weight.
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| CN114799049B (en) * | 2022-03-30 | 2024-02-09 | 西安航天发动机有限公司 | Processing die and method for sand core for variable-section blade casting of aerospace liquid engine |
| CN115069984B (en) * | 2022-06-27 | 2023-06-30 | 共享装备股份有限公司 | Flexible guiding device for sand mould core setting and sand mould |
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