CN114226645A - Casting method of thin-wall rolling mill frame - Google Patents
Casting method of thin-wall rolling mill frame Download PDFInfo
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- CN114226645A CN114226645A CN202111276775.8A CN202111276775A CN114226645A CN 114226645 A CN114226645 A CN 114226645A CN 202111276775 A CN202111276775 A CN 202111276775A CN 114226645 A CN114226645 A CN 114226645A
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- 238000005266 casting Methods 0.000 title claims abstract description 54
- 238000000034 method Methods 0.000 title claims abstract description 28
- 238000005096 rolling process Methods 0.000 title claims abstract description 16
- 239000004576 sand Substances 0.000 claims abstract description 51
- 239000002023 wood Substances 0.000 claims abstract description 48
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 35
- 238000004519 manufacturing process Methods 0.000 claims abstract description 21
- 229910052742 iron Inorganic materials 0.000 claims abstract description 17
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 13
- 239000010959 steel Substances 0.000 claims abstract description 13
- 239000007787 solid Substances 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 59
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 4
- 235000000396 iron Nutrition 0.000 claims description 4
- 239000000377 silicon dioxide Substances 0.000 claims description 4
- 244000025254 Cannabis sativa Species 0.000 claims description 3
- 239000000919 ceramic Substances 0.000 claims description 3
- 125000004185 ester group Chemical group 0.000 claims description 3
- 239000006260 foam Substances 0.000 claims description 3
- 239000003110 molding sand Substances 0.000 claims description 3
- 238000007670 refining Methods 0.000 claims description 3
- 238000009489 vacuum treatment Methods 0.000 claims description 3
- 238000000465 moulding Methods 0.000 abstract description 2
- 230000001914 calming effect Effects 0.000 abstract 1
- 230000007547 defect Effects 0.000 description 7
- 150000002148 esters Chemical class 0.000 description 4
- 229910052804 chromium Inorganic materials 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 238000001514 detection method Methods 0.000 description 3
- 230000002035 prolonged effect Effects 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 238000003754 machining Methods 0.000 description 2
- 239000006247 magnetic powder Substances 0.000 description 2
- 238000004088 simulation Methods 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 244000035744 Hura crepitans Species 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000003034 coal gas Substances 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000003031 feeding effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000010200 validation analysis Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
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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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
-
- 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
-
- 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
Abstract
A casting method of a thin-wall rolling mill frame is divided into four parts to manufacture a wood type structure; the whole outer skin of the wood type solid sample adopts a live skin structure and is connected in a matched manner by adopting a dovetail groove structure; when the bottom plane of the frame is manufactured, a latticed iron framework is manufactured and placed in a bottom plane sand mold; arranging a stop iron outside the wood type real sample of the rack, and manufacturing a wood strip between the outer wall of the wood type real sample and the stop iron; a side water gap open type pouring system is adopted; before pouring, the calming time of molten steel is ensured; and (5) low-temperature quick casting. The casting method of the thin-wall rolling mill frame solves the problems that the length of the frame is too long and a model is deformed in a lifting process; the precision and quality requirements of the rack wood pattern are ensured; the deformation ruler difference in the frame casting molding process is reduced; the production cost is reduced; the production efficiency is improved; the quality of the casting product is improved.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a casting method of a thin-wall rolling mill frame.
Background
Different types of rolling stands bear higher load during working, so that the requirements on the surface quality and the dimensional precision of castings are strict, the requirements on the internal quality of the castings are strict, and all the processing surfaces of the stands are subjected to ultrasonic flaw detection and magnetic powder inspection. And after the casting is inspected to be qualified, performing rough machining and reserving a certain fine machining allowance. In recent years, the company has gathered a batch of racks with the length of 6040mm, the width of 3500mm and the height of 350mm, and the racks with the longer length and the smaller height cannot meet the requirements of customers according to the conventional casting process method. The time is tight, the task is heavy, the company organization carries out the attack and customs aiming at the existing manufacturing difficulty, the casting process is greatly improved, and the conventional casting process production method of the rack is broken through. The deformation problem of the casting of the large thin-wall rack always troubles the production of the blank casting of the rack.
Disclosure of Invention
The invention aims to provide a casting method of a thin-wall rolling mill frame, which solves the problems of overlong frame length and model deformation in the hoisting process; the precision and quality requirements of the rack wood pattern are ensured; the deformation ruler difference in the frame casting molding process is reduced; the production cost is reduced; the production efficiency is improved; the quality of the casting product is improved.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method of casting a thin wall rolling mill stand, the method comprising:
1) the wood-type structure is manufactured by dividing into four parts: the upper part of the frame, the lower part of the frame and two upright post parts;
2) the whole outer skin of the wood type solid sample adopts a live skin structure, the middle slideway core is directly manufactured by the solid sample, and the upper part of the rack, the lower part of the rack and the two upright post parts are in matched connection by adopting a dovetail groove structure;
3) after the wood type real sample is manufactured in parts, pre-installing a wood type platform, cutting a cross central line on the wood type real sample, and cutting a cross contour line of a middle core on a real sample outer skin;
4) using ester hardening type sand pounding to be more than or equal to 500mm thick bottom plane, using phi 12 mm-phi 16mm iron rods when pounding the bottom plane of the frame of the machine, manufacturing a latticed iron frame with grid density of (200 mm-300 mm) × (200 mm-300 mm), placing the latticed iron frame in a sand mold of the bottom plane, exhausting air at the bottom of the sand mold when pounding the bottom plane, leading out two exhaust pipes which are not less than phi 108mm from the bottom of a mold core, uniformly cutting exhaust holes on the exhaust pipes at intervals of 200 mm-300 mm, and winding grass ropes on the exhaust pipes; the water content of the ester hardened molding sand is required to be less than or equal to 2.0 wt%;
5) assembling the four parts of wood type full samples according to the positions of dovetail grooves, placing the wood type full samples on the leveled bottom plane of the sand mold, arranging a stop iron on the outer side of the rack wood type full sample according to the thickness of the sand-eating quantity of the outer skin, and manufacturing wood strips to be supported between the outer wall of the wood type full sample and the stop iron so as to prevent the position of the full sample from deviating;
6) firstly pounding an intermediate core on the inner side of a rack, wherein the thickness of sand put in each layer is 200-250 mm, tamping the sand to be compact, simultaneously placing a plurality of foam strips with the thickness of 80-100 mm in the sand, and filling dry sand blocks in the center of the intermediate core during pounding;
7) after pounding the middle core, pounding a machine frame outer skin sand mold, and binding a net 20-30 mm away from the upper surface of the wood type solid sample before manufacturing a box; an air exhaust hole is bound in the upper box, the bottom of the air exhaust hole is 5-10 mm away from the upper surface of the wood type real sample, and an open air exhaust channel is arranged at the same time; the mesh density of the net is (200-300 mm) × (200-300 mm);
8) the strip-shaped external iron (700 plus 900mm) × (1100 plus 1200mm) is placed at the lower part of the latticed iron framework on the lower surface of the casting at the bottom of the large riser, so that the shrinkage defect at the lower part of the riser is prevented, the welding repair finishing cost is saved, and the service life of the rack is prolonged;
9) adopting a side gate open type pouring system, wherein a straight pouring gate is phi 150 mm-phi 160mm, a horizontal pouring gate is phi 110 mm-phi 120mm in annular joint, an inner pouring gate is phi 90 mm-phi 100mm, and the pouring system is completely made of ceramic tubes;
10) refining molten steel for casting in an electric furnace and LF, and then performing vacuum treatment to remove most of gas and non-metallic inclusions;
11) the pot opening with the diameter of 90 mm-100 mm is adopted, the casting low temperature is less than or equal to 1550 ℃, the casting time is less than or equal to 7 minutes, after the riser reaches the casting height of 1000 mm-1100 mm, the furnace molten steel is used for replacing a point riser nozzle with a point riser nozzle to evenly perform point riser compensation, and the furnace molten steel is used for point riser compensation for more than 20 minutes.
All the face sand is chromium ore with the thickness of 20-30 mm; the back sand is ester-hardened new silica sand with the thickness of 200-300 mm; the rest is ester hardened reclaimed sand.
Compared with the prior art, the invention has the beneficial effects that:
1) the crack defect of the thick and large frame is reduced; the service life of the frame is prolonged; saving the cost of repair welding and finishing.
2) All the face sands of the invention adopt chromium ores; the back sand adopts ester-hardened new silica sand; and the rest of the sand is ester-hardened reclaimed sand, so that the production cost is reduced.
3) The invention simplifies the manufacturing and hoisting process of the model, shortens the production period and improves the production efficiency.
Drawings
Fig. 1 is a schematic view of the structure of a roll stand.
FIG. 2 is a roll stand casting process diagram.
Fig. 3 is a sectional view of a division portion of fig. 1.
In the figure: 1-upper part of frame, 2-division part, 3-upright part, 4-lower part of frame, 5-riser and 6-exhaust pipe.
Detailed Description
The following examples are intended to illustrate the invention in detail, and are intended to be a general description of the invention, and not to limit the invention.
A casting method of a thin-wall rolling mill frame comprises the following specific steps:
SolidWorks software is used for converting the ordering mechanical part drawing of the rack into a three-dimensional drawing, so that the research problem is more visualized;
because this frame length overlength (6060mm), thickness is lower (360mm) moreover, according to traditional casting process: the wood mold is manufactured by the scheme of the full sample and the core assembly, the wood mold can be seriously deformed and cannot be lifted, and the precision requirement of a casting cannot be guaranteed, so that the casting process scheme is redesigned: SolidWorks software is used for converting the ordering mechanical part drawing of the rack into a three-dimensional drawing, so that the research problem is more visualized; a rack casting process is newly established according to a rack structure, a strip-shaped external chill is placed at the lower part of a riser according to different wall thicknesses, a rack feeding area is divided into three hot spot to-be-fed areas, two heat-insulating risers are arranged on thick wall parts of the heads on two sides, and two risers are arranged in the middle part; final simulation validation was performed using MAGMA software, confirming that there were no internal casting defects after simulation, and production was resumed.
1) The wood-type structure is manufactured by dividing into four parts: the upper part of the frame, the lower part of the frame and two upright post parts.
2) The whole outer skin of the wood type full sample adopts a live skin structure, all parts inside and outside the full sample including the core print are live skins, and the thinnest part of the live skin is 60mm and 40 degrees; the upper part of the machine frame, the lower part of the machine frame and the two upright post parts are connected in a dovetail groove structure.
Four parts all set up overhead hoist, make things convenient for the handling transportation, can solve frame length overlength, the problem of handling in-process wood type deformation. The hoisting device at the real sample part needs to be stressed uniformly and has enough strength, so that the model is not deformed after hoisting.
3) After the wood type real sample is manufactured in parts, a cross central line is carved on the wood type real sample on the preassembly of the wood type platform, and a cross contour line of the middle core is carved on the real sample outer skin.
4) According to the size of a casting wood model, pounding a thick bottom plane with the thickness of more than or equal to 500mm by using ester hardening sand, wherein the water content of the ester hardening sand is required to be less than or equal to 2.0 wt%, and the pounding machine is operable, in order to improve the strength of a sand mold when pounding the bottom plane of the machine frame, a phi 12mm iron rod is used according to the shape of the machine frame to manufacture a latticed iron framework with the grid density of 200mm x 200mm and is placed in a bottom plane sand mold, so that the strength of the bottom plane sand mold is increased, when pounding the bottom plane, the sand mold bottom is exhausted, two exhaust pipes with the thickness of not less than phi 108mm are uniformly and symmetrically led out from the bottom of a mold core, the exhaust pipes are uniformly cut at intervals of 200mm, and grass ropes are wound on the exhaust pipes; pounding, scraping with wooden plate, and correcting the levelness of the bottom plane with far infrared horizontal measuring instrument.
5) Assembling the four parts of wood type full samples according to the positions of dovetail grooves, placing the wood type full samples on the bottom plane of the leveled sand mold, arranging stop irons at the outer sides of the wood type full samples of the rack according to the thickness (500-600 mm) of the sand-eating amount of the outer skin, replacing special sand boxes to prevent the wood mold from expanding outwards when an inner side slide way core is pounded, and manufacturing wood strips between the outer wall of the wood type full sample and the stop irons; meanwhile, the size of the frame is ensured according to the method of aligning the center line of the wood pattern with the center line of the sand mold bottom plane.
6) The middle core of the rack is pounded firstly, the thickness of each layer of sand is 200-250 mm, the sand is tamped tightly, the foam strips with the thickness of 80-100 mm are placed simultaneously, and the central part of the middle core is filled with sand blocks when pounding, so that the collapsibility of the slide core is improved, and the rack is prevented from generating crack defects due to over-hard shrinkage of sand core strength.
7) After pounding the inner side slide way core, pounding a rack outer skin sand mold, and binding a net 20-30 mm away from the upper surface of the wood type solid sample; and the sand falling is prevented. The grid density is (200-300 mm) × (200-300 mm).
8) The upper box is tied with an exhaust hole, the bottom of the exhaust hole is 5 mm-10 mm away from the upper surface of the wood type real sample, and an open exhaust channel is arranged at the same time.
9) A strip-shaped external chill (700-900mm) is placed at the lower part of the net on the lower surface of the casting at the bottom of the large riser, so that the shrinkage defect of the lower part of the riser is prevented, the welding repair finishing cost is saved, and the service life of the rack is prolonged;
10) a side gate open type pouring system is adopted, a straight pouring gate is 150 mm-160 mm in diameter, a horizontal pouring gate is 110 mm-120 mm in diameter in annular joint, an inner pouring gate is 90 mm-100 mm in diameter, and the pouring system is completely made of ceramic tubes.
11) After the box is closed, a cavity detector is used for detecting whether sundries exist in the sand mold cavity;
12) the purity of the molten steel is ensured, and besides normal electric furnace and LF refining, the molten steel smelting process is added with vacuum treatment, so that gas and impurities in the molten steel are reduced to the maximum extent, and the quality of the molten steel is improved;
13) because the height of the frame is only 360mm, in order to ensure the pouring speed of the frame, a tank opening with the diameter of 90-100 mm is adopted, low-temperature fast pouring is carried out, the pouring temperature is less than or equal to 1550 ℃, the pouring time is less than or equal to 7 minutes, after the pouring riser reaches the pouring height of 1000-1100 mm, the furnace molten steel is used for changing the point feeder from the point feeder nozzle to evenly point feeder, the point feeder of the furnace molten steel is added for more than 20 minutes, a heat preservation agent is added to preserve the temperature of the feeder, and the feeder feeding effect is improved.
13) After the casting is boxed, the quality control is carried out on the aspects of loading the rack into a kiln and the like by controlling the heat treatment process; primarily correcting the flatness of the rack by using an infrared level gauge; ultrasonic UT flaw detection is adopted, and the internal superscript defects such as cracks are guaranteed to be free.
14) Ultrasonic UT and magnetic powder flaw detection are adopted, and the internal and external standard exceeding defects such as cracks are avoided.
15) In order to prevent sand from adhering to the surface of a casting, all surface sand is specified to be chromium ore sand in the casting process, and the thickness of the surface sand is 20-30 mm; the back sand is ester-hardened new silica sand with the thickness of 200-300 mm; the rest is ester hardened reclaimed sand. Spraying alcohol-based paint for 2 times, and drying by using a coal gas fire meter; the external chill needs to be derusted and the position needs to be accurate.
The invention simplifies the casting process of the special type frame casting, solves the problem of deformation of the whole wood mold of the type frame and ensures the casting precision.
Claims (8)
1. A method of casting a thin wall rolling mill stand, the method comprising:
1) the wood-type structure is manufactured by dividing into four parts: the upper part of the frame, the lower part of the frame and two upright post parts;
2) the whole outer skin of the wood type solid sample adopts a live skin structure, the middle slideway core is directly manufactured by the solid sample, and the upper part of the rack, the lower part of the rack and the two upright post parts are in matched connection by adopting a dovetail groove structure;
3) when the bottom plane of the rack is manufactured by pounding, manufacturing a latticed iron framework and placing the latticed iron framework in a bottom plane sand mold;
4) assembling the four parts of wood type full samples according to the positions of dovetail grooves, placing the assembled four parts of wood type full samples on the bottom plane of the leveled sand mold, arranging stop irons at the outer sides of the rack wood type full samples according to the thickness of the sand-eating quantity of the outer skins, and manufacturing wood strips to be supported between the outer walls of the wood type full samples and the stop irons;
5) firstly pounding the middle core at the inner side of the rack, wherein the thickness of each layer of put sand is 200-250 mm, the sand is tamped tightly, a plurality of foam strips with the thickness of 80-100 mm are put in the sand, dry sand blocks are filled in the center of the middle core during pounding, and after the middle core is pounded, pounding the shell sand mold of the rack;
6) placing strip-shaped external iron at the lower part of a latticed iron framework on the lower surface of a casting at the bottom of the large riser;
7) adopting a side gate open type pouring system, wherein a straight pouring gate is phi 150 mm-phi 160mm, a horizontal pouring gate is phi 110 mm-phi 120mm in annular joint, an inner pouring gate is phi 90 mm-phi 100mm, and the pouring system is completely made of ceramic tubes;
8) refining molten steel for casting in an electric furnace and LF, and then carrying out vacuum treatment;
9) the pot opening with the diameter of 90 mm-100 mm is adopted, the casting low temperature is less than or equal to 1550 ℃, the casting time is less than or equal to 7 minutes, after the riser reaches the casting height of 1000 mm-1100 mm, the furnace molten steel is used for replacing a point riser nozzle with a point riser nozzle to evenly perform point riser compensation, and the furnace molten steel is used for point riser compensation for more than 20 minutes.
2. The method of casting a thin wall mill stand according to claim 1, wherein the wood pattern is partially fabricated, and then the wood pattern platform is pre-assembled, the cross center line is cut on the wood pattern, and the contour line of the core is cut on the outer skin of the wood pattern.
3. The method for casting a thin wall rolling mill housing as claimed in claim 1, wherein the ester-hardened molding sand is used in the step 3) to pounder a slab having a thickness of 500mm or more, and the water content of the ester-hardened molding sand is 2.0 wt% or less.
4. The casting method for a thin wall rolling mill stand according to claim 1, wherein the iron rods with a diameter of 12mm to 16mm are used in the step 3) to produce the latticed iron skeleton with a lattice density of (200mm to 300mm) x (200mm to 300 mm).
5. The casting method of the thin-wall rolling mill frame according to the claim 1, characterized in that, when the bottom plane of the frame is pounded in the step 3), the sand mold bottom is used for exhausting, two exhaust pipes with the diameter not less than 108mm are led out from the bottom of the core, the exhaust holes are uniformly cut at the interval of 200 mm-300 mm on the exhaust pipes, and the exhaust pipes are wound with grass ropes.
6. The casting method of a thin-wall rolling mill frame according to claim 1, characterized in that before the upper box is manufactured, a net is tied 20-30 mm away from the upper surface of the wood model real sample, the upper box is tied with an exhaust hole, the bottom of the exhaust hole is 5-10 mm away from the upper surface of the wood model real sample, and an open exhaust channel is arranged.
7. A casting method for a thin wall rolling mill stand according to claim 6, characterized in that the mesh density of the mesh is (200-300 mm) × (200-300 mm).
8. The casting method of a thin-wall rolling mill stand according to claim 1, characterized in that all the facing sand is chrome ore with a thickness of 20-30 mm; the back sand is ester-hardened new silica sand with the thickness of 200-300 mm; the rest is ester hardened reclaimed sand.
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| CN202111276775.8A CN114226645A (en) | 2021-10-29 | 2021-10-29 | Casting method of thin-wall rolling mill frame |
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| CN202111276775.8A CN114226645A (en) | 2021-10-29 | 2021-10-29 | Casting method of thin-wall rolling mill frame |
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