CN114453559B - Time-delay pouring method for large castings - Google Patents

Time-delay pouring method for large castings Download PDF

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Publication number
CN114453559B
CN114453559B CN202210102543.9A CN202210102543A CN114453559B CN 114453559 B CN114453559 B CN 114453559B CN 202210102543 A CN202210102543 A CN 202210102543A CN 114453559 B CN114453559 B CN 114453559B
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pouring
casting
time
delay
molten iron
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CN114453559A (en
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裴志勇
薛吉庆
殷立坤
杨继伟
郑永杰
钱红武
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Dalian Huarui Heavy Industry Casting Co ltd
Dalian Huarui Heavy Industry Group Co Ltd
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Dalian Huarui Heavy Industry Casting Co ltd
Dalian Huarui Heavy Industry Group Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082Sprues, pouring cups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D35/00Equipment for conveying molten metal into beds or moulds
    • B22D35/04Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D37/00Controlling or regulating the pouring of molten metal from a casting melt-holding vessel

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

The invention provides a time-delay pouring method of a large casting, which comprises the steps of determining parameters of an inner pouring gate according to the structure of the casting and the required molten iron amount, obtaining an original pouring system, calculating the vertical height between the inner pouring gate at the lowest point and the inner pouring gate at the highest point, and calculating the time required for filling the casting in the height; if the time exceeds 20s, a time-delay pouring system is established to pour the castings, the inner pouring gates near the inner pouring gate at the highest point are divided into one type, an independent pouring system is established for the inner pouring gates, and the rest inner pouring gates are main body pouring systems; and determining the time T for which the independent pouring system needs to be opened in a delayed manner. The invention solves the problems that the large castings with a large number of inner gates and a height difference are easy to generate defects of cold shut, insufficient casting and the like when the traditional casting system is adopted, and can realize reasonable casting of the castings and stable molten iron filling, thereby avoiding major quality hidden danger and reducing the scrapping risk of large casting products.

Description

Time-delay pouring method for large castings
Technical Field
The invention relates to the technical field of pouring of large castings, in particular to a time-delay pouring method of a large casting.
Background
The large-scale steel casting and the iron casting which are cast by adopting the sand mold are usually provided with a bottom pouring type pouring system, namely, the inner pouring gate is arranged at the bottom of the casting, molten metal is introduced into the cavity from the bottom of the casting through the straight pouring gate, the transverse pouring gate and the inner pouring gate, and the mold filling device has the advantages of uniform and stable mold filling, reduction of molten metal oxidation and splashing, contribution to exhaust and the like. In actual production, the molten iron amount of a large casting is large (often more than 60 t), the structure is complex, and dozens of in-gates are required to be arranged at different positions at the bottom of the casting at the same time so as to meet the pouring requirement. When the profile of the bottom of the casting mold with the inner gate is large and is in a non-horizontal state, the inner gates at different positions have height differences. At this time, in the same pouring system, according to the principle of a communicating vessel, a molten iron rising plane is at the same height, a runner gate positioned at a low position will enter molten iron first, and for the runner gate positioned at a high position, molten iron is stagnated in a runner ceramic tube for a long time until the whole molten iron liquid level rises to the same height, and the molten iron can be introduced into a cavity. In the process, because the size of the ingate is small (the diameter is about 50mm or 60 mm), the temperature of a small amount of molten iron which is stagnant in the ingate at a high position can be reduced very rapidly, and when the liquid level rises to the late stage and the molten iron can be introduced into the cavity, the low-temperature molten iron in a stagnant state flows into the cavity, so that the risk of cold separation of the casting part exists. If the height difference of the inner pouring gate is particularly large and the liquid level rising speed is low, the stagnant molten iron in the inner pouring gate positioned at the high position is in a liquid-solid coexisting state or a solidification state, so that the injection of the molten iron is blocked, and risks such as insufficient pouring and the like are caused.
Therefore, there is a need to develop a time-lapse pouring method for large castings to solve the above-mentioned problems caused by the conventional pouring system in response to the large height difference of the in-gate arrangement.
Disclosure of Invention
According to the technical problems, the delay pouring method for the large castings is provided.
The invention adopts the following technical means:
a time-delay pouring method for a large casting comprises the following steps:
determining the number, the position and the size of the inner pouring gates according to the structure of the casting and the required molten iron amount thereof;
determining the sizes and the numbers of pouring boxes, cross runners and sprue gates used in the pouring process according to the amount of molten iron, the distribution of the internal pouring gates and the technological parameters required by casting pouring, so as to obtain an original pouring system;
calculating the vertical height between the inner gate positioned at the lowest point and the inner gate positioned at the highest point in the plurality of inner gates, calculating the weight of molten iron required by the casting in the height, and obtaining the time for filling the molten iron of the part of casting according to the weight of molten iron;
if the time is not longer than 20s, pouring the casting by adopting an original pouring system;
if the time exceeds 20s, a time-delay pouring system is established to pour the casting, and the time-delay pouring system is established in the following way: dividing the inner gates near the inner gate at the highest point into one type, establishing independent pouring systems for the inner gates, taking the rest of the inner gates as main body pouring systems, reconfirming the sizes and the numbers of pouring boxes, cross runners and straight runners used by the independent pouring systems, reconfirming the sizes and the numbers of the pouring boxes, the cross runners and the straight runners used by the main body pouring systems on the basis of the original pouring systems, and combining the main body pouring systems and the independent pouring systems into a time delay pouring system;
and determining the time T for opening the independent pouring system in a time delay manner, wherein T=T1-T2, T1 is the time required by the main body pouring system to pour into the lowest inner gate of the independent pouring system, and T1 comprises two parts, wherein one part is the time required by the main body pouring system to fill the mold, and the other part is the time required by the molten iron to fill the inner gate of the lowest point of the independent pouring system after entering the casting mold. T2 is only the time required by the self-filling of the independent pouring system; the filling time of T1 and T2 in the formula is obtained according to the weight of molten iron filled in each part.
And (3) carrying out three-dimensional modeling on the delay pouring system, carrying out simulation by using simulation software, verifying the accuracy of the time of filling and opening the delay of the delay pouring system, and the like, and optimizing and correcting deviation. The simulation software is Magma.
Compared with the prior art, the invention has the following advantages:
1. the problems that the large castings with a large number of inner gates and a height difference are easy to generate defects of cold insulation, insufficient casting and the like when a traditional casting system is adopted are solved, reasonable casting of the castings and stable molten iron filling can be realized, thereby avoiding major quality hidden danger and reducing the scrapping risk of large casting products.
2. The method and the theoretical basis for calculating the delay time of the independent pouring system are provided, verification is carried out through simulation software, the rationality and the accuracy of the prenatal preparation technical scheme are greatly improved, the development period of new products is reduced, and the development risk is reduced.
3. The method has the advantages of definite product characteristics, wide application range and strong popularization and application.
Based on the reasons, the invention can be widely popularized in the fields of large casting pouring and the like.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a diagram showing the distribution of the positions of the gates in the original casting system according to the embodiment of the present invention;
FIG. 2 is a schematic diagram of an original casting system in an embodiment of the present invention;
FIG. 3 is a diagram of a header height differential analysis of an original gating system in accordance with an embodiment of the present invention;
FIG. 4 is a distribution diagram of the position of a runner in a time-lapse gating system according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a time delay pouring system in an embodiment of the invention;
FIG. 6 is a schematic diagram of time calculation of a time delay pouring system in an embodiment of the invention;
FIG. 7 is a simulation result of the original gating system filling in the embodiment of the present invention;
FIG. 8 is a simulation result (35 s) of the self-initiated filling of the independent casting system in the embodiment of the invention;
FIG. 9 is a simulation result (40 s) of the filling of a mold by the independent casting system in an embodiment of the present invention.
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of 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, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present invention. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
The relative arrangement of the components and steps, numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless it is specifically stated otherwise. Meanwhile, it should be clear that the dimensions of the respective parts shown in the drawings are not drawn in actual scale for convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail, but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any specific values should be construed as merely illustrative, and not a limitation. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numerals and letters denote like items in the following figures, and thus once an item is defined in one figure, no further discussion thereof is necessary in subsequent figures.
In the description of the present invention, it should be understood that the azimuth or positional relationships indicated by the azimuth terms such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal", and "top, bottom", etc., are generally based on the azimuth or positional relationships shown in the drawings, merely to facilitate description of the present invention and simplify the description, and these azimuth terms do not indicate and imply that the apparatus or elements referred to must have a specific azimuth or be constructed and operated in a specific azimuth, and thus should not be construed as limiting the scope of protection of the present invention: the orientation word "inner and outer" refers to inner and outer relative to the contour of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "upper surface at … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial location relative to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "above" or "over" other devices or structures would then be oriented "below" or "beneath" the other devices or structures. Thus, the exemplary term "above … …" may include both orientations of "above … …" and "below … …". The device may also be positioned in other different ways (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
In addition, the terms "first", "second", etc. are used to define the components, and are only for convenience of distinguishing the corresponding components, and the terms have no special meaning unless otherwise stated, and therefore should not be construed as limiting the scope of the present invention.
As shown in fig. 1 to 9, a method for time-lapse pouring of a large casting comprises:
1. in-gate parameter confirmation: the estimated molten iron amount of the casting is 84-88 tons, the diameter size of phi 60 is selected as the inner gate, the initial number is set to be 44, and the positions are uniformly distributed at the bottom of the casting, as shown in figure 1.
2. And (3) estimating parameters of other components of the pouring system: preliminary estimating parameters of each component of an original pouring system, wherein 2 pouring boxes are planned to be selected according to the quantity value of molten iron, and 2 pouring boxes are planned to be selected, namely, 2 pouring boxes of 45 tons; and determining that the size of the sprue is phi 120, and the size of the runner is phi 110 and phi 70 according to the distribution of the inner gate and the parameters required by the open pouring system. The sum proportion of the sectional areas among the components is Σ straight: sigma-transverse: Σ=1:1.18:5.5, as shown in fig. 2.
3. And (3) header height difference analysis: the vertical height between the lowest point and the highest point in the in-gate position was calculated to be about 700mm, and the weight of molten iron occupied by the casting at this height was calculated to be about 20.5 tons (as shown in fig. 3). And (2) under the design of the original casting system preset in the step (2), calculating the partial filling time, wherein the formula is as follows: t ' =t1 ' — T2 '. Wherein T' is the molten iron filling time of the high-low difference casting part; t1' is the time required for filling the molten iron to the highest point of the inner pouring gate; t2' is the time required for the molten iron to fill to the lowest point of the in-gate.
Calculating, when the molten iron is filled to the lowest point of the inner pouring gate, the amount of the co-flowed molten iron is about 6.2 tons, and the filling time T2% = 10s; when the molten iron is filled to the highest point of the inner pouring gate, 26.7 tons of molten iron is co-flowed, and the filling time is T1% =44s; therefore, the molten iron filling time T ' of the high-low difference casting part=T1 ' -T2 ' =34s >20s, a certain risk of cold shut and insufficient casting exists, and the problem needs to be solved by adopting the time-delay casting system.
4. Establishing a time-delay pouring system: according to the analysis result, the delay pouring system is adopted, and the delay pouring system is established in the following way:
(1) The final position of the inner gate is optimized, and the inner gate near the inner gate at the highest point is divided, so that a set of independent pouring systems is established. After calculation and analysis, the casting iron water quantity is corrected to 84 tons, the number of the inner gates is set to 42, and after the distribution mode is locally modified, 13 inner gate locating points (14 inner gates with the highest point are calculated) near the inner gate with the highest point are set as independent pouring systems, as shown in fig. 4.
(2) And according to the 14 divided in-gates, confirming each component parameter of the independent pouring system. Through calculation, 1 pouring gate box of 35 tons, 1 straight pouring gate of phi 120 and 2 transverse pouring gates of phi 100 are determined. The sum proportion of the sectional areas among the components of the independent pouring system is Sigma straight: sigma-transverse: Σ=1:1.39:3.5, as shown in fig. 5.
(3) And (3) carrying out parameter recalculation and checking on the other inner pouring gates on the basis of the original pouring system, and updating the sizes and the number of the selected pouring boxes, the selected cross pouring gates, the selected sprue gates and the selected number of the pouring gates to obtain the main body pouring system. After the parameters are corrected, the main body pouring system needs to use 2 pouring boxes of 30 tons, 2 pouring gates of phi 110 are arranged, and the transverse pouring gates are fixed by a pouring gate seat. The main body pouring system is straight, the sum proportion of the sectional areas of the inner pouring channels is Sigma straight: Σ=1:4.17, as shown in fig. 5.
(4) After the design is finished, the integral structure of the time-delay pouring system is formed, and the inner pouring gate groups positioned at the high point and the low point are divided into an independent pouring system and a main pouring system, and are controlled and controlled respectively, so that basic conditions are created for time-delay pouring. Wherein, the inflow of the independent pouring system into the molten iron amount of 28 tons is planned, and the inflow of the main body pouring system into the molten iron amount of 56 tons is planned.
5. The calculation of the time T of the delay opening is needed by the independent pouring system: the calculation formula of the delay time is T=T1-T2, and the calculation formula is specifically as follows:
(1) Calculating the time T1 required by the main body pouring system to pour to the lowest inner gate of the independent pouring system, wherein the inflow of the molten iron is formed by two parts, the first part is the time required by the self-filling of the main body pouring system, and the inflow of the molten iron in the time is about 4.35 tons; the second part is the time required for filling the molten iron into the inner pouring gate at the lowest point of the independent pouring system after the molten iron enters the casting mould, and the inflow amount of the molten iron in the time is about 16.85 tons; therefore, the total inflow amount of the molten iron was about 21.2 tons, and t1=40s was obtained from the inflow amount of the molten iron, as shown in fig. 6.
(2) And calculating the self-filling time T2 of the independent pouring system, wherein the self-filling weight of the self-filling molten iron of the independent pouring system is about 1.68 tons, so that the self-filling time T2 = 5s.
(3) Calculating the time t=t1-t2=35 s for which the independent casting system needs to be opened with a delay.
6. And (3) filling simulation and verification: and carrying out three-dimensional modeling according to the structure of the delay pouring system and the calculated component parameters, and carrying out filling simulation by using simulation software to verify the filling condition, the accuracy of the delay time and the like of the delay pouring system. The simulation software is Magma.
Proved by verification, the original pouring system has obvious filling problem, in the early stage of filling, molten iron at the highest position of an inner pouring gate cannot be introduced into a cavity, but remains in the inner pouring gate for a long time until the molten iron is filled to the position after 44S, and the retained molten iron enters the cavity, wherein the retained molten iron temperature is about 1200 ℃ and is 100 ℃ higher than that of the molten iron in other areas, and a large cold shut risk exists, as shown in fig. 7.
After the time-delay pouring system is applied, the main body pouring system is opened preferentially and is filled with molten iron, the independent pouring system is opened at the 35 th s after the pouring is started and is filled with molten iron (shown in figure 8), the molten iron in the independent pouring system at the 40 th s is introduced into the cavity and is converged with the liquid level of the molten iron which is injected earlier, the temperature of the molten iron which is injected at the moment is about 1340 ℃, the temperature difference between the molten iron and the water in other areas is within 10 ℃, the verification effect is very ideal, and calculated data do not need to be corrected again as shown in figure 9.
7. In actual production, a time delay pouring system is adopted according to the calculation and analysis results. The product is verified by NDT test, has compact structure and no cold shut defect, and is an example of successful application of the invention.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.

Claims (3)

1. A time-delay pouring method for a large casting comprises the following steps:
determining parameters of an inner pouring gate according to the structure of the casting and the required molten iron amount;
determining parameters of other components used in the casting process according to the amount of molten iron, parameters of an inner pouring gate and process parameters required by casting to obtain an original casting system, and the method is characterized by further comprising the following steps:
calculating the vertical height between the inner gate positioned at the lowest point and the inner gate positioned at the highest point in the plurality of inner gates, calculating the weight of molten iron required by the casting in the height, and obtaining the time for filling the molten iron of the part of casting according to the weight of molten iron;
if the time is not longer than 20s, pouring the casting by adopting an original pouring system;
if the time exceeds 20s, a time-delay pouring system is established to pour the casting, and the time-delay pouring system is established in the following way: dividing the inner gates near the inner gate at the highest point into one type, establishing independent pouring systems for the inner gates, taking the rest inner gates as main body pouring systems, reconfirming parameters of other components used by the independent pouring systems, reconfirming parameters of other components used by the main body pouring systems on the basis of the original pouring systems, and combining the main body pouring systems and the independent pouring systems into a time delay pouring system;
determining time T for opening the independent pouring system in a time delay manner, wherein T=T1-T2, T1 is time required by the main body pouring system to pour to the lowest inner gate of the independent pouring system, and T2 is time required by the independent pouring system to fill the mold;
three-dimensional modeling is carried out on the delay pouring system, simulation is carried out by using simulation software, the accuracy of the time of filling and delay opening of the delay pouring system is verified, and the deviation is optimized and corrected;
parameters of the in-gates include the number, location and size of the in-gates;
parameters of other components include size and number of the pouring boxes, the cross runners and the sprue.
2. The method according to claim 1, wherein T1 comprises two parts, one part is the time required for the main body pouring system to self-mold, and the other part is the time required for the molten iron to fill the inner gate at the lowest point of the independent pouring system after entering the casting mold.
3. A method of time-lapse casting of large castings according to claim 1 or 2, wherein said simulation software is Magma.
CN202210102543.9A 2022-01-27 2022-01-27 Time-delay pouring method for large castings Active CN114453559B (en)

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