CN114505447A - Wax mold tray for large-scale complex thin-wall casting, wax mold slurry-sticking shell-making system and method - Google Patents
Wax mold tray for large-scale complex thin-wall casting, wax mold slurry-sticking shell-making system and method Download PDFInfo
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- CN114505447A CN114505447A CN202210136461.6A CN202210136461A CN114505447A CN 114505447 A CN114505447 A CN 114505447A CN 202210136461 A CN202210136461 A CN 202210136461A CN 114505447 A CN114505447 A CN 114505447A
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- 238000005266 casting Methods 0.000 title claims abstract description 119
- 238000000034 method Methods 0.000 title claims abstract description 43
- 239000002002 slurry Substances 0.000 claims abstract description 117
- 239000004576 sand Substances 0.000 claims abstract description 52
- 239000002344 surface layer Substances 0.000 claims abstract description 52
- 239000010410 layer Substances 0.000 claims abstract description 48
- 238000005507 spraying Methods 0.000 claims abstract description 29
- 239000007788 liquid Substances 0.000 claims abstract description 23
- 238000005253 cladding Methods 0.000 claims abstract description 4
- 239000002184 metal Substances 0.000 claims description 18
- 238000004519 manufacturing process Methods 0.000 claims description 14
- 238000013461 design Methods 0.000 claims description 8
- 238000007667 floating Methods 0.000 claims description 7
- 239000007921 spray Substances 0.000 claims description 5
- 238000007598 dipping method Methods 0.000 claims description 2
- 238000005495 investment casting Methods 0.000 description 11
- 239000011248 coating agent Substances 0.000 description 7
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- 238000011161 development Methods 0.000 description 3
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- 238000007581 slurry coating method Methods 0.000 description 2
- 206010063385 Intellectualisation Diseases 0.000 description 1
- 229920000715 Mucilage Polymers 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 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
- B22C7/02—Lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
- B22C13/085—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores by investing a lost pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C23/00—Tools; Devices not mentioned before for moulding
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Abstract
The invention provides a wax mould tray for a large-scale complex thin-wall casting, a wax mould slurry-sticking shell-making system and a method, wherein a first hole is formed in the center of a circle of the tray, a plurality of second holes are uniformly formed in the concentric circle position of the tray, and the diameter of each second hole is smaller than that of the first hole; the fixed hasp is installed at the center of tray, and the cladding of the outer lane of tray has the wax board that keeps off. The shell making system comprises a wax mould, a mechanical arm, a surface layer slurry barrel, a sand drenching machine, an image acquisition module, a control module and a tray; the method comprises the following steps: the manipulator drives the wax mold to be immersed into the surface layer pulp barrel, and primary back layer pulp pasting is carried out; according to the image information of the back layer slurry, when the surface layer slurry flowing down from the wax mould is changed into an intermittent liquid flow, the mechanical arm carries out primary sand spraying on a sand spraying machine; and after the surface layer slurry on the wax mold is completely dried, the manipulator drives the wax mold to repeatedly carry out back layer slurry sticking and sand spraying until the required number of layers is reached. The invention can obviously improve the surface quality of the large complex thin-wall casting.
Description
Technical Field
The invention relates to the technical field of high-temperature alloy precision casting, in particular to a wax mold tray, a wax mold slurry-sticking shell-making system and a wax mold slurry-sticking shell-making method for a large-scale complex thin-wall casting.
Background
Investment precision casting generally comprises the processes of pressing and assembling wax molds, shell making, pouring and the like, and can be used for manufacturing metal castings with complex inner cavity structures, high smelting temperature and high chemical activity, and is widely applied to manufacturing large complex-structure castings, particularly high-temperature alloy precision castings for aerospace. With the urgent requirements of development of aerospace equipment such as higher use temperature, larger structure-efficiency ratio and higher maneuverability, the development of high-temperature alloy precision castings towards extreme large-scale, complicated and thin-wall is promoted. At present, the maximum size of a high-temperature alloy precision casting is nearly 2000mm, the wall thickness of 80% of the casting is less than 3mm, the minimum wall thickness is only 1mm, and the section thickness projection is up to 10 times. The large complex thin-wall wax mould is very easy to deform or even damage under stress due to low integral strength, and thus, a great challenge is provided for the shell manufacturing process of slurry sticking and sand spraying of the large complex thin-wall wax mould.
Through the literature search of the prior art, the following findings are found: the invention discloses a Chinese invention patent with application number of 201911335934.X, and relates to investment casting shell-making complete equipment and a shell-making method thereof. The mechanical arm only grabs the main gate stick to glue, and although stable gluing can be achieved in batches for small-sized wax materials such as blades, the single main gate stick is difficult to support the weight of the whole wax mold for the large-sized complex thin-wall casting, so that the main structure of the wax mold is damaged, and the shell making process is difficult to complete.
The utility model discloses a chinese utility model patent of application number 201921835081.1 relates to a be applied to supplementary viscous liquid device of precision casting spare wax matrix, specifically including being used for bearing the thick liquid bucket of wax matrix viscous liquid and placing in the viscous liquid complementary unit at thick liquid bucket top, viscous liquid complementary unit is including bearing tray, tray and visit into thick liquid bucket motion. The utility model discloses a can realize batchization wax matrix sizing, not only improve work efficiency, guarantee the uniformity of wax matrix sizing effect moreover. However, the device can only perform simple up-and-down and left-and-right movement, and although a certain advantage is shown in the aspect of slurry sticking of a small wax mould with a simple structure and even a large wax mould, the uniform coating of slurry of the large complex thin-wall structure wax mould cannot be ensured, and the uniform coating of slurry is one of key links for ensuring high-quality forming of large complex thin-wall castings, especially castings with semi-closed inner cavity structures.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a wax mould tray for a large-scale complex thin-wall casting, a wax mould slurry shell making system and a wax mould slurry shell making method, which are expected to provide support for the development of high dimensional precision and metallurgical quality of the large-scale complex thin-wall casting and provide a solution idea for realizing the digitization and intellectualization of the investment precision casting shell making process.
According to a first aspect of the invention, a wax mold tray for a large-scale complex thin-wall casting is provided, the tray is a circular metal tray, a first hole is formed in the center of the tray, a plurality of second holes are uniformly formed in the concentric circle position of the tray, and the diameter of each second hole is smaller than that of each first hole; the fixed hasp is installed at the center of tray one side, the outer lane cladding of tray opposite side has the wax board that keeps off.
According to a second aspect of the invention, a wax mold slurry-sticking shell-making system for a large-scale complex thin-wall casting is provided, which comprises a wax mold, a manipulator, a surface layer slurry barrel, a sand-sprinkling machine, an image acquisition module, a control module and the wax mold tray for the large-scale complex thin-wall casting;
the wax mould comprises a main casting head and a plurality of other casting heads, the main casting head corresponds to the first hole, the other casting heads correspond to the second hole, and the top surfaces of the main casting head and the other casting heads are positioned on the same plane; the main casting head and the other casting heads are respectively provided with a screw rod, and the screw rods respectively penetrate through the first hole and the second hole and are fixed by nuts; the surface layer slurry barrel is used for containing surface layer slurry; the image acquisition module is used for acquiring the image information of the back layer slurry sticking of the wax mould; the sand drenching machine is used for carrying out sand drenching treatment on the wax mould; the control module is used for controlling the manipulator to drive the wax mold to carry out back layer slurry pasting in the surface layer slurry barrel and sand spraying on the sand spraying machine according to a preset motion track; and the manipulator is used for grabbing the fixed lock catch and driving the wax pattern to carry out back layer slurry sticking and sand spraying according to the instruction of the control module.
According to a third aspect of the present invention, there is provided a method for making a shell by using wax mold slurry for a large complex thin-walled casting, the method is implemented based on the above-mentioned system for making a shell by using wax mold slurry for a large complex thin-walled casting, and includes:
a mechanical hand grabs and fixes the lock catch to drive the wax mould to be immersed into the surface layer pulp barrel and rotate according to a first preset motion trail to carry out primary back layer pulp pasting;
according to the image information of the back layer slurry obtained by the image obtaining module, when the surface layer slurry flowing down from the wax mold is changed into an intermittent liquid flow, the first back layer slurry is completed, the mechanical arm rotates along a second preset motion track on the sand drenching machine, and the first sand drenching is performed;
and after the surface layer slurry on the wax mold is completely dried, the manipulator drives the wax mold to repeatedly carry out back layer slurry sticking and sand spraying until the number of layers required by the casting process design is reached.
Further, before the manipulator grasps the fixing lock catch, the method further comprises the following steps: and uniformly covering the surface of the tray close to one side of the wax mould with liquid bonding wax, and filling gaps between the main casting head and other casting heads and the tray with the liquid bonding wax.
Further, the tray drives the wax matrix and immerses surface course thick liquid bucket to it is rotatory according to first predetermined movement track, carries out the back layer mucilage binding for the first time, includes:
the tray drives the wax mold to vertically dip into the surface layer pulp barrel, and the wax mold is respectively rotated clockwise and anticlockwise for a first preset number of turns;
then the manipulator horizontally puts the wax pattern on the tray downwards into a surface layer slurry dipping barrel, and then the wax pattern rotates clockwise and anticlockwise for a second preset number of cycles respectively.
Further, the first preset period number and the second preset period number are both determined according to the structure of the wax mould.
Further, the second preset motion trajectory includes: and horizontally rotating and vertically rotating for a third preset period, wherein the third preset period is determined according to the structure of the wax mould.
Further, before the manipulator drives the wax pattern to repeatedly carry out back layer slurry sticking and sand spraying, the method further comprises the following steps: and removing floating sand on the surface of the wax mould by using an air spray gun.
Further, the manipulator drives the wax matrix to repeatedly carry out back layer slurry sticking and sand spraying, and the method comprises the following steps: and repeatedly carrying out back layer slurry bonding by adopting the same motion track as the first back layer slurry bonding, and repeatedly carrying out sand spraying by adopting the same motion track as the first sand spraying.
Further, after the surface layer slurry on the wax mould is completely dried, the method comprises the following steps: and waiting for 8-24 hours to completely dry the surface layer slurry on the wax mould.
Compared with the prior art, the invention has the following beneficial effects:
1. the wax mould tray for the large-scale complex thin-wall casting, the wax mould slurry shell manufacturing system and the wax mould slurry shell manufacturing method adopt the tray distributed bearing method, solve the problem of high dead weight when the large-scale complex thin-wall wax mould slurry is used for manufacturing the shell, and further avoid the problem that the wax mould is low in strength and easy to damage.
2. According to the wax mould tray for the large-scale complex thin-wall casting, the wax mould slurry pasting and shell making system and method, the uniform coating and hanging of the shell can be guaranteed through mechanical arm slurry pasting, and the quality stability and the process consistency of the shell are good.
3. According to the wax mould tray for the large complex thin-wall casting, the wax mould slurry-sticking shell-making system and the wax mould slurry-sticking shell-making method, disclosed by the invention, the intelligent image identification and automatic manipulator control are combined through the control module, the image acquisition module and the manipulator, the slurry-sticking process error caused by human intervention is solved, and the surface quality of the large complex thin-wall casting can be obviously improved.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a schematic structural diagram of a wax mold slurry-sticking shell-making system for large complex thin-walled castings according to an embodiment of the present invention;
in the figure: the device comprises a tray 1, a fixed lock catch 2, a screw rod 3, a nut 4, a wax baffle 5, a main casting head 6, other casting heads 7, a wax mould 8, a manipulator 9, a surface layer slurry barrel 10, an image acquisition module 11 and a control module 12.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications can be made by persons skilled in the art without departing from the spirit of the invention. All falling within the scope of the present invention. In the description of the embodiments of the present invention, it should be noted that the terms "first", "second", and the like in the description and the claims of the present invention and the drawings described above are used for distinguishing similar objects and not necessarily for describing a particular order or sequence. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in sequences other than those illustrated or described herein.
The embodiment of the invention provides a wax mould tray for a large-scale complex thin-wall casting, wherein the tray 1 is a circular metal tray, a first hole is formed in the center of the tray 1, a plurality of second holes are uniformly formed in the concentric circle position of the tray 1, and the diameter of each second hole is smaller than that of each first hole; fixed hasp 2 is installed at the center of tray 1 one side, and the outer lane cladding of tray 1 opposite side has wax board 5.
In the tray of the embodiment, the first holes correspond to the positions of the wax mould main casting heads, the second holes are positioned on the concentric circles of the tray or the first holes and are used for bearing other casting heads, in some preferred embodiments, the diameter of each first hole is 20-40mm, the diameter of each second hole is 10-20mm, and the sector angle formed by two adjacent second holes and the first holes ranges from 30 degrees to 60 degrees.
The outer ring at the other side of the tray 1 is covered with a wax baffle 5, which can prevent the liquid bonding wax from flowing out of the tray when covering the surface of the tray 1 close to one side of the wax mould, and in some preferred embodiments, the height of the wax baffle is 3-5 mm.
The embodiment of the invention adopts a tray distributed bearing method, solves the problem of high dead weight when a large complex thin-wall wax mould is pasted and made into a shell, and can avoid the problem that the wax mould is low in strength and easy to damage.
The embodiment of the invention also provides a wax mold slurry-sticking shell-making system for the large-scale complex thin-wall casting, which comprises a wax mold 8, a manipulator 9, a surface layer slurry barrel 10, a sand-sprinkling machine, an image acquisition module 11, a control module 12 and the wax mold tray 1 for the large-scale complex thin-wall casting in the embodiment;
the wax mold 8 is a wax mold for large-scale complex thin-wall castings and comprises a main casting head 6 and a plurality of other casting heads 7, the main casting head 6 corresponds to the first hole, the other casting heads 7 correspond to the second holes, and the top surfaces of the main casting head 6 and the other casting heads 7 are positioned on the same plane; the main casting head 6 and other casting heads 7 are respectively provided with a screw rod 3, and the screw rods 3 respectively penetrate through the first hole and the second hole and are fixed by nuts 4; the surface layer slurry barrel 10 is used for containing surface layer slurry; the image acquisition module 11 is used for acquiring image information of back layer slurry sticking of the wax mould 8; the sand pouring machine is used for performing sand pouring treatment on the wax mould 8; the control module 12 is used for controlling the manipulator 9 to drive the wax mold 8 to carry out back layer slurry pasting in the surface layer slurry barrel 10 and sand spraying on a sand spraying machine according to a preset motion track; the manipulator 9 is used for grasping the fixed lock catch 2 and driving the wax mold 8 to carry out back layer slurry sticking and sand spraying according to the instruction of the control module 12.
In some preferred embodiments, the screws 3 are metal screws, and the number and type of the screws 3 used are different according to the shape and size of the wax pattern.
To ensure uniformity of the slurry coating of the robot 9, in some preferred embodiments, the robot 9 may employ a 500-stage ABB robot.
The embodiment of the invention also provides a shell making method by using the wax mold slurry for the large-scale complex thin-wall casting, which is realized based on the wax mold slurry shell making system for the large-scale complex thin-wall casting in the embodiment and comprises the following steps:
the manipulator 9 grabs and fixes the lock catch 2, drives the wax mould 8 to dip into the surface layer pulp barrel 10, and rotates according to a first preset motion trail to carry out primary back layer pulp pasting;
according to the image information of the back layer slurry acquired by the image acquisition module 11, when the surface layer slurry flowing down from the wax mold 8 is changed into an intermittent liquid flow, the first back layer slurry pasting is completed, and the manipulator 9 rotates along a second preset motion track on the sand drenching machine to conduct first sand drenching;
after the surface layer slurry on the wax mold 8 is completely dried, the manipulator 9 drives the wax mold 8 to repeatedly carry out back layer slurry sticking and sand spraying until the number of layers required by the casting process design is reached.
In order to prevent the slurry from adhering to the tray 1 during slurry adhesion, in some preferred embodiments, before the robot 9 grasps the fixing lock catch 2, the following is further included: the surface of the tray 1 close to one side of the wax mould 8 is evenly covered by liquid bonding wax, and gaps between the main casting head 6 and other casting heads 7 and the tray 1 are filled with the liquid bonding wax.
In order to uniformly coat the surface of the wax pattern 8 with the surface layer slurry, in some preferred embodiments, the tray 1 drives the wax pattern 8 to immerse into the surface layer slurry barrel 10, and rotates according to a first preset motion track to perform a first back layer slurry coating, including:
the tray 1 drives the wax mould 8 to vertically dip into the surface layer pulp barrel 10, and clockwise and anticlockwise rotate for a first preset number of turns respectively; then the manipulator 9 horizontally puts the wax mould 8 on the tray 1 downwards and immerses the wax mould into the surface layer slurry barrel 10, and then the wax mould rotates clockwise and anticlockwise respectively for a second preset period.
In order to ensure that the shell coating is uniform, in some preferred embodiments, the first preset period and the second preset period are determined according to the structure of the wax pattern 8. The second preset motion profile comprises: and horizontally rotating and vertically rotating for a third preset number of cycles, wherein the third preset number of cycles is determined according to the structure of the wax mold 8.
In order to ensure that the shell is coated evenly, in some preferred embodiments, the first preset number of weeks is 2-3 weeks; the second preset number of weeks is 2-3 weeks; the third preset number of weeks is 2-3 weeks.
In order to improve the quality of the formwork, in some preferred embodiments, before the robot 9 drives the wax mold 8 to repeatedly perform back layer slurry sticking and sand pouring, the method further comprises the following steps: and removing floating sand on the surface of the wax mold 8 by using an air spray gun. If the floating sand is not removed, the floating sand enters the slurry in the surface layer slurry barrel when the slurry is pasted next time, the physical characteristics of the slurry, such as viscosity, coating property and the like, are changed, and the quality of the formwork is reduced.
In order to ensure the uniform coating and hanging of the shell and the quality stability and process consistency of the shell, in some preferred embodiments, the manipulator 9 drives the wax mold 8 to repeatedly carry out back layer slurry sticking and sand spraying, including: and repeatedly carrying out back layer slurry bonding by adopting the same motion track as the first back layer slurry bonding, and repeatedly carrying out sand spraying by adopting the same motion track as the first sand spraying.
In order to improve the surface quality of large complex thin-wall castings, the drying time is determined according to the structural complexity of the castings, such as completely open castings, semi-closed castings, castings with long and narrow flow passages and the like, and the more complex the casting structure is, the longer the drying time is. In some preferred embodiments, after the surface layer slurry on the wax pattern 8 is completely dried, the method comprises the following steps: waiting for 8-24 hours to completely dry the surface sizing agent on the wax mould 8.
According to the embodiment of the invention, the uniform coating and hanging of the shell can be ensured through mechanical arm slurry sticking, and the quality stability and the process consistency of the shell are good; through the control module, the image acquisition module and the manipulator, the intelligent image identification and the automatic manipulator control are combined, the problem of slurry sticking process errors caused by human intervention is solved, and the surface quality of large-scale complex thin-wall castings can be obviously improved.
The wax mold tray, the wax mold slurry shell making system and the method for large complex thin-wall castings according to the present invention will be described in more detail with reference to specific embodiments.
Example 1
The casting is a large thin-wall high-temperature alloy hollow casing component of an aeroengine, and has the diameter of 1360mm, the height of 270mm and the minimum wall thickness of 2.5 mm. According to the casting process design, the size of the investment precision casting wax material is large and exceeds 1500mm, a pouring system is complex, a large number of inner cavity structures exist, and the quality of a shell is difficult to ensure by the traditional manual slurry sticking method.
Firstly, a large circular metal tray with the diameter of 1700mm is prepared, and a circular hole with the diameter of 30mm, namely a first hole, is machined at the center of the tray. Because the casting is in a ring sleeve structure, two rings of small holes with the diameter of 20mm, namely second holes, are machined uniformly at the concentric circle positions of the metal tray corresponding to the casting, a fixed lock catch is installed at the center of one side of the metal tray, and a wax blocking plate with the height of 5mm is coated on the outer ring of the other side of the metal tray.
After the large wax die set is waxed, the top surfaces of the main casting head and two rows of annular casting heads, namely the top surfaces of other casting heads, are ensured to be on the same plane, and M12 metal screws are arranged on all the casting heads. A large complex thin-wall casting is inverted by using a wax mold, a metal screw on a main dead head penetrates through a central circular hole of a metal tray and then is locked by using a nut, and two rows of other dead heads penetrate through small holes in corresponding positions of the metal tray and then are fixed by using nuts. And uniformly covering the surface of the metal tray close to one side of the wax mould with liquid bonding wax, and filling gaps between the main casting head and other casting heads and the tray.
A500 kg-level ABB manipulator is adopted to tightly grasp a fixed lock catch on one side of a tray, the tray provided with the large-scale complex thin-wall casting wax mold is vertically immersed into a surface layer slurry barrel for 700mm, the tray rotates clockwise and anticlockwise for 2 weeks respectively, then the 500 kg-level ABB manipulator is automatically controlled to horizontally place the large-scale complex thin-wall casting on the tray downwards with the wax mold, and the tray is immersed into the surface layer slurry barrel for 300mm and rotates clockwise and anticlockwise for 2 weeks respectively. The control module is a computer control system, the image acquisition module adopts an intelligent identification camera, the slurry sticking is monitored by a wax mold for the large-scale complex thin-wall casting through the intelligent identification camera connected with the computer control system, after 7s of slurry sticking is found, the surface layer slurry under the strand flow on the wax mold for the large-scale complex thin-wall casting is changed into an intermittent liquid flow, and the computer control system automatically controls the 500-level ABB manipulator to horizontally and vertically rotate on the sand drenching machine for 2 weeks. After the surface layer slurry is completely dried for 24 hours, removing floating sand on the surface layer by using an air spray gun, automatically controlling a 500 kg-grade ABB manipulator by a computer control system to carry out back layer slurry pasting and sand spraying by adopting the same motion track as the surface layer slurry until 10 layers required by the casting process design are reached, completing the shell manufacturing process of the large-scale complex thin-wall casing casting by using the wax mold slurry pasting, and successfully manufacturing the casing casting shell, thereby verifying the engineering application feasibility and the technical innovation of the design.
Example 2
The casting is an aeroengine rectifying blade component, the length is 360mm, the height is 150mm, and the minimum wall thickness is 1.5 mm. According to the casting process design, although the size of the investment precision casting wax material is small, an engineer can finish the shell making operation by manually pasting slurry, but the shell consistency is poor, the rejection rate is high, and the precision casting cost is high. Therefore, the technical scheme of forming a plurality of large trays at one time is adopted.
Firstly, a large circular metal tray with the diameter of 1700mm is prepared, and a circular hole with the diameter of 30mm, namely a first hole, is machined at the center of the tray. Because the overall mass of the wax mould for the casting is light, only one main casting head is arranged, a wax mould is arranged in the middle of the tray, 11 small holes with the diameter of 20mm, namely second holes, are machined uniformly in the concentric circle position of the tray, 11 wax moulds are arranged, a fixed lock catch is installed in the center of one side of the tray, and a layer of wax blocking plate with the height of 5mm is coated on the outer ring of the other side of the tray.
After the large wax die set is waxed, the top surfaces of the main casting head and other casting heads are ensured to be on the same plane, and M12 metal screws are arranged on the wax die casting heads. And (3) standing the wax pattern upside down, locking the metal screw on the main casting head by using a nut after the metal screw penetrates through a central circular hole of the metal tray, and fixing the other casting heads by using nuts after the other casting heads penetrate through corresponding small hole positions of the tray so as to increase the strength of the whole wax pattern. And uniformly covering the surface of the tray close to one side of the wax mould with liquid bonding wax, and filling a gap between the riser and the tray. A500 kg-grade ABB manipulator is adopted to tightly grasp the fixed lock catch on one side of the tray, the tray provided with the wax mold is horizontally placed, and the tray is immersed into the surface layer pulp barrel for 400mm and rotates clockwise and anticlockwise for 3 circles respectively. The control module is a computer control system, the image acquisition module adopts an intelligent identification camera, the slurry sticking is monitored by the intelligent identification camera connected with the computer control system, after 3s of slurry sticking is found, the surface layer slurry under the strand flow on the wax mold is changed into an intermittent liquid flow, and the computer control system automatically controls the 500-level ABB manipulator to horizontally and vertically rotate on the sand drenching machine for 2 weeks. After the surface layer slurry is completely dried for 24 hours, removing floating sand on the surface layer by using an air spray gun, automatically controlling a 500 kg-grade ABB manipulator by a computer control system to carry out back layer slurry pasting and sand spraying by adopting the same motion track as the surface layer slurry until 5 layers required by the casting process design are reached, completing the shell manufacturing process of the rectification blade casting by using wax mold slurry pasting, successfully preparing the shell of the rectification blade casting, and finding out that the qualified rate of the casting is greatly improved through pouring and the crystal grain structure of the casting is uniform. The technology can meet the requirement of shell making by using the wax mold for large complex thin-wall castings, and can be applied to shell making by using the wax mold for small castings in batches.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The above-described preferred features may be used in any combination without conflict with each other.
Claims (10)
1. A wax pattern tray for a large-scale complex thin-wall casting is characterized in that the tray is a circular metal tray, a first hole is formed in the center of the tray, a plurality of second holes are uniformly formed in the concentric circle position of the tray, and the diameter of each second hole is smaller than that of each first hole;
the fixed hasp is installed at the center of tray one side, the outer lane cladding of tray opposite side has the wax board that keeps off.
2. A wax mold slurry-sticking shell-making system for large-scale complex thin-wall castings is characterized by comprising a wax mold, a manipulator, a surface layer slurry barrel, a sand-pouring machine, an image acquisition module, a control module and the wax mold tray for large-scale complex thin-wall castings according to claim 1;
the wax mould comprises a main casting head and a plurality of other casting heads, the main casting head corresponds to the first hole, the other casting heads correspond to the second hole, and the top surfaces of the main casting head and the other casting heads are positioned on the same plane; the main casting head and the other casting heads are respectively provided with a screw rod, and the screw rods respectively penetrate through the first hole and the second hole and are fixed by nuts;
the surface layer slurry barrel is used for containing surface layer slurry;
the image acquisition module is used for acquiring the image information of the back layer slurry sticking of the wax mould;
the sand drenching machine is used for carrying out sand drenching treatment on the wax mould;
the control module is used for controlling the manipulator to drive the wax mould to carry out back layer slurry pasting in the surface layer slurry barrel and sand spraying on the sand spraying machine according to a preset motion track;
the manipulator is used for grabbing the fixed lock catch and driving the wax mold to carry out back layer slurry sticking and sand spraying according to the instruction of the control module.
3. A wax mold slurry shell making method for large complex thin-wall castings, which is realized by the wax mold slurry shell making system for large complex thin-wall castings according to claim 2, and comprises the following steps:
a mechanical hand grabs and fixes the lock catch to drive the wax mould to be immersed into the surface layer pulp barrel and rotate according to a first preset motion trail to carry out primary back layer pulp pasting;
according to the image information of the back layer slurry obtained by the image obtaining module, when the surface layer slurry flowing down from the wax mold is changed into an intermittent liquid flow, the first back layer slurry is completed, the mechanical arm rotates along a second preset motion track on the sand drenching machine, and the first sand drenching is performed;
and after the surface layer slurry on the wax mold is completely dried, the manipulator drives the wax mold to repeatedly carry out back layer slurry sticking and sand spraying until the number of layers required by the casting process design is reached.
4. The method for making the shell of the large-scale complex thin-wall casting by using the wax mold slurry as claimed in claim 3, wherein before the mechanical hand grasps and fixes the lock catch, the method further comprises the following steps: and uniformly covering the surface of the tray close to one side of the wax mould with liquid bonding wax, and filling gaps between the main casting head and other casting heads and the tray with the liquid bonding wax.
5. The method for manufacturing the shell by using the wax mold slurry for the large-scale complex thin-wall casting according to claim 3, wherein the tray drives the wax mold to be immersed into the surface layer slurry barrel and rotate according to a first preset motion track to carry out primary back layer slurry bonding, and the method comprises the following steps:
the tray drives the wax mould to vertically dip into the surface layer pulp barrel, and the wax mould is respectively rotated clockwise and anticlockwise for a first preset number of turns;
then the manipulator horizontally puts the wax pattern on the tray downwards into a surface layer slurry dipping barrel, and then the wax pattern rotates clockwise and anticlockwise for a second preset number of cycles respectively.
6. The method for manufacturing the shell of the large-scale complex thin-wall casting by using the wax mold slurry as claimed in claim 5, wherein the first preset number of the cycles and the second preset number of the cycles are determined according to the structure of the wax mold.
7. The method for manufacturing the shell of the large-scale complex thin-wall casting by using the wax mold slurry as claimed in claim 3, wherein the second preset motion track comprises: and horizontally rotating and vertically rotating for a third preset period, wherein the third preset period is determined according to the structure of the wax mould.
8. The method for making the shell by using the wax mold slurry for the large-scale complex thin-wall casting according to claim 3, wherein before the manipulator drives the wax mold to repeatedly carry out back layer slurry bonding and sand spraying, the method further comprises the following steps: and removing floating sand on the surface of the wax mould by using an air spray gun.
9. The method for manufacturing the shell by using the wax mold slurry for the large-scale complex thin-wall casting according to claim 3, wherein the manipulator drives the wax mold to repeatedly carry out back layer slurry bonding and sand spraying, and the method comprises the following steps: and repeatedly carrying out back layer slurry bonding by adopting the same motion track as the first back layer slurry bonding, and repeatedly carrying out sand spraying by adopting the same motion track as the first sand spraying.
10. The method for manufacturing the shell by using the wax mold slurry for the large-scale complex thin-wall casting according to claim 3, wherein after the surface layer slurry on the wax mold is completely dried out, the method comprises the following steps: and waiting for 8-24 hours to completely dry the surface layer slurry on the wax mould.
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