CN114850405A - Casting process and casting mold for preventing shrinkage cavity of ductile iron flywheel shell casting of automobile engine - Google Patents
Casting process and casting mold for preventing shrinkage cavity of ductile iron flywheel shell casting of automobile engine Download PDFInfo
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- CN114850405A CN114850405A CN202210577253.XA CN202210577253A CN114850405A CN 114850405 A CN114850405 A CN 114850405A CN 202210577253 A CN202210577253 A CN 202210577253A CN 114850405 A CN114850405 A CN 114850405A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/06—Core boxes
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- 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
- B22C9/088—Feeder heads
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D15/00—Casting using a mould or core of which a part significant to the process is of high thermal conductivity, e.g. chill casting; Moulds or accessories specially adapted therefor
Abstract
The invention discloses a casting die for preventing a gas shrinkage cavity of a ductile iron flywheel housing casting of an automobile engine, which relates to the technical field of casting and comprises an upper shape template die, a lower shape template die and a pouring system, wherein the upper shape template die and the lower shape template die are butted to form a film cavity, the pouring system is communicated with the film cavity, a film-coated sand core is arranged in the film cavity, the pouring system comprises a sprue, a cross gate, a first feeding head and a second feeding head, and the first feeding head and the second feeding head are positioned at a geometric hot spot of the casting. The invention also discloses a casting process for preventing the shrinkage cavity of the ductile iron flywheel shell casting of the automobile engine. The invention effectively avoids preheating the hot spot when the feeding riser neck of the gating system is filled, and the feeding riser can instantaneously supply molten iron liquid shrinkage and first-time body shrinkage in the casting mold filling and solidifying process, thereby effectively avoiding the defect of forming a shrinkage cavity in the casting.
Description
Technical Field
The invention relates to the technical field of casting, in particular to a casting process and a casting mold for preventing a gas shrinkage cavity of a ductile iron flywheel shell casting of an automobile engine.
Background
The light weight of automobiles has become a trend of the development of automobiles in the world due to the need for environmental protection and energy conservation. As the quality of the vehicle decreases, the fuel consumption of the vehicle decreases, and the pressure on the vehicle tires and the brake system decreases.
The traditional automobile engine flywheel shell mainly uses gray iron HT250 as a main material, and along with the overall requirement of light weight of an automobile, a host factory adjusts the material of the engine flywheel shell, and gradually adjusts the gray iron HT250 into ductile iron QT 450-12. The product material is adjusted, so that the product strength is greatly improved, the wall thickness of the product can be greatly reduced, the weight of the casting is reduced, and a foundation is laid for saving the cost and reducing the consumption of the whole automobile.
As the liquid iron filling solidification properties of the gray iron and the ductile iron are different, the gray iron is solidified in a layered mode, the shrinkage rate is relatively small, the ductile iron is solidified in a pasty mode and is not beneficial to feeding, and the shrinkage rate of the ductile iron is large, so that the ductile iron product is easy to have the shrinkage cavity defect at the geometric thermal node.
Disclosure of Invention
The invention aims to solve the technical problem of overcoming the defects of the prior art and provides a casting process and a casting mold for preventing a ductile iron flywheel shell casting of an automobile engine from being provided with a shrinkage cavity.
In order to solve the technical problems, the technical scheme of the invention is as follows:
the utility model provides a casting mould of prevention automobile engine ductile iron flywheel casing foundry goods gas shrinkage cavity, includes appearance cope match-plate pattern, appearance bottom mould and the gating system, appearance cope match-plate pattern with appearance bottom mould passes through the sand box and the butt joint of green sand carrier forms the die cavity, the gating system with the die cavity intercommunication, be provided with the first chamber of placing that is used for placing the tectorial membrane psammitolite in the die cavity, the gating system includes sprue, the cross gate that communicates with the sprue and communicate first feeding riser and the second feeding riser on the cross gate, first feeding riser with the second feeding riser is 25 degrees with the arc core angle between the adjacent geometry thermal node of foundry goods, just first feeding riser with the arc core angle between second feeding riser and the foundry goods motor hole is greater than the arc core angle between adjacent geometry thermal node and the foundry goods motor hole.
As a preferred scheme of the casting mould for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting mould comprises the following components: and a second placing cavity for placing a chill is formed in the film-coated sand core.
As a preferred scheme of the casting mould for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting mould comprises the following components: and the chiller is positioned on the casting surface corresponding to the geometric hot spot of the casting.
As a preferred scheme of the casting mould for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting mould comprises the following components: the shape of the chilling block is matched with the shape of the casting surface of the adjacent geometric hot spot.
As a preferred scheme of the casting mould for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting mould comprises the following components: the area of the contact surface between the chilling block and the adjacent geometric hot joint is larger than 80% of the area of the adjacent geometric hot joint.
As a preferred scheme of the casting mould for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting mould comprises the following components: the hot core box assembly comprises a fixed hot core box and a movable hot core box which are oppositely arranged, and the fixed hot core box is butted with the movable hot core box to form a cavity for manufacturing the coated sand core.
The invention also discloses a casting process for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, which comprises the following steps,
manufacturing an exterior upper template mould, an exterior bottom template mould and a matched sand box by taking the upper plane of the flywheel shell as a parting plane;
manufacturing a hot core box assembly according to the shape of the flywheel shell casting, and manufacturing a required film-coated sand core through the hot core box assembly;
arranging the sand box on the exterior upper template mould, adding green sand, compacting by jolting, releasing the exterior upper template mould, and forming an upper cavity by the sand box and the green sand;
arranging the sand box on the exterior bottom template mould, adding green sand, compacting, releasing the exterior bottom template mould, and forming a lower cavity by the sand box and the green sand;
placing the manufactured chilling block in a second placing cavity of the precoated sand core, placing the precoated sand core in a first placing cavity of the green sand lower cavity, and then butting and clamping the upper cavity and the lower cavity by adopting a positioning long pin to form a cavity;
and pouring molten iron into the cavity through a pouring system, cooling after pouring, and separating the casting from the molding sand by shaking shakeout to obtain the casting.
As a preferred scheme of the casting process for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting process comprises the following steps: and the cooling time after the pouring is 30-60 min.
As a preferred scheme of the casting process for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine, the casting process comprises the following steps: the pouring time is 18-22 s.
The beneficial effects of the invention are:
(1) the feeding head is arranged at the geometric hot junction of the casting, so that the hot junction is effectively prevented from being preheated when a pouring system feeding riser neck is filled, namely, the indirect formation of a contact hot junction is prevented, the feeding head can instantaneously supply molten iron liquid shrinkage and first time body shrinkage in a casting mold in the casting mold filling and solidifying process, and the defect of forming a shrinkage cavity in the casting is effectively avoided.
(2) The invention arranges the chilling block at the geometric hot joint of the casting, and moves the hot joint which is easy to form the shrinkage cavity and shrinkage porosity defect outwards to enable the hot joint to approach the action range of a feeding head, thereby assisting in eliminating the shrinkage cavity defect of the ductile iron flywheel shell casting in the casting molding process.
(3) The reasonable thickness of the chilling block is designed, so that molten metal at the thick hot junction and the thin wall is simultaneously cooled, and the thin wall and the thick wall of the casting are simultaneously and uniformly solidified when molten metal of the ductile iron flywheel shell is filled, so that a high-quality casting with compact and uniform integral structure is obtained.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise.
FIG. 1 is a schematic structural diagram of an upper template mold of the middle and outer shape of a casting mold for preventing a ductile iron flywheel housing casting of an automobile engine provided by the invention;
FIG. 2 is a schematic structural diagram of a middle-outer bottom template of the casting mold for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine provided by the invention;
FIG. 3 is a schematic structural diagram of a coated sand core assembly in a casting mold for preventing a ductile iron flywheel housing casting from being subjected to shrinkage cavity shrinkage;
FIG. 4 is a simulation process diagram of a gating system and a casting in the casting mold for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine provided by the invention;
FIG. 5 is a simulated process diagram of a gating system and a casting in a conventional casting mold;
FIG. 6 is a schematic structural diagram of a casting cast by the casting mold for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine provided by the invention;
FIG. 7 is a schematic flow chart of a casting process for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine provided by the invention;
wherein: 1. shaping the template on the appearance; 2. a bottom profile plate mold; 3. a sprue; 4. a horizontal runner; 5. a first feeding head; 6. a second feeding head; 7. performing cold iron; 8. casting; 9. a first sand make-up core; 10. a second sand make-up core; 11. a third sand supplementing core; 12. a fourth sand make-up core; 13. a large circular core of the inner cavity; 14. a motor hole.
Detailed Description
In order that the present invention may be more readily and clearly understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings.
Fig. 1-4 are schematic structural diagrams of a casting mold for preventing a ductile iron flywheel housing casting from being shrinkage cavity in an automobile engine according to an embodiment of the present application. The casting mold comprises an outer shape upper template mold 1, an outer shape bottom template mold 2 and a pouring system.
Specifically, referring to fig. 1 and 2, an outer upper mold block and an outer bottom mold block matched with the casting 8 are respectively disposed on the outer upper mold plate 1 and the outer bottom mold plate 2. After the outer upper template die 1 is butted with the outer bottom template die 2, the outer upper template die block is butted with the outer bottom template die block, and a cavity is formed between the outer upper template die 1 and the outer bottom template die 2.
A first placing cavity for placing the film-coated sand core is arranged in the cavity. Wherein, the tectorial membrane psammitolite is made by hot core box subassembly. The hot core box assembly comprises a hot core box fixed die and a hot core box movable die. And a cavity matched with the shape of the coated sand core is formed between the fixed die of the hot core box and the movable die of the hot core box. In this embodiment, three sets of hot core box assemblies, namely a first hot core box assembly, a second hot core box assembly and a third hot core box assembly, are designed according to the casting molding requirement of the side surface of the flywheel housing casting 8. The first hot box assembly can produce a first make-up core 9 and a third make-up core 11, and the second hot box assembly can produce a second make-up core 10 and a fourth make-up core 12. The third hot core box can manufacture the large round core 13 of the precoated sand inner cavity. The four sand replenishment cores are combined in the sequence of fig. 3 to form the side shape of the flywheel housing casting 8. The large round core 13 of the precoated sand inner cavity falls to a specified position according to the design requirement, namely figure 3, and the inner cavity of the casting 8 is formed.
Preferably, a second placing cavity is formed in the second sand make-up core 10 and the fourth sand make-up core 12, and the chill 7 can be placed in the second placing cavity.
The gating system is in communication with the mold cavity. The pouring system specifically comprises a sprue 3, a runner 4 communicated with the sprue 3, and a first feeding head 5 and a second feeding head 6 which are respectively communicated with the runner 4. Referring to fig. 4, the runner 4 has a circular arc shape and a shape matching the side shape of the casting 8. A sprue 3 is arranged on the runner 4, and molten iron can enter the runner 4 through the sprue 3. The first feeding head 5 and the second feeding head 6 are both in communication with the runner 4. Wherein the first feeding head 5 and the second feeding head 6 are both located in the vicinity of the geometric thermal joint of the casting 8.
In a traditional casting mould, a feeding head is directly positioned at the upper part of a geometric hot junction, when pouring is carried out, metal liquid flow preheats the geometric hot junction for a long time, so that the solidification time of the metal liquid of the 8 geometric hot junction of a casting after filling is prolonged, ductile iron is solidified in a pasty state, the wall thickness of the root of the feeding head is only 5-7mm, after filling is completed, the root is basically solidified before the geometric hot junction is solidified, so that a feeding channel is blocked, gas at the hot junction cannot overflow, and meanwhile, a metal liquid solidification forming body at the geometric hot junction contracts. In this embodiment, the arc center angle between the first feeding head 5 and the geometric heat node adjacent to the casting 8 is 25 degrees, the arc center angle between the second feeding head 6 and the geometric heat node adjacent to the casting 8 is also 25 degrees, the arc center angle between the first feeding head 5 and the motor hole 14 of the casting 8 is greater than the arc center angle between the geometric heat node adjacent to the first feeding head 5 and the motor hole 14 of the casting 8, and the arc center angle between the second feeding head 6 and the motor hole 14 of the casting 8 is greater than the arc center angle between the geometric heat node adjacent to the second feeding head 6 and the motor hole 14 of the casting 7. Fig. 5 is a schematic position diagram of a gating system and a casting 8 in an original casting process, and it can be known through comparison that the two feeding heads and the integral gating system in the casting mold provided in this embodiment are obtained by rotating the feeding head position and the integral gating system of the conventional casting mold counterclockwise by 25 degrees with the flywheel housing center hole axis as a reference point (in a direction away from the motor hole 14), so that after adjustment, preheating of a thermal node when the feeding head neck of the gating system is filled is effectively avoided, that is, indirect formation of a contact thermal node is prevented.
It should be noted that, the design makes full use of the metal mold filling simulation software to find out the reasonable position of the iron liquid mold filling feeding of the ductile iron casting 8 with the structure, and the casting head system can instantaneously supply the iron liquid shrinkage and the first body shrinkage in the casting mold in the process of mold filling and solidification of the casting 8. And (4) closing the riser neck of the hot riser when the ductile iron graphite is expanded after the mold filling is finished, and forming self-feeding by utilizing the expansion of the molten iron graphite. The design of the process system meets the requirements of supplementing molten iron of a hot junction in the flywheel shell of the automobile ductile iron and self-sealing of a riser rib during graphite expansion in the solidification process of the flywheel shell casting 8 by using a casting head process system in the molten iron mold-filling solidification process to the maximum extent, and the hot junction part of the casting 8 is fed by using graphite expansion pressure so as to make foundation prevention for preventing the casting 8 from forming a gas shrinkage cavity defect.
In addition, in the embodiment, the shape-following corresponding chills 7 are designed at two symmetrical geometric hot spot positions of the casting 8, where the shrinkage cavity defect is easily formed, and the chills 7 at the hot spot positions are designed on the second sand make-up core 10 and the fourth sand make-up core 12, that is, the chills 7 are placed in the second placing cavities on the second sand make-up core 10 and the fourth sand make-up core 12. The chiller 7 does not compensate for the shrinkage effect, but the chiller 7 has the effect of transferring the geometric thermal budget of the casting 8. The purpose of placing the chilling block 7 is to move a thermal node which is easy to form shrinkage cavity and shrinkage porosity defect outwards to enable the thermal node to approach the action range of a riser, and the chilling block 7 is utilized to assist in eliminating the shrinkage cavity defect of the ductile iron flywheel shell casting 8 in the casting molding process.
It should be noted that the chiller 7 is conformed to the shape of the geometric hot spot of the casting 8, so as to ensure a sufficient contact surface and thus a cooling effect. Wherein, the contact surface area between the chiller 7 and the adjacent geometric thermal joints is more than 80 percent of the area of the adjacent geometric thermal joints. Meanwhile, the thickness of the chilling block 7 is set in advance, namely, the thick hot spot and the thin wall are guaranteed to be cooled simultaneously through simulation software. In the embodiment, the thickness of the casting chilling block is designed to be 30-35 mm, so that the thin wall and the thick wall of the casting 8 are uniformly solidified at the same time when the ductile iron flywheel shell is filled with molten metal, and the high-quality casting 8 with compact and uniform integral structure is obtained.
FIG. 7 is a schematic flow chart of a casting process for preventing the shrinkage cavity of the ductile iron flywheel housing casting of the automobile engine provided by the embodiment of the application. The casting process comprises the following steps of S101-S106, wherein the specific steps are as follows:
step S101: and (3) taking the upper plane of the flywheel shell as a parting plane, and manufacturing an exterior upper template die 1, an exterior bottom template die 2 and a matched sand box.
Step S102: and manufacturing the hot core box assembly according to the shape of the flywheel shell casting, and manufacturing the required film-coated sand core through the hot core box assembly.
Step S103: and arranging the sand box on the exterior upper template mould 1, adding green sand, compacting and compacting, separating the exterior upper template mould 1, and forming an upper cavity by the sand box and the green sand.
Step S104: and arranging the sand box on the exterior bottom template 2, adding green sand, compacting and compacting, separating the exterior bottom template 2, and forming a lower cavity by the sand box and the green sand.
Step S105: placing the manufactured chilling block in a second placing cavity of the precoated sand core, placing the precoated sand core in a first placing cavity of the green sand lower cavity, arranging the precoated sand core according to the sequence shown in the figure 3, and then butting and clamping the upper cavity and the lower cavity by adopting a positioning long pin to form a cavity.
Specifically, the chills 7 are placed in a second placement chamber above the second sand patch core 10 and the fourth sand patch core 12. After the second sand make-up core 10 and the fourth sand make-up core 12 are placed in the cavity, the chiller 7 is located at the geometric hot spot of the casting 8.
Step S106: and pouring molten iron into the cavity through a pouring system, cooling after pouring, and separating the casting 8 from the molding sand by shaking shakeout to obtain the casting 8.
Specifically, when pouring is carried out, the pouring time is controlled to be 18-22 s, and the temperature of the whole molten iron in the pouring process is guaranteed to meet the pouring requirement. And after the pouring is finished, cooling for 45-60 min to ensure that the casting 8 is completely cooled.
The casting 8 produced by the casting process is verified, dissected and checked through electron microscope examination and pressure test, and no shrinkage cavity defect is found at the thick real part of the casting 8 or other parts of the casting 8. Through a plurality of process verifications, the casting process proves that the defect of the shrinkage cavity of the casting 8 is effectively overcome, and the phenomenon of the casting defect caused by the shrinkage cavity and the shrinkage porosity due to the fluctuation of the chemical components of the molten iron can be avoided.
In addition to the above embodiments, the present invention may have other embodiments; all technical solutions formed by adopting equivalent substitutions or equivalent transformations fall within the protection scope of the claims of the present invention.
Claims (9)
1. The utility model provides a casting mould of prevention automobile engine nodular iron flywheel shell foundry goods gas shrinkage cavity, includes appearance cope match-plate pattern (1), appearance bottom template (2) and the gating system, appearance cope match-plate pattern (1) with appearance bottom template (2) form the die cavity through sand box and the butt joint of green sand carrier, the gating system with the die cavity intercommunication, be provided with in the die cavity and be used for placing the first chamber of placing of tectorial membrane psammitolite, its characterized in that: the gating system comprises a sprue (3), a runner (4) communicated with the sprue (3), and a first feeding head (5) and a second feeding head (6) which are communicated with the runner (4), wherein an arc center angle between the second feeding head (5) and a geometric heat section adjacent to the casting (8) is 25 degrees, and the arc center angle between the second feeding head (6) and the motor hole (14) of the casting (8) is larger than that between the geometric heat section adjacent to the motor hole (14) of the casting (8) and the arc center angle between the motor hole (14) of the casting (8) and the second feeding head (5).
2. The casting mold for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine according to claim 1, wherein: and a second placing cavity for placing a chill (7) is formed in the film-coated sand core.
3. The casting mold for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine according to claim 2, wherein: the chiller (7) is positioned on the casting surface corresponding to the geometric hot spot of the casting (8).
4. The casting mold for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine according to claim 3, wherein: the shape of the chilling block (7) is matched with the shape of a casting surface of an adjacent geometric hot spot.
5. The casting mold for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine according to claim 4, wherein: the area of the contact surface between the chilling block (7) and the adjacent geometric hot joint is more than 80 percent of the area of the adjacent geometric hot joint.
6. The casting mold for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine according to claim 1, wherein: the hot core box assembly comprises a hot core box fixed die and a hot core box movable die which are oppositely arranged, and the hot core box fixed die and the hot core box movable die are butted to form a cavity for manufacturing the coated sand core.
7. The casting process for preventing the shrinkage cavity of the ductile iron flywheel shell casting of the automobile engine is characterized in that: comprises the steps of (a) preparing a mixture of a plurality of raw materials,
manufacturing an exterior upper template mould, an exterior bottom template mould and a matched sand box by taking the upper plane of the flywheel shell as a parting plane;
manufacturing a hot core box assembly according to the shape of the flywheel shell casting, and manufacturing a required film-coated sand core through the hot core box assembly;
arranging the sand box on the exterior upper template mould, adding green sand, compacting by jolting, releasing the exterior upper template mould, and forming an upper cavity by the sand box and the green sand;
arranging the sand box on the exterior bottom template mould, adding green sand, compacting by jolting, releasing the exterior bottom template mould, and forming a lower cavity by the sand box and the green sand;
placing the manufactured chilling block in a second placing cavity of the precoated sand core, placing the precoated sand core in a first placing cavity of the green sand lower cavity, and then butting and clamping the upper cavity and the lower cavity by adopting a positioning long pin to form a cavity;
and pouring molten iron into the cavity through a pouring system, cooling after pouring, and separating the casting from the molding sand by shaking shakeout to obtain the casting.
8. The casting process for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine as claimed in claim 7, wherein: and the cooling time after the pouring is 45-60 min.
9. The casting process for preventing the shrinkage cavity of the ductile iron flywheel casing casting of the automobile engine as claimed in claim 7, wherein: the pouring time is 18-22 s.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210577253.XA CN114850405A (en) | 2022-05-25 | 2022-05-25 | Casting process and casting mold for preventing shrinkage cavity of ductile iron flywheel shell casting of automobile engine |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202210577253.XA CN114850405A (en) | 2022-05-25 | 2022-05-25 | Casting process and casting mold for preventing shrinkage cavity of ductile iron flywheel shell casting of automobile engine |
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