CN114932199B - Casting process of centrifugal double-suction pump - Google Patents
Casting process of centrifugal double-suction pump Download PDFInfo
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- CN114932199B CN114932199B CN202210710629.XA CN202210710629A CN114932199B CN 114932199 B CN114932199 B CN 114932199B CN 202210710629 A CN202210710629 A CN 202210710629A CN 114932199 B CN114932199 B CN 114932199B
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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
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
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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
- B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
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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
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
- B22D31/002—Cleaning, working on castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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Abstract
The invention discloses a casting process of a centrifugal double suction pump, which comprises the steps of establishing a three-dimensional model according to a two-dimensional drawing of a product, and determining that the dimension is qualified by converting the three-dimensional model back to a new two-dimensional drawing and comparing the new two-dimensional drawing with the two-dimensional drawing of the original product; designing a reasonable pouring system and a cold iron placing position by using three-dimensional digital-analog design software, designing a core-in-core scheme, melting and pouring molten iron, and carrying out shakeout treatment; and (5) checking and warehousing, and completing the casting process of the centrifugal double suction pump body through the flow. The 3D sand mould printing process is adopted, so that the model manufacturing period is greatly shortened; placing the inverted anchor of the product upwards, and designing molten iron to enter a cavity from a bottom flange by a pouring system to ensure that the molten iron rises stably; controlling the cooling process of the molten iron by matching with reasonably placed chiller; product quality is guaranteed through multiple operation control points such as core assembly, molten iron pouring, casting cleaning, casting inspection and the like, so that the production period and the production cost of customized products are greatly reduced.
Description
Technical Field
The invention belongs to the technical field of casting of pipe pump valve products, and particularly relates to a casting process of a centrifugal double-suction pump.
Background
The centrifugal double suction pump is an important form of centrifugal pump, and is widely applied in engineering due to the characteristics of high lift, large flow and the like. The pump impeller is actually composed of two back-to-back impellers, and the water flowing out of the impellers is led into a volute. The double suction pump has the following characteristics: the double-flow-rate single-suction impeller is equivalent to that of two single-suction impellers with the same diameter and works simultaneously, and the flow rate can be doubled under the same impeller outer diameter; the pump shell is horizontally opened, so that the inspection and maintenance are convenient, and meanwhile, the inlet and the outlet of the double suction pump are in the same direction and are vertical to the pump shaft, thereby being beneficial to the arrangement and the installation of the pump and the water inlet and outlet pipes; the impeller structure of the double-suction pump is symmetrical, no axial force exists, the operation is stable, in the casting process design process, especially the centrifugal double-suction pump made of ductile iron is subjected to process design, and the sequential solidification of molten metal is realized by designing a riser and a chill, so that the defects of shrinkage cavity, shrinkage cavity and the like are controlled to be reduced or transferred.
At present, a related casting process is manufactured by adopting a wood model or metal model scheme conventionally, a flange surface of a product is generally placed on the side surface so as to facilitate parting and core assembly processes, but the important position of the centrifugal double-suction pump product is the flange surface, and the flange is placed on the side surface, so that the following problems are caused:
1. the chill cannot be placed normally;
2. the core head counterweight which is as large as the inner cavity of the product is needed to avoid the tilting of the cantilever core, and the sand iron of the product is higher;
3. the feeding area of the riser is too large, a larger riser is required for feeding, and the product yield is low;
4. the model engraving period is longer;
5. the cost is too high for custom products.
Disclosure of Invention
The invention aims to provide a casting process of a centrifugal double-suction pump, which aims to solve the problems that in the prior art, a flange surface of a product is generally placed on the side surface in the use process so as to facilitate parting and core assembly, but the important position of the centrifugal double-suction pump product is the flange surface, and the flange is placed on the side surface, so that the problems of the following aspects are solved: the chill cannot be placed normally; the core head counterweight which is as large as the inner cavity of the product is needed to avoid the tilting of the cantilever core, and the sand iron of the product is higher; the feeding area of the riser is too large, a larger riser is required for feeding, and the product yield is low; the model engraving period is longer; and the cost of the customized product is too high.
In order to achieve the above purpose, the present invention provides the following technical solutions: a casting process of a centrifugal double suction pump comprises the following steps:
s1, digital-to-analog conversion:
converting the required product two-dimensional drawing into a product three-dimensional model by using three-dimensional modeling software, converting and comparing the converted three-dimensional model with the original product two-dimensional drawing in a 1:1 view, and completing digital-analog conversion and inspection qualification after confirming that the sizes and shapes of all views are completely consistent with the original product drawing;
s2, designing a pouring system and arranging chill:
firstly analyzing the structure of a product, particularly paying attention to the thick and large structure of the product and the relatively important processing surface, placing the relatively important processing surface in a process lower box, further setting the positions of a feeding riser and an exhaust riser according to the basic principle of riser design in casting process design and the design experience of similar products, further placing a chill at the position where the riser cannot be fed back and the important processing position so as to control the solidification sequence of molten metal, further selecting a bottom pouring mode for ensuring the stable flow of the molten metal, then simulating the molten metal filling and solidification process by using casting simulation software, adjusting the positions and the sizes of the riser and the chill according to the simulation result, and further circularly simulating and adjusting the process until the simulation result meets the product quality requirement so as to finish casting system and chiller arrangement;
s3, core package core separation:
1. firstly, ensuring that the sand feeding amount of the outer side of the combined overall outline of the product and the pouring system and the chill designed in the above is required to be not less than 100mm, adjusting and increasing the sand feeding amount according to the local thickness of the overall combined outline so as to ensure the overall strength of the core package, and performing Boolean operation on the designed solid core package and the combined overall outline to obtain a hollow core package;
2. the method is characterized in that the complete opening of the cross gate in the pouring system is required to be ensured, and no sight shielding is ensured when sand cleaning work is carried out, namely, core separation is carried out for the first time at the bottom surfaces of the cross gate and the product casting; the secondary core separation is carried out without shielding of sight lines when sand cleaning work is carried out in each place in the cavity; the third core separation of the separated sand cores from the interference combination in the positive Z axis or Y axis direction is required to be ensured; according to the size limitation of the printing box of the 3D printing, the sand cores which do not meet the size limitation are subjected to fourth core separation; performing fifth core separation according to the requirement that the weight of the single sand core does not exceed the safety weight; marking sand core numbers on the sand cores according to the sequence of arranging the core groups in the integral parting process; core-in-core separation is completed immediately;
s4, sand core combination:
assembling the sand cores with the printing, sand cleaning, applying, surface drying, cold iron placing and other procedures according to the designed sequence in the core separating scheme, confirming that the clearance fit among the sand cores is reasonable, and then fastening the whole core package and the independent sand cores;
s5, smelting and casting:
according to the material requirements of the product, the raw materials are sent into a melting furnace to be melted into molten metal, then spheroidizing agent, inoculant and alloy are added to carry out modification treatment to obtain molten metal meeting the product requirements, and the molten metal flows into a core-dividing core-wrapping cavity through a pouring cup until a riser is full of the molten metal, thus completing pouring;
s6, sand removal, inspection:
and when the metal liquid is completely solidified and the surface temperature is proper, forming a product casting, taking out the core-covered broken and separated sand core, taking out the casting, performing a rough cleaning process to remove the skin seam formed by the redundant pouring system and the core-covered gap, performing annealing treatment in a heat treatment process, removing impurities such as surface oxide skin in a shot blasting process, performing fine surface treatment in a fine cleaning process, detecting the quality of the casting in a detection process, and completing the detection work after all the detection is qualified.
Preferably, in step S2, the placement positions of the chills are that the positions of the chills are placed and arranged in a circular flange portion by adopting a properly sized chiller to make equidistant circumferential arrays at a distance of 20-40mm from the outer circle of the flange, the placement of the chills is performed at a distance larger than the radial distance of the chills, the other chills with regular flanges with similar shapes are similarly arranged in equidistant manner, and the placement flanges with irregular shapes are used for placing the chills according to actual conditions.
Preferably, in step S2, a sprue is selected: and (3) a cross gate: the proportion of the inner pouring gate is 1 (1.2-2): (1.2-2) an open casting system.
Preferably, in step S4, the fastening is designed to use external force such as channel steel, square steel, screw rod or sand box sleeved and resin sand poured to ensure that the combined core package will not undergo dimensional deviation such as displacement when expanding in the process of metal liquid impact and solidification.
Preferably, in step S5, the raw material is one or a combination of more of pig iron, recycled iron, industrial offal and alloy.
Preferably, in step S6, the inspection process includes measuring the size and appearance of the casting, and performing physicochemical detection on the metallographic phase, tensile strength, elongation and the like of the product casting.
Compared with the prior art, the invention has the beneficial effects that:
1. according to the casting process, a 3D sand mould printing process is adopted, so that the model manufacturing period is greatly shortened; placing the inverted anchor of the product upwards, and designing molten iron to enter a cavity from a bottom flange by a pouring system to ensure that the molten iron rises stably; controlling the cooling process of the molten iron by matching with reasonably placed chiller; product quality is guaranteed through multiple operation control points such as core assembly, molten iron pouring, casting cleaning, casting inspection and the like, so that the production period and the production cost of customized products are greatly reduced.
Drawings
FIG. 1 is an overall schematic of a product casting, pouring system and chiller of the present invention;
FIG. 2 is a schematic illustration of a split core package of the present invention.
In the figure: 1. riser; 2. a flange; 3. a chill; 4. casting products; 5. a sprue; 6. a cross gate; 7. an inner runner; 8. core-separating core bags; 9. a pouring cup.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. 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.
Example 1
Referring to fig. 1-2, the present invention provides a technical solution: a casting process of a centrifugal double suction pump comprises the following steps:
s1, digital-to-analog conversion:
converting the required product two-dimensional drawing into a product three-dimensional model by using three-dimensional modeling software, converting and comparing the converted three-dimensional model with the original product two-dimensional drawing in a 1:1 view, and completing digital-analog conversion and inspection qualification after confirming that the sizes and shapes of all views are completely consistent with the original product drawing;
s2, designing a pouring system and arranging chill 3:
firstly analyzing the structure of a product, particularly paying attention to the thick and large structure of the product and the relatively important processing surface, placing the relatively important processing surface in a process lower box, further setting the positions of a feeding riser 1 and an exhaust riser 1 according to the basic principle of riser 1 design in casting process design and the design experience of similar products, further placing a chill 3 at the position where the riser 1 cannot be fed and the important processing position so as to control the solidification sequence of molten metal, adopting a circular flange 2 part to adopt a proper size chill 3 to make equidistant circumferential array placement and arrangement of the chill 3 at a distance of 20-40mm from the outer circle of the flange 2, adopting equidistant arrangement of the other similar shape regular flange 2 chills 3, placing the chill 3 at an irregular shape position according to actual conditions, further selecting a bottom pouring mode for ensuring the stable flow of the molten metal, and selecting a sprue 5: cross gate 6: the proportion of the inner pouring gate 7 is 1 (1.2-2): the open pouring system of (1.2-2), then the casting simulation software is required to simulate the molten metal filling and solidifying process, the positions and the sizes of the riser 1 and the chill 3 are adjusted according to the simulation result, and the simulation and adjustment process is further circulated until the simulation result meets the product quality requirement, namely the pouring system and the chill 3 are distributed;
s3, core package core separation:
1. firstly, ensuring that the sand feeding amount of the outer side of the combined overall outline of the product, the pouring system designed in the above and the chill 3 is required to be not less than 100mm, and on the premise that the sand feeding amount is required to be not less than 100mm, adjusting and increasing the sand feeding amount according to the local thickness of the overall combined outline to ensure the overall strength of the core package, and then carrying out Boolean operation on the designed solid core package and the combined overall outline to obtain a hollow core package;
2. the complete opening of the cross gate 6 in the pouring system is required to be ensured, and no sight shielding is ensured when sand cleaning work is carried out, namely, the first core separation is carried out at the bottom surfaces of the cross gate 6 and the product casting 4; the secondary core separation is carried out without shielding of sight lines when sand cleaning work is carried out in each place in the cavity; the third core separation of the separated sand cores from the interference combination in the positive Z axis or Y axis direction is required to be ensured; according to the size limitation of the printing box of the 3D printing, the sand cores which do not meet the size limitation are subjected to fourth core separation; performing fifth core separation according to the requirement that the weight of the single sand core does not exceed the safety weight; marking sand core numbers on the sand cores according to the sequence of arranging the core groups in the integral parting process; taking the strength of the integral core package, the influence of factors such as the buoyancy of the molten metal, the solidification expansion force of the molten metal and the like into consideration, the integral core package and the independent sand core are required to be fastened, so that the local displacement of the combined core package is avoided, and the core package core separation is completed immediately;
s4, sand core combination:
assembling sand cores after finishing the procedures of printing, sand cleaning, applying, surface drying, placing chill 3 and the like according to the designed sequence in a core separating scheme, confirming that clearance fit among the sand cores is reasonable, fastening and designing the whole core package and the independent sand cores, and ensuring that the combined core package cannot generate dimensional deviations such as displacement and the like when expanding in the metal liquid impact and solidification process by using external forces such as channel steel, square steel, screw rods or embedding sand boxes and pouring resin sand;
s5, smelting and casting:
according to the material requirements of the product, the mixed raw materials of pig iron, return iron, industrial leftovers and alloy are sent into a melting furnace to be melted into molten metal, then spheroidizing agent, inoculant and alloy are added to carry out modification treatment to obtain molten metal meeting the product requirements, and the molten metal flows into the cavity of the split core package 8 through the pouring cup 9 until the riser 1 is full of the molten metal, thus completing pouring;
s6, sand removal, inspection:
and when the metal liquid is completely solidified and the surface temperature is proper, forming a product casting 4, taking out the core-covered broken separated sand core, taking out the casting, performing a rough cleaning process to remove the skin seam formed by the redundant pouring system and the core-covered gap, performing annealing treatment in a heat treatment process, removing impurities such as surface oxide skin in a shot blasting process, performing fine surface treatment in a fine cleaning process, measuring the size and appearance of the casting in a testing process, performing physicochemical detection such as metallographic phase, tensile strength and elongation of the product casting 4, and completing the testing work after confirming that all the detection is qualified.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (6)
1. A casting process of a centrifugal double suction pump is characterized in that: the method comprises the following steps:
s1, digital-to-analog conversion:
converting the required product two-dimensional drawing into a product three-dimensional model by using three-dimensional modeling software, converting and comparing the converted three-dimensional model with the original product two-dimensional drawing in a 1:1 view, and completing digital-analog conversion and inspection qualification after confirming that the sizes and shapes of all views are completely consistent with the original product drawing;
s2, designing a pouring system and arranging a chiller (3):
firstly analyzing a product structure, placing an important processing surface in a process lower box, further setting the positions of a feeding riser (1) and an exhaust riser (1) according to the basic principle of riser (1) design in casting process design and the design experience of similar products, further placing a chill (3) at a position where the riser (1) cannot be fed and the important processing position so as to control the solidification sequence of molten metal, further selecting a bottom pouring mode for ensuring the stable flow of the molten metal, then simulating the filling and solidification processes of the molten metal by using casting simulation software, adjusting the positions and the sizes of the riser (1) and the chill (3) according to simulation results, and further circularly simulating and adjusting the processes until the simulation results meet the product quality requirements so as to finish pouring system and chiller (3) arrangement;
s3, core package core separation:
s31, firstly, ensuring sand consumption of the outer side of the combined overall profile of the product and the pouring system and the chill (3) designed in the steps, and on the premise that the sand consumption is not less than 100mm, adjusting and increasing the sand consumption according to the local thickness of the overall combined profile to ensure the overall strength of the core package, and then carrying out Boolean operation on the designed solid core package and the combined overall profile to obtain a hollow core package;
s32, ensuring that the cross gate (6) in the pouring system is completely opened, and ensuring that no sight shielding exists when sand cleaning work is carried out, namely, carrying out primary core separation at the bottom surfaces of the cross gate (6) and the product casting (4); the secondary core separation is carried out without shielding of sight lines when sand cleaning work is carried out in each place in the cavity; the third core separation of the separated sand cores from the interference combination in the positive Z axis or Y axis direction is required to be ensured; according to the size limitation of the printing box of the 3D printing, the sand cores which do not meet the size limitation are subjected to fourth core separation; performing fifth core separation according to the requirement that the weight of the single sand core does not exceed the safety weight; marking sand core numbers on the sand cores according to the sequence of arranging the core groups in the integral parting process; core-in-core separation is completed immediately;
s4, sand core combination:
assembling sand cores with the procedures of printing, sand cleaning, applying, surface drying, cold iron (3) placing and the like according to the designed sequence in the core separating scheme, confirming that clearance fit among the sand cores is reasonable, and then fastening and designing the whole core package and the independent sand cores;
s5, smelting and casting:
according to the material requirements of the product, the raw materials are sent into a melting furnace to be melted into molten metal, then spheroidizing agent, inoculant and alloy are added to carry out modification treatment to obtain molten metal meeting the product requirements, and the molten metal flows into a cavity of a core-splitting core package (8) through a pouring cup (9) until a riser (1) is full of the molten metal, and then pouring is completed;
s6, sand removal, inspection:
and (3) forming a product casting (4) when the metal liquid is completely solidified and the surface temperature is proper, taking out the core-covered broken and separated sand core from the casting, performing a rough cleaning process to remove the skin seam formed by the redundant pouring system and the core-covered gap, performing annealing treatment by a heat treatment process, removing surface impurities by a shot blasting process, performing fine surface treatment by a fine cleaning process, detecting the quality of the casting by a detection process, and completing the detection work after all the detection is qualified.
2. The casting process of the centrifugal double suction pump according to claim 1, wherein: in the step S2, the placement position of the chill (3) is that the appropriate size of the chill (3) is adopted at the part of the circular flange (2), and the equally-spaced circumferential array placement of the chill (3) is carried out at a distance of 20-40mm from the outer circle of the flange (2) at a distance larger than the radius distance of the chill (3).
3. The casting process of the centrifugal double suction pump according to claim 1, wherein: in the step S2, a sprue (5) is selected: cross gate (6): the proportion of the inner pouring gate (7) is 1 (1.2-2): (1.2-2).
4. The casting process of the centrifugal double suction pump according to claim 1, wherein: in the step S4, the fastening design is that channel steel, square steel, a screw rod or a sand box is sleeved in and resin sand is poured in, and the combined core package is ensured not to have dimensional deviation when expanding in the process of metal liquid impact and solidification by using the action of external force.
5. The casting process of the centrifugal double suction pump according to claim 1, wherein: in the step S5, the raw materials are one or a combination of more of pig iron, recycled iron, industrial offcuts and alloys.
6. The casting process of the centrifugal double suction pump according to claim 1, wherein: in step S6, the inspection process comprises measuring the size and appearance of the casting, and simultaneously carrying out physicochemical detection on the product casting (4).
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| CN116851726B (en) * | 2023-09-04 | 2023-11-24 | 泊头市亚奇铸业有限公司 | Casting device and process of compressor shell |
| CN117505776B (en) * | 2024-01-05 | 2024-04-16 | 烟台冰轮智能机械科技有限公司 | Casting process of centrifugal compressor base |
| CN117773059A (en) * | 2024-01-18 | 2024-03-29 | 烟台冰轮智能机械科技有限公司 | Naked casting manufacturing process of cylinder cover |
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