CN115041634B - Casting method of wind power planet carrier casting - Google Patents
Casting method of wind power planet carrier casting Download PDFInfo
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- CN115041634B CN115041634B CN202210309185.9A CN202210309185A CN115041634B CN 115041634 B CN115041634 B CN 115041634B CN 202210309185 A CN202210309185 A CN 202210309185A CN 115041634 B CN115041634 B CN 115041634B
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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
- 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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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C1/00—Refining of pig-iron; Cast iron
- C21C1/10—Making spheroidal graphite cast-iron
- C21C1/105—Nodularising additive agents
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/08—Making cast-iron alloys
- C22C33/10—Making cast-iron alloys including procedures for adding magnesium
- C22C33/12—Making cast-iron alloys including procedures for adding magnesium by fluidised injection
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
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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
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Abstract
A casting method of a wind power planet carrier casting comprises the following steps: firstly, casting resin sand according to the structure of a planet carrier casting to form a casting system; adding the molten iron raw material into a smelting furnace to be melted to obtain a raw molten iron; then adopting a flushing method to spheroidize, firstly adding a spheroidizing agent into a spheroidizing dyke at one side of a spheroidizing ladle, compacting, then adding an inoculant with the particle size of 3-8mm, compacting, and finally adding 0.004-0.005% of pure antimony by mass of the raw iron liquid and 0.4-0.6% of electrolytic copper by mass of the raw iron liquid; then, carrying out slag skimming and standing on the obtained molten iron, and pouring the molten iron into a casting system when the temperature of the molten iron is reduced to 1310-1370 ℃ so as to form a casting; performing stream inoculation by using inoculation powder while pouring, wherein the addition amount of the inoculation powder is 0.1-0.12% of the total weight of the raw iron liquid; and after the casting is cooled, the planet carrier casting is obtained. The method has the advantages that casting defects such as shrinkage cavities, shrinkage porosity and the like can not occur, and the yield of castings is greatly improved.
Description
Technical Field
The application relates to the technical field of wind power planet carrier castings, in particular to a casting method of a wind power planet carrier casting.
Background
Wind energy is a renewable pollution-free clean energy source, and is valued by various countries, and the powerful development of wind energy is a reliable way for solving the production and living energy sources, so that the world wind power industry is rapidly developed, and in recent years, the wind power industry is more in the first place of various new energy sources with higher speed increasing position. With the rapid development of the wind power industry, the requirements of wind power ductile iron accessories are rapidly increased, the ductile iron for wind power is rapidly developed, and the ductile iron is widely applied at home and abroad due to low cost and high toughness, but compared with common ductile iron, the requirements on the quality and the performance of wind power castings are higher, and the requirements on the quality and the service performance of the wind power castings are higher due to the severe working environment and the difficult maintenance of the wind power units.
With the rapid development of the wind power industry, the requirements of wind power ductile iron accessories are rapidly increased, the ductile iron for wind power is rapidly developed, and the ductile iron is widely applied at home and abroad due to low cost and high toughness, but compared with common ductile iron, the requirements on the quality and the performance of wind power castings are higher, and the requirements on the quality and the service performance of the wind power castings are higher due to the severe working environment and the difficult maintenance of the wind power units. The planet carrier product is used as an important component for the wind generating set, and the quality of the planet carrier product directly influences the service life of the whole generating set. Taking a SYZ15 planet carrier as an example, a casting product is shown in fig. 1, the structure of the casting product mainly comprises a casting body 1', the casting body is composed of a long shaft part 101', a column part 102' and a short shaft part 103' which are sequentially connected along the axial direction, wherein the two axial ends of the column part are provided with an upper web plate and a lower web plate or called an upper flange plate and a lower flange plate (the upper web plate is close to the short shaft part, the lower web plate is close to the long shaft part, the short shaft part is positioned on the upper flange plate and the long shaft part is positioned on the lower flange plate), the upper web plate and the lower web plate are provided with shaft pin holes 14' (shaft pin holes positioned on the upper web plate are through holes, the shaft pin holes positioned on the lower web plate are counter bores, and small cold irons are arranged in the shaft pin holes in the counter bores; 2400Kg of product blank weight and 2650Kg of casting weight are required to be extremely high, and casting defects such as shrinkage cavities, shrinkage porosity and the like are not allowed, wherein the casting weight is 2650Kg, the material is spheroidal graphite cast iron QT700-2, the external dimension phi 1156mm multiplied by 1195mm, the maximum wall thickness is 110mm, and the minimum wall thickness is 20 mm.
The whole planet carrier casting belongs to a frame structure, molten iron in a casting mold is not very stable in mold filling, defects such as oxide slag, air holes and the like are easy to generate, slag inclusion is the most common defect when spheroidal graphite cast iron is produced, the slag inclusion defect is mostly generated on the upper plane or the upper surface part of a core of the casting, the mechanical property of the casting is seriously influenced, particularly the toughness and the yield strength are easy to cause cracks or cracking; the heat joints of the frame structure casting are isolated, dispersed and more, the heat joints are not independent, but the heat joints of the long shaft root and the long shaft radials are mutually overlapped and connected together, so that the heat joints cannot be eliminated from unilateral reinforced chilling, the elimination of one heat joint can cause the blockage of solidification feeding of the other heat joint, and the acquisition of a compact tissue is difficult; the ultrasonic flaw detection method comprises the steps of 100% ultrasonic flaw detection and 100% magnetic powder flaw detection, wherein the long shaft, the short shaft and the upright post of a planet carrier are in accordance with the level 01 requirement of EN 12680-3 standard, all other parts of a planet carrier main body are in accordance with the level 1 requirement of EN 1268-3 standard, the magnetic powder flaw detection is in accordance with the level 2 requirement of EN 1369 standard, and the welding repair is not allowed, so that the production and manufacturing difficulties are quite large.
Therefore, it is necessary to design a method for casting a carrier that is free from casting defects such as shrinkage cavities and shrinkage porosity.
Disclosure of Invention
The application provides a casting method of a wind power planet carrier casting, which can not generate shrinkage cavity, shrinkage porosity and other casting defects and greatly improves the casting yield.
In order to solve the technical problems, the application adopts the following technical scheme: a casting method of a wind power planet carrier casting comprises the following steps:
(1) Firstly, casting resin sand according to the structure of a planet carrier casting to form a casting system;
(2) Preparing molten iron: weighing the following raw materials in percentage by mass: 40-60% of pig iron, 40-50% of scrap steel, 0-20% of return furnace material and silicon carbide: 0.7 to 0.9 percent of the total mass of pig iron, scrap steel and returned furnace materials; carburant: 0.9 to 1.2 percent of the total mass of pig iron, scrap steel and returned furnace materials;
all silicon carbide, pig iron, scrap steel and return furnace materials are put into a smelting furnace, and carburant is added in the middle of charging; heating to melt furnace burden, adding FeMn65 ferromanganese and FeSi75 ferrosilicon after the furnace burden is melted, wherein the addition amount of ferromanganese is 0.3-0.5% of the total mass of pig iron, scrap steel and returned furnace burden, and the addition amount of ferrosilicon is 0.3-0.6% of the total mass of pig iron, scrap steel and returned furnace burden, and then obtaining raw iron liquid;
Continuously heating the raw iron liquid to 1440-1500 ℃, wherein the raw iron liquid comprises the components of, by mass, 3.70-3.90% of C, 1.0-1.2% of Si, 0.35-0.45% of Mn, less than or equal to 0.025% of P, less than or equal to 0.025% of S, and the balance of iron;
(3) Spheroidizing by adopting a pouring method, adding a spheroidizing agent into a spheroidizing dyke at one side of a spheroidizing ladle, compacting, adding an inoculant with the particle size of 3-8mm, compacting, and finally adding 0.004-0.005% of pure antimony by mass of the raw iron liquid and 0.4-0.6% of electrolytic copper by mass of the raw iron liquid; controlling the detonation time of the spheroidizing reaction and the duration of the magnesium explosion reaction, and starting the detonation reaction when the iron yield reaches 70% -80% of the spheroidizing treatment iron liquid amount, wherein the duration of the magnesium explosion reaction is 90-120 s;
the components and mass percentages of the obtained molten iron after spheroidization and inoculation are as follows: 3.55 to 3.75 percent of C, 1.95 to 2.10 percent of Si, 0.35 to 0.45 percent of Mn, less than or equal to 0.025 percent of P, 0.008 to 0.012 percent of S, 0.025 to 0.038 percent of Mg, 0.002 to 0.005 percent of RE (rare earth), 0.003 to 0.005 percent of Sb, 4.20 to 4.40 percent of CE=and the balance of iron;
(4) Slag skimming and standing are carried out on the molten iron obtained in the step (3), and when the temperature of the molten iron is reduced to 1310-1370 ℃, the molten iron is poured into a casting system to form a casting; performing stream inoculation by using inoculation powder while pouring, wherein the addition amount of the inoculation powder is 0.1-0.12% of the total weight of the raw iron liquid; and after the casting is cooled, the planet carrier casting is obtained.
Preferably, the silicon carbide in the step (2) is an element mass percentage: siC is more than or equal to 85%, si is more than or equal to 60%, C is more than or equal to 25%, S is 0.02% -0.05%, and the granularity is 1-5mm, such as silicon carbide produced by Anhui Jiuhua Fukang Metallurgical materials Co.
Preferably, the carburant in the step (2) is an element in mass percent: c is more than or equal to 98%, S is less than or equal to 0.05%, N is less than or equal to 0.01%, ash (ash) is less than or equal to 0.3%, volatile matters (volatile matters) are less than or equal to 0.3%, and granularity is 0.5-3mm, such as DC series carburant (DC- (1-4) carburant produced by Danchen industry (Shanghai) Limited company.
Preferably, the spheroidizing agent in the step (3) is a rare earth magnesium alloy: 5.5 to 6.0 percent of Mg, 0.4 to 0.6 percent of RE, 42 to 46 percent of Si, less than or equal to 1.0 percent of Ca, less than or equal to 0.6 percent of Al, less than or equal to 0.40 percent of MgO and the balance of Fe.
Preferably, the inoculant in the step (3) is a silicon-barium inoculant, and the element mass percentages are as follows: 71 to 73 percent of Si, 0.7 to 1.3 percent of Ca, 1.6 to 2.4 percent of Ba, less than or equal to 1.2 percent of Al, less than or equal to 0.02 percent of S and the balance of iron.
Preferably, the adding amount of the nodulizer in the step (3) is 0.9-1.15% of the total amount of the raw iron liquid; the addition amount of the inoculant is 0.6-0.8% of the mass of the original iron liquid.
Preferably, the inoculating powder in the step (4) is a silicon-barium inoculant, and the mass percentages of the elements are as follows: 71 to 73 percent of Si, 0.7 to 1.3 percent of Ca, 1.6 to 2.4 percent of Ba, less than or equal to 1.2 percent of Al, less than or equal to 0.02 percent of S and the balance of iron.
Further, the casting system comprises a casting cavity and a pouring system which are communicated with each other; the pouring system comprises a sprue, a cross runner and an inner runner; the sprue is vertically communicated with the transverse runner, and the inner runner is vertically communicated with the transverse runner; the horizontal pouring gate is further provided with a transition pouring gate, the transition pouring gate comprises a first group of transition pouring gates and a second group of transition pouring gates, the first group of transition pouring gates and the second group of transition pouring gates are respectively arranged at two ends of the horizontal pouring gate, and the first group of transition pouring gates and the second group of transition pouring gates are communicated with inner pouring gates.
By adopting the structure, the number of the inlets for molten iron to enter the casting cavity is increased through the arrangement of the two groups of transition pouring channels, so that the molten iron is ensured to enter the cavity more uniformly and stably, the floating of molten iron slag is facilitated, the molten iron is also facilitated to enter the cavity more stably, and the generation of oxidized slag inclusion is reduced; the speed that the molten iron got into foundry goods die cavity is slowed down through setting up of two sets of transition runner to this application to can effectually reduce and control the turbulent flow of molten iron, improve yield and the casting quality of foundry goods.
Further, the casting cavity comprises a long shaft part, a stand column part and a short shaft part which are axially and sequentially connected, and the stand column part is provided with a shaft pin hole; the inner runner is communicated with the end part of the long shaft part; by adopting the structure, the casting mold can ensure that the molten iron is gradually filled into the whole mold cavity from the bottom of the casting mold cavity, and the casting defect is reduced.
Further, the first group of transition pouring gates or the second group of transition pouring gates comprise a large transition pouring gate positioned at the upper part and a small transition pouring gate positioned at the lower part, two small transition pouring gates are arranged, and each small transition pouring gate is communicated with one inner pouring gate; by adopting the technical scheme, two ingates can be communicated on each group of transition pouring channels, and the arrangement of four ingates can be realized altogether, so that the stability of molten iron entering castings is effectively improved.
Further, a foam filter (silicon carbide foam filter) is arranged between the large transition runner and the small transition runner positioned at the lower part, and two ends of the cross runner are respectively communicated with the foam filter; by adopting the structure, the iron slag in the molten iron can be effectively filtered, the entering of castings is avoided, and the casting quality of the castings is improved; in addition, in order to prevent the foam filter from deforming or crushing under the dual action of high-temperature molten iron and hot air flow impact, the small transition pouring gate adopts a two-block design, the foam filter is supported by molding sand between the blocks, and meanwhile, each small pouring gate is respectively connected with the inner pouring gate, so that the floating of molten iron slag is facilitated, the molten iron can enter the cavity more stably, and the generation of oxidized slag inclusion is reduced.
Further, the cross runner is arranged in an arc shape, and the bending radian of the arc shape is matched with the outer diameter of the long shaft part; by adopting the structure, molten iron can be guided to enter the casting cavity in an arc shape, so that the obstruction of the molten iron in the flowing process is reduced, and the occurrence of turbulent flow of the molten iron is avoided.
Further, a short ingate and a long ingate are respectively communicated with the two small transitional runners, and the short ingate is positioned at the inner side of the long ingate; by adopting the structure, the molten iron can be effectively and uniformly distributed at the inlet of the casting cavity.
Further, the sprue is provided with a first bending part and a second bending part, and the first bending part and the second bending part are in transitional connection through a transverse transitional runner; adopt this structure, mainly cooperate the foundry goods structure of this application, because foundry goods length is longer in axial direction, adopt foretell kink structure can ensure the quick full state of sprue part, the setting of kink at the back can reduce the production of molten iron oxidation slag inclusion thing and slow down and fill type velocity of flow, improves the stationarity that molten iron got into foundry goods die cavity.
Furthermore, the height of the sprue above the first bending part is 400-700 mm, and by adopting the structure, the distribution of all parts of the sprue can be effectively distributed.
Further, the upper end face of the large transition runner is 20-30 mm higher than the upper end face of the cross runner; by adopting the structure, the iron slag in the molten iron can be effectively trapped and floated, and the probability of entering the casting cavity is reduced.
Further, the vertical distance that the ingate that this application described gets into foundry goods die cavity is 60-130mm, the height of that section of vertical direction between ingate and the foundry goods die cavity promptly, adopts this structure, can effectually reduce the speed that the molten iron got into foundry goods die cavity and to the impact force of type chamber to the integrality of protection die cavity prevents molten iron slag inclusion.
Further, each main casting unit is provided withThe ratio of the total cross-sectional area (cross-sectional area of each component) is: sigma and method for producing the same A straight pouring gate ∶Σ A horizontal pouring gate ∶Σ A inner pouring channel ＝1∶1.3～1.4∶1.1～1.2。
Further, an exothermic riser and a riser strain relief are arranged on the end face of the short shaft part, and the riser strain relief is positioned at the upper part of the exothermic riser; the setting of this structure can cancel the shaping chill of original minor axis hole to the work load of placing and surperficial chill imprinting polishing when having reduced the preparation of chill, molding has directly reduced manufacturing cost, simultaneously in order to avoid the influence of chill to molten iron quality.
Further, the outer edges of the large filtering pouring gate and the small filtering pouring gate are retracted inwards by 8 mm-12 mm relative to the outer edge of the foam filter; namely, each outer side edge of the large transition pouring gate and each outer side edge of the small transition pouring gate are retracted inwards by 8-12 mm relative to each outer side edge of the foam filter, the structure can provide a larger contact area between the sand mould and the filter, the supporting effect of the molding sand on the foam filter is enhanced, and the foam filter is prevented from being displaced in the pouring process.
Further, the outer side of the long shaft part is coated with a first chill, and the inner cavity of the long shaft part is filled with a sand core; the outer side of the short shaft part is provided with a second chill, and a third chill is arranged in the shaft pin hole; the first chill is composed of a plurality of large chill blocks with the axial length equal to that of the long shaft part, the second chill is composed of a plurality of small chill blocks, and the sand core comprises a steel pipe core bar and a sand layer coated on the outer side surface of the steel pipe core bar.
By adopting the structure, the sand core structure formed by the steel pipe core bars and the sand layer coated on the outer side surfaces of the steel pipe core bars is adopted, so that the sand core and the direct chill in the inner cavity of the original long shaft part are canceled, the workload of manufacturing the chill, placing the chill during core manufacturing and imprinting and polishing the inner hole part is reduced, the production cost is directly reduced, and meanwhile, the influence of the direct chill on the quality of molten iron is avoided; the strength of the sand core can be enhanced by arranging the steel pipe core bars, and the weight of the whole sand core can be reduced; according to the method, the large chilling block with the length equal to that of the long shaft part is arranged on the outer side of the long shaft part to replace the structure of the traditional small chilling block, so that gaps are reduced, and the surface of a casting is smoother; and because the gap is formed between large chill blocks, the gap can form compact molding sand through the dead weight of sand and the sand plugs in two directions (axial direction and radial direction), and the situation that the sand plugs in the chill gap are not compact and shrinkage cavity shrinkage porosity defects occur at the chill gap position caused by multiple gaps and narrow gaps formed by a plurality of small chill blocks in the prior art can not occur.
Further, the third chill is in a hollow cylinder shape, the outer side surface of the hollow cylinder-shaped third chill is provided with a plurality of sand hanging grooves, and the sand hanging grooves are recessed inwards along the radial direction of the side wall of the third chill; by adopting the structure, the chill can be better fixed in the molding sand through the hollow center hole of the third chill and the sand hanging groove, and the problem that the small indirect chill is shifted or falls off under the impact of high-temperature molten iron and heat waves is prevented.
Furthermore, the steel tube core bar is arranged in a hollow mode, sand blocks or dry sand are filled in the hollow position, and an air outlet rope or a refractory porcelain tube is led out of the hollow position; the hollow position is filled with sand blocks or dry sand, so that the rapid increase of the molten iron for pouring caused by the leakage of the molten iron into the hollow inner cavity of the steel tube core bar can be prevented, the risk of scrapping products is reduced, and the sand blocks or dry sand are arranged in the hollow position and do not influence the discharge of air; through arranging the air outlet rope or the fire-resistant porcelain tube in the hollow position, air in the steel tube (the air expansion in the steel tube is easily caused by high temperature of molten iron pouring) is directly led out from the upper box through the pre-discharged air outlet rope (such as the air outlet rope produced by the Changxing pond fire-resistant material company) in the casting mould or the pre-buried fire-resistant porcelain tube or the hollow channel in the casting mould, so that potential safety hazards are avoided, and the cooling efficiency of the molten iron at the position is improved; with the structure, when molten iron is poured, the ignition is carried out, and hot gas in the steel pipe is led out by burning air, so that the casting is chilled.
Further, the steel tube core bar is provided with an axial opening at one end and a bottom plate at the other end, and the opening is downwards arranged; by adopting the structure, the risk that molten iron enters the steel tube core bar can be reduced.
Further, a plurality of steel bars are arranged on the outer side wall of the steel tube core bar, and extend along the axial direction of the outer side wall of the steel tube core bar; by adopting the structure, the sand outside the steel pipe can be better wrapped on the steel pipe, and the problem that the sand pressed outside the steel pipe falls off due to the impact of high-temperature molten iron and heat waves is prevented.
Furthermore, a hanging shaft round steel is arranged on the steel tube core bar; by adopting the structure, the lifting movement of the steel pipe can be facilitated, and the lifting shaft round steel is particularly welded on the inner hole of the steel pipe in a perforation way.
The application has the advantages and beneficial effects that:
1. according to the casting method, the casting belongs to the large-section spheroidal graphite cast iron, and the cooling speed is low, so that the heat capacity is high during casting, the solidification is slow, and spheroidization degradation and inoculation degradation are extremely easy to cause, so that the structure and the matrix of the casting are changed, and particularly the core of the casting is more serious; the main manifestation is that the graphite nodules are coarse, the quantity of the graphite nodules is reduced, the graphite floats, the graphite nodules generate distortion to form various non-spherical graphite, and the non-spherical graphite mainly comprises flaky, vermiform, broken blocks and the like; meanwhile, serious element segregation, a series of problems such as intergranular carbide, a blush mouth and the like can occur due to redistribution of solute elements during solidification, and as a result, the mechanical properties of the spheroidal graphite cast iron are deteriorated, and particularly the elongation and the plasticity are obviously reduced; in order to overcome the defects, various elements and the dosage of the molten iron are specifically set, so that the defects of the prior art are effectively overcome, and the obtained casting is free from casting defects such as shrinkage cavities, shrinkage porosity and the like.
2. The casting method is completed by controlling the duration of the magnesium explosion reaction within 90-120 s, so that the absorptivity of magnesium and rare earth can be improved, the desulfurization effect is enhanced, and the addition amount of the nodulizer can be correspondingly reduced, wherein the addition amount of the nodulizer is 0.9-1.15% of the total amount of the original iron liquid; the addition amount of the inoculant is 0.6-0.8% of the mass of the original iron liquid.
3. According to the casting method, the casting system with the specific structure is combined, so that the molten iron is more stable, the cooling speed of the molten iron is improved through the specific chill structure, solidification is accelerated, spheroidization degradation and inoculation degradation are not easy to cause, and the stability of the structure and the matrix of the casting is maintained.
4. The planet carrier casting produced by the casting method has good forming, the formed matrix structure is compact (see the metallographic structure diagram in the embodiment of the application, the spheroidization rate is high, the graphite size and the dispersion are uniform, and no coarse structure exists), the casting is subjected to 100% ultrasonic flaw detection and 100% magnetic powder flaw detection, the ultrasonic flaw detection meets the EN12680-3 standard 01 level requirement, and the magnetic powder flaw detection meets the EN1369 standard 1 level requirement.
Drawings
Fig. 1 is a schematic view of the casting system of the present application in a configuration that is visible from the top.
FIG. 2 is a schematic structural diagram of a top view of the casting system of the present application.
Fig. 3 is a schematic view of the lower part of the casting system of the present application.
Fig. 4 is a schematic structural view of a bottom view of the casting system of the present application.
Fig. 5 is a schematic view of the structure of the pouring system according to the present application at a first angle.
Fig. 6 is a schematic view of the structure of the pouring system according to the second aspect of the present application.
Fig. 7 is a schematic view of a third angle of the casting system of the present application.
Fig. 8 is a schematic view of a fourth angle of the casting system of the present application.
Fig. 9 is a schematic view of a fifth angle of the casting system of the present application.
Fig. 10 is a schematic view of a sixth angle of the casting system of the present application.
FIG. 11 is a schematic structural view of the casting of the present application.
Fig. 12 is a schematic view of the mold structure of the casting of the present application (with the long axis portion facing upward).
Fig. 13 is a schematic view of the mold structure of the casting of the present application (short axis portion up).
Fig. 14 is a schematic structural view of the third chill of the present application.
Fig. 15 is a schematic structural view of a cross-sectional view of a third chill of the present application.
FIG. 16 is a schematic view of a third chiller in combination with a pin bore.
Fig. 17 is a schematic structural view of the steel core bar of the present application.
Fig. 18 is a schematic structural view of a cross-sectional view of a casting cavity of the present application in combination with a sand core.
FIG. 19 is a metallographic view of a casting prepared in example 1 of the present application.
FIG. 20 is a metallographic view of a casting prepared in example 2 of the present application.
As shown in the accompanying drawings: cast body, 101', long shaft portion, 102', pillar portion, 103', short shaft portion, 104', shaft pin bore, 1, cast cavity, 101, long shaft portion, 102, pillar portion, 103, short shaft portion, 104, shaft pin bore, 2, straight runner, 201, first bend, 202, second bend, 203, lateral transition runner, 3, cross runner, 4, inner runner, 401, short runner, 402, long inner runner, 5, transition runner, 501, first set of transition runners, 502, second set of transition runners, 503, large transition runner, 504, small transition runner, 6, foam filter, 7, exothermic riser, 8, dead head, 9, first chill, 901, large chill, 10, sand core, 11, second chill, 1101, small chill, 12, third chill, 1201, sand groove, 13, steel pipe core, 14, sand layer, 15, 16, hanging shaft round steel, 17, dry sand block or dry sand.
Detailed Description
The technical solutions of the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments, and it is apparent that the described embodiments are only preferred embodiments, not all embodiments. All other embodiments, based on the embodiments herein, which a person of ordinary skill in the art would obtain without undue effort, are within the scope of protection of the present application;
The casting cavity has the same size and shape as the casting, so the part names of all positions of the casting cavity can be understood to be consistent with the part names of all corresponding positions of the casting.
Furthermore, it is to be noted that: when an element is referred to as being "fixed" to another element (and other means similar to the means by which it is "fixed"), it can be directly on the other element or be present with another intervening element(s) by which it is fixed. When an element is referred to as being "connected" (and other means similar to "connected") to another element, it can be directly connected to the other element or intervening elements may also be present. When an element is referred to as being "disposed on" (and other means similar to "disposed on") another element, it can be directly on the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like are used herein for illustrative purposes only. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the description of the application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
The structural dimensions of the casting cavity of the present application are consistent with those of the casting of the present application, so that the specification dimensions and names of the various positions in the casting cavity can be understood as the corresponding specification dimensions and names of the casting.
1-10, a casting system of a wind power planet carrier casting comprises a casting cavity 1 and a pouring system which are communicated with each other; the pouring system comprises a sprue 2, a cross runner 3 and an inner runner 4; the sprue 2 is vertically communicated with the cross runner 3, and the inner runner 4 is vertically communicated with the cross runner 3; the horizontal pouring gate 3 is further provided with a transitional pouring gate 5, the transitional pouring gate 5 comprises a first group of transitional pouring gates 501 and a second group of transitional pouring gates 502, the first group of transitional pouring gates 501 and the second group of transitional pouring gates 502 are respectively arranged at two ends of the horizontal pouring gate 3, and the first group of transitional pouring gates 501 and the second group of transitional pouring gates 502 are communicated with the inner pouring gate 4.
By adopting the structure, the number of the inlets for molten iron to enter the casting cavity is increased through the arrangement of the two groups of transition pouring channels, so that the molten iron is ensured to enter the cavity more uniformly and stably, the floating of molten iron slag is facilitated, the molten iron is also facilitated to enter the cavity more stably, and the generation of oxidized slag inclusion is reduced; the speed that the molten iron got into foundry goods die cavity is slowed down through setting up of two sets of transition runner to this application to can effectually reduce and control the turbulent flow of molten iron, improve yield and the casting quality of foundry goods.
As shown in fig. 3, the casting cavity 1 in the present application includes a long shaft portion 101, a column portion 102 and a short shaft portion 103 that are sequentially connected in an axial direction, two ends of the column portion 102 are respectively connected with corresponding upper and lower webs (i.e., disc structures located at two ends of the column portion in the axial direction in the drawing, wherein an upper web is located near the short shaft portion and a lower web is located near the long shaft portion), shaft pin holes 104 are formed in the upper and lower webs (a through hole is located in the upper web and a counter bore is located in the lower web), and a third chill in the present application is placed in the counter bore and no chill is disposed in the through hole); the inner runner 4 is communicated with the end part of the long shaft part 101; by adopting the structure, the casting mold can ensure that the molten iron is gradually filled into the whole mold cavity from the bottom of the casting mold cavity, and the casting defect is reduced.
As shown in fig. 3 and 5-10, the first group of transition pouring channels 501 or the second group of transition pouring channels 502 in the application comprise a large transition pouring channel 503 positioned at the upper part and a small transition pouring channel 504 positioned at the lower part, two small transition pouring channels 504 are arranged, and each small transition pouring channel 504 is communicated with one inner pouring channel 4; by adopting the technical scheme, two ingates can be communicated on each group of transition pouring channels, and the arrangement of four ingates can be realized altogether, so that the stability of molten iron entering castings is effectively improved.
As shown in fig. 1, 3 and 5-10, a foam filter (silicon carbide foam filter) 6 is arranged between a large transition runner 503 and a small transition runner 504 positioned at the lower part, and two ends of the runner 3 are respectively communicated with the foam filter 6; the cross runner is communicated with the foam filter and extends to the position of the large transition runner; by adopting the structure, the iron slag in the molten iron can be effectively filtered, the entering of castings is avoided, and the casting quality of the castings is improved; in addition, in order to prevent the foam filter from deforming or crushing under the dual action of high-temperature molten iron and hot air flow impact, the small transition pouring gate adopts a two-block design, the foam filter is supported by molding sand between the blocks, and meanwhile, each small pouring gate is respectively connected with the inner pouring gate, so that the floating of molten iron slag is facilitated, the molten iron can enter the cavity more stably, and the generation of oxidized slag inclusion is reduced.
As shown in fig. 8 and 9, the runner 3 is provided in an arc shape, and the bending radian of the arc shape is adapted to the outer diameter of the long shaft portion 101; namely, the two are in a concentric circle state, and the radian of the transverse runner is larger than that of the outer diameter of the long shaft part; by adopting the structure, molten iron can be guided to enter the casting cavity in an arc shape, so that the obstruction of the molten iron in the flowing process is reduced, and the occurrence of turbulent flow of the molten iron is avoided.
As shown in fig. 4-10, a short ingate 401 and a long ingate 402 are respectively connected to the two small transition pouring channels 504, and the short ingate 401 is located at the inner side of the long ingate 402; specifically, the inner gate of the short ingate is closer to the gating system; by adopting the structure, the molten iron can be effectively and uniformly distributed at the inlet of the casting cavity.
As shown in fig. 5, the sprue 2 described in the present application has a first bending portion 201 and a second bending portion 202, and the first bending portion 201 and the second bending portion 202 are in transitional connection through a transverse transitional runner 203; the structure of the straight pouring gate is a vertical first straight pouring gate section, a first bending, a horizontal transition pouring gate, a second bending and a vertical second straight pouring gate section; adopt this structure, mainly cooperate the foundry goods structure of this application, because foundry goods length is longer in axial direction, adopt foretell kink structure can ensure the quick full state of sprue part, the setting of kink at the back can reduce the production of molten iron oxidation slag inclusion thing and slow down and fill type velocity of flow, improves the stationarity that molten iron got into foundry goods die cavity.
By way of example, the height of the sprue, i.e., the first sprue section, above the first bending portion described herein is 400mm to 7000mm, and by adopting the above structure, the distribution of each portion of the sprue can be effectively laid out.
By way of example, as shown in FIG. 5, the upper end surface of the large transition runner 503 described herein is 20mm to 30mm higher than the upper end surface of the runner; by adopting the structure, the iron slag in the molten iron can be effectively trapped and floated, and the probability of entering the casting cavity is reduced.
As shown in fig. 3 and 10, the vertical distance of the ingate 4 entering the casting cavity 1 is 60-130mm, namely the height of the section in the vertical direction between the ingate and the casting cavity.
As an example, the ratio of the total cross-sectional area of each main casting unit (cross-sectional area of each component) described in the present application is: sigma and method for producing the same A straight pouring gate ∶Σ A horizontal pouring gate ∶Σ A inner pouring channel ＝1∶1.3～1.4∶1.1～1.2。
As shown in fig. 1, the end face of the short shaft part 103 is provided with a heating riser 7 and a riser outlet 8, and the riser outlet 8 is positioned at the upper part of the heating riser 7, namely, the riser outlet is positioned on the upper end face of the heating riser and is used for communicating with the outside; the setting of this structure can cancel the shaping chill of original minor axis hole to the work load of placing and surperficial chill imprinting polishing when having reduced the preparation of chill, molding has directly reduced manufacturing cost, has avoided the influence of chill to molten iron quality simultaneously.
By way of example, the outer edges (i.e., the respective peripheral edges) of the large and small filter runners described herein are recessed from 8mm to 12mm inwardly relative to the outer edges of the foam filter; namely, each outer side edge of the large transition pouring gate and each outer side edge of the small transition pouring gate are retracted inwards by 8-12 mm relative to each outer side edge of the foam filter, the structure can provide a larger contact area between the sand mould and the filter, the supporting effect of the molding sand on the foam filter is enhanced, and the foam filter is prevented from being displaced in the pouring process.
According to the pouring system, the semi-closed bottom pouring system is adopted according to the principle of 'low flow rate and stable clean filling' and the structural characteristics of castings, the minimum sectional area is arranged on a sprue, the sprue is locally bent at a right angle of 90 degrees by adopting variable diameter, the sprue is ensured to be in a rapid filling state, the generation of molten iron oxidation slag inclusion and the filling flow rate are reduced, the molten iron inlet height H of an inner opening of a ceramic tube above a first bending part of the sprue is 400-700 mm (namely, the distance between an inlet and the first bending part), and the total sectional area ratio of each main pouring unit is as follows: sigma and method for producing the same A straight pouring gate ∶Σ A horizontal pouring gate ∶Σ A inner pouring channel =1:1.3 to 1.4:1.1 to 1.2. In order to reduce sand washing defects, the sprue and the inner pouring gate are all made of refractory ceramic tubes. The foam filter and the exothermic riser are selected from silicon carbide foam filter and FT type exothermic riser available from Jinan holy spring group Co., ltd.
As shown in fig. 12-13, the outer side of the long shaft part 101 is coated with a first chiller 9, and the inner cavity of the long shaft part 101 is filled with a sand core 10; the outer side of the short shaft part 103 is provided with a second chill 11, and the shaft pin hole 104 is internally provided with a third chill 12; the first chill 9 is composed of a plurality of large chill blocks 901 with the axial length equal to that of the long shaft part, the second chill 11 is composed of a plurality of small chill blocks 1101, and the sand core 10 comprises a steel pipe core bar 13 and a sand layer 14 coated on the outer side surface of the steel pipe core bar.
By adopting the structure, the sand core structure formed by the steel pipe core bars and the sand layer coated on the outer side surfaces of the steel pipe core bars is adopted, so that the sand core and the direct chill in the inner cavity of the original long shaft part are canceled, the workload of manufacturing the chill, placing the chill during core manufacturing and imprinting and polishing the inner hole part is reduced, the production cost is directly reduced, and meanwhile, the influence of the direct chill on the quality of molten iron is avoided; the strength of the sand core can be enhanced by arranging the steel pipe core bars, and the weight of the whole sand core can be reduced; according to the method, the large chilling block with the length equal to that of the long shaft part is arranged on the outer side of the long shaft part to replace the structure of the traditional small chilling block, so that gaps are reduced, and the surface of a casting is smoother; and because the gap is formed between large chill blocks, the gap can form compact molding sand through the dead weight of sand and the sand plugs in two directions (axial direction and radial direction), and the situation that the sand plugs in the chill gap are not compact and shrinkage cavity shrinkage porosity defects occur at the chill gap position caused by multiple gaps and narrow gaps formed by a plurality of small chill blocks in the prior art can not occur.
As shown in fig. 12, the first chill 9 described in the present application is provided with six pieces and is uniformly distributed on the outer surface of the long shaft portion 101 of the casting cavity 1; with the adoption of the structure, the use quantity of single chilling blocks can be greatly simplified, and more ideal casting surfaces can be formed.
As an example, the distance between every two adjacent blocks of the first chill 9 is 15 mm-35 mm, because the first chills are positioned on the outer surface of the long shaft part of the casting cavity and are spliced with each other, and a gap is formed between the two adjacent blocks, and the gap extends along the axial length; because the expansion amounts of the large-sized forming chill and the sand are different when heated, the space between the large-sized forming chills is effectively controlled, so that the surface of a casting formed by the sand in the space between the adjacent chills is smoother.
As shown in fig. 14-16, the third chiller 12 described in the present application is in a hollow cylindrical shape, and a plurality of sand hanging grooves 1201 are formed on the outer side surface of the hollow cylindrical third chiller 12, and the sand hanging grooves 1201 are recessed radially inward along the side wall of the third chiller 12; by adopting the structure, the chill can be better fixed in the molding sand through the hollow center hole of the third chill and the sand hanging groove, and the problem that the small indirect chill is shifted or falls off under the impact of high-temperature molten iron and heat waves is prevented.
By way of example, the axial width of the sand hanging groove 1201 described herein is 15mm to 25mm and the radial depth is 2mm to 5mm; with this structure, a better fixing effect can be achieved.
As an example, as shown in fig. 16, the distance between the outer side wall of the third chiller 12 and the inner wall of the pin hole 104 where the outer side wall of the third chiller is located is 10mm to 20mm (specifically, the radial distance between the outermost side wall of the third chiller and the corresponding pin hole); by adopting the structure, reasonable sand filling thickness between the two can be ensured, the sand is easy to fall off due to too thin thickness, and the chilling effect is poor due to too thick thickness of the sand.
As shown in fig. 17 and 18, the steel core 13 is hollow, sand blocks or dry sand 17 are filled in the hollow position, and an air outlet rope or a refractory porcelain tube is led out of the hollow position (in specific fig. 17, an air outlet rope is led out of a hollow cavity of the steel core, and a refractory porcelain tube can also be arranged); the hollow position is filled with sand blocks or dry sand, so that the rapid increase of the molten iron for pouring caused by the leakage of the molten iron into the hollow inner cavity of the steel tube core bar can be prevented, the risk of scrapping products is reduced, and the sand blocks or dry sand are arranged in the hollow position and do not influence the discharge of air; through arranging the air outlet rope or the fire-resistant porcelain tube in the hollow position, air in the steel tube (the air expansion in the steel tube is easily caused by high temperature of molten iron pouring) is directly led out from the upper box through the pre-discharged air outlet rope (such as the air outlet rope produced by the Changxing pond fire-resistant material company) in the casting mould or the pre-buried fire-resistant porcelain tube or the hollow channel in the casting mould, so that potential safety hazards are avoided, and the cooling efficiency of the molten iron at the position is improved; the structure can be ignited by igniting when molten iron is poured, and hot gas in the steel pipe is led out by burning air, so that the casting is chilled.
As shown in fig. 18, the steel tube core 13 of the present application is a cylindrical hollow structure having an axial opening and an axial bottom plate, wherein the opening (axial opening) is downward arranged, i.e., is on the same side as the opening side of the long shaft portion (the sand box of the present application can be provided with a cope box, a middle sand box and a drag box, which are combined with each other to form a cavity, and the combining position is provided with a parting surface; so that when the sand boxes around the casting cavity are combined with each other to form the casting cavity, in order to prevent the molten iron from entering the steel tube core from the parting surface to cause the molten iron to increase, the opening is downward arranged, thereby reducing the probability of the molten iron entering the steel tube core and preventing the molten iron from filling into the cavity of the steel tube core), and the hollow structure cavity is filled with sand blocks or dry sand; by adopting the structure, the hot gas in the steel pipe is led out by the burning air when the molten iron is poured and ignited, and the chilling effect is achieved on the casting.
As shown in fig. 17, a plurality of steel bars 15 are arranged on the outer side wall of the steel tube core 13, and the steel bars 15 axially extend along the outer side wall of the steel tube core 13; by adopting the structure, the sand outside the steel pipe can be better wrapped on the steel pipe, and the problem that the sand pressed outside the steel pipe falls off due to the impact of high-temperature molten iron and heat waves is prevented.
As an example, the size of the rebar 15 described herein is Φ6mm to 8mm; the steel bars with the size can be welded and fixed on the outer side wall of the steel tube core bar in a welding mode, and the arrangement of the steel bars can improve the contact area between the molding sand and the steel tube core bar so as to better wrap the sand outside the tube on the steel tube.
As shown in fig. 17, a steel pipe core 13 is provided with a hanging shaft round steel 16, and the hanging shaft round steel is specifically arranged on the side wall of the steel pipe core near the opening side in a penetrating way along the radial direction; by adopting the structure, the lifting movement of the steel pipe can be facilitated, and the lifting shaft round steel is particularly welded on the inner hole of the steel pipe in a perforation way.
The following are examples of specific casting methods for preparing a planet carrier casting using the casting system set forth in the present application:
example 1
(1) Weighing the following raw materials in percentage by mass: 40% of pig iron, 40% of scrap steel, 20% of returned furnace material and silicon carbide: 0.75% of the total amount of pig iron, scrap steel and returned furnace charge, carburant: 1.2% of the total amount of pig iron, scrap steel and returned furnace charge.
(2) All silicon carbide, pig iron, scrap steel and return furnace materials are put into a smelting furnace, and carburant with the formula dosage is added at one time in the feeding process; heating to melt furnace burden, adding FeMn65 (65 ferromanganese) ferromanganese and FeSi75 ferrosilicon (ferrosilicon FeSi 75) after the furnace burden is melted, wherein the addition amount of ferromanganese is 0.4% of the total mass of pig iron, scrap steel and returned furnace burden, and the addition amount of ferrosilicon is 0.3% of the total mass of pig iron, scrap steel and returned furnace burden, so as to obtain raw iron liquid; continuously heating the raw iron liquid to 1490 ℃, wherein the raw iron liquid comprises the following components in percentage by mass: 3.75% of C, 1.15% of Si, 0.41% of Mn, 0.021% of P, 0.023% of S and the balance of iron;
(3) Spheroidizing by adopting a pouring method, firstly adding a spheroidizing agent into a spheroidizing dyke at one side of a spheroidizing ladle, compacting, then adding an inoculant with the particle size of 3-8 mm, compacting, and then adding 0.004% of pure antimony by mass of the raw iron liquid and 0.4% of electrolytic copper by mass of the raw iron liquid;
wherein, the adding amount of the nodulizer is 1.1 percent of the mass of the raw iron liquid, and when the iron yield reaches 75 percent of the nodulizing iron liquid, initiating reaction (magnesium explosion reaction) is started, and the duration time of the magnesium explosion reaction is 105s;
the nodulizer is rare earth magnesium alloy, and comprises the following elements in percentage by mass: 5.9% of Mg, 0.49% of RE, 44.8% of Si, 0.98% of Ca, 0.49% of Al, 0.37% of MgO and the balance of Fe;
wherein, the addition of the inoculant is 0.65 percent of the mass of the original iron liquid, the inoculant is a silicon-barium inoculant, and the element mass percentages are as follows: 72% of Si, 1.0% of Ca, 2.0% of Ba, 0.70% of Al, 0.015% of S and the balance of iron;
the obtained molten iron comprises the following components in percentage by mass: 3.68% of C, 2.05% of Si, 0.41% of Mn, 0.021% of P, 0.0098% of S, 0.035% of Mg, 0.004% of RE, 0.0038% of Sb, CE=4.38, and the balance of iron;
slag is removed from molten iron, the molten iron is stood, and when the temperature is reduced to 1336 ℃, the molten iron is poured into a casting mould to form a casting; performing stream inoculation by using inoculation powder at the same time of casting, wherein the addition amount is 0.12% of the total mass of the raw iron liquid; after the casting is cooled, the planet carrier casting is obtained;
The inoculating powder is a silicon-barium inoculant, and the mass percentages of the elements are as follows: 72% of Si, 0.85% of Ca, 2.1% of Ba, 0.8% of Al, 0.012% of S and the balance of iron.
The casting is subjected to 100% ultrasonic flaw detection and 100% magnetic powder flaw detection, the ultrasonic flaw detection meets the grade 01 requirement of EN12680-3 standard, and the magnetic powder flaw detection meets the grade 1 requirement of EN1369 standard.
The physical properties of the attached cast test pieces (70 mm. Times.70 mm. Times.105 mm) of the castings obtained in the above examples of the present application are shown in tables 1 and 2 below:
TABLE 1 mechanical Properties of the additional cast test block
| Project | Tensile strength (MPa) | Yield strength (MPa) | Elongation (%) | Hardness (HB) | Remarks |
| Standard value | ≥650 | ≥380 | ≥1 | 225-305 | Customer standard |
| Actual measurement value | 708 | 433 | 2.5 | 249 | Product testing |
TABLE 2 metallographic structure of additional cast test block
| Project | Spheroidization rate | Graphite size |
| Standard value | ≥90％ | 5～8 |
| Actual measurement value | 92.3％ | 6 |
。
Example 2
(1) Weighing the following raw materials in percentage by mass: 50% of pig iron, 40% of scrap steel, 10% of returned furnace material and silicon carbide: 0.75% of the total amount of pig iron, scrap steel and returned furnace charge, carburant: 1.05% of the total amount of pig iron, scrap steel and returned materials;
(2) All silicon carbide, pig iron, scrap steel and return furnace materials are put into a smelting furnace, and carburant with the formula dosage is added at one time in the feeding process; heating to melt furnace burden, adding FeMn65 ferromanganese and FeSi75 ferrosilicon after the furnace burden is melted, wherein the addition amount of ferromanganese is 0.42% of the total mass of pig iron, scrap steel and returned furnace burden, and the addition amount of ferrosilicon is 0.4% of the total mass of pig iron, scrap steel and returned furnace burden, so as to obtain a stock iron solution; continuously heating the raw iron liquid to 1480 ℃, wherein the raw iron liquid contains, by mass, 3.73% of C, 1.12% of Si, 0.39% of Mn, 0.020% of P, 0.022% of S and the balance of iron;
(3) Spheroidizing by adopting a pouring method, firstly adding a spheroidizing agent into a spheroidizing dyke at one side of a spheroidizing ladle, compacting, adding an inoculant with the grain size of 3-8 mm, compacting, and then adding 0.005% pure antimony and 0.5% electrolytic copper by mass of the original iron liquid;
the adding amount of the nodulizer is 1.15 percent of the mass of the original iron liquid, the nodulizer is rare earth magnesium alloy, and the element mass percentages are as follows: 5.8% of Mg, 0.48% of RE, 45% of Si, 0.96% of Ca, 0.51% of Al, 0.38% of MgO and the balance of Fe;
starting an initiation reaction (magnesium explosion reaction) when the tapping amount reaches 78% of the spheroidizing tapping amount, wherein the duration of the magnesium explosion reaction is 100s;
the addition amount of the inoculant is 0.7% of the mass of the original iron liquid, the inoculant is a silicon-barium inoculant, and the mass percentages of the elements are as follows: 72.5% of Si, 0.98% of Ca, 2.1% of Ba, 0.75% of Al, 0.018% of S and the balance of iron;
the obtained iron liquid comprises the components of, by mass, 3.65% of C, 2.10% of Si, 0.39% of Mn, 0.020% of P, 0.0096% of S, 0.034% of Mg, 0.004% of RE, 0.0042% of Sb, CE=4.36, and the balance of iron;
(4) Slag skimming and standing are carried out on the molten iron obtained in the step (3), and when the temperature is reduced to 1320 ℃, the molten iron is poured into a casting mould to form a casting; performing stream inoculation by using inoculation powder at the same time of pouring, wherein the inoculation powder accounts for 0.10% of the total addition amount of the raw iron liquid, and obtaining the planet carrier casting after the casting is cooled;
The inoculating powder is a silicon-barium inoculant, and the mass percentages of the elements are as follows: 72% of Si, 0.85% of Ca, 2.1% of Ba, 0.8% of Al, 0.012% of S and the balance of iron.
The castings obtained in the embodiment are subjected to 100% ultrasonic flaw detection and 100% magnetic particle flaw detection, wherein the ultrasonic flaw detection meets the grade 01 requirement of EN12680-3 standard, and the magnetic particle flaw detection meets the grade 1 requirement of EN1369 standard.
The physical properties of the cast test pieces (70 mm. Times.70 mm. Times.105 mm) obtained in this example are shown in tables 3 and 4 below:
TABLE 3 mechanical Properties of the additional cast test block
TABLE 4 metallographic structure of additional cast test block
| Project | Spheroidization rate | Graphite size |
| Standard value | ≥90％ | 5～8 |
| Actual measurement value | 93.2％ | 6 |
。
Claims (10)
1. A casting method of a wind power planet carrier casting is characterized by comprising the following steps of: the method comprises the following steps:
(1) Firstly, casting resin sand according to the structure of a planet carrier casting to form a casting system;
(2) Preparing molten iron: weighing the following raw materials in percentage by mass: 40-60% of pig iron, 40-50% of scrap steel, 0-20% of return furnace material and silicon carbide: 0.7 to 0.9 percent of the total mass of pig iron, scrap steel and returned furnace materials; carburant: 0.9 to 1.2 percent of the total mass of pig iron, scrap steel and returned furnace materials;
all silicon carbide, pig iron, scrap steel and return furnace materials are put into a smelting furnace, and carburant is added in the middle of charging; heating to melt furnace burden, adding FeMn65 ferromanganese and FeSi75 ferrosilicon after the furnace burden is melted, wherein the addition amount of ferromanganese is 0.3-0.5% of the total mass of pig iron, scrap steel and returned furnace burden, and the addition amount of ferrosilicon is 0.3-0.6% of the total mass of pig iron, scrap steel and returned furnace burden, and then obtaining raw iron liquid;
Continuously heating the raw iron liquid to 1440-1500 ℃, wherein the raw iron liquid comprises, by mass, 3.70% -3.90% of C, 1.0% -1.2% of Si, 0.35% -0.45% of Mn, less than or equal to 0.025% of P, less than or equal to 0.025% of S, and the balance of iron;
(3) Spheroidizing by adopting a pouring method, adding a spheroidizing agent into a spheroidizing dyke at one side of a spheroidizing ladle, compacting, adding an inoculant with the particle size of 3-8mm, compacting, and finally adding 0.004-0.005% of pure antimony by mass of the raw iron liquid and 0.4-0.6% of electrolytic copper by mass of the raw iron liquid; controlling the detonation time of the spheroidizing reaction and the duration of the magnesium explosion reaction, and starting the detonation reaction when the iron yield reaches 70% -80% of the spheroidizing treatment iron liquid amount, wherein the duration of the magnesium explosion reaction is 90-120 s;
the components and mass percentages of the obtained molten iron after spheroidization and inoculation are as follows: 3.55 to 3.75 percent of C, 1.95 to 2.10 percent of Si, 0.35 to 0.45 percent of Mn, less than or equal to 0.025 percent of P, 0.008 to 0.012 percent of S, 0.025 to 0.038 percent of Mg, 0.002 to 0.005 percent of RE, 0.003 to 0.005 percent of Sb, 4.20 to 4.40 percent of CE=and the balance of iron;
(4) Slag skimming and standing are carried out on the molten iron obtained in the step (3), and when the temperature of the molten iron is reduced to 1310-1370 ℃, the molten iron is poured into a casting system to form a casting; performing stream inoculation by using inoculation powder while pouring, wherein the addition amount of the inoculation powder is 0.1-0.12% of the total weight of the raw iron liquid; after the casting is cooled, the planet carrier casting is obtained;
The casting system comprises a casting cavity and a pouring system which are communicated with each other; the casting cavity comprises a long shaft part, a shaft pin part and a short shaft part which are axially and sequentially connected, and the shaft pin part is provided with a shaft pin hole; the pouring system comprises a sprue, a cross runner and an inner runner; the sprue is vertically communicated with the transverse runner, and the inner runner is vertically communicated with the transverse runner; the cross gate is also provided with a transition gate, the transition gate comprises a first group of transition gate and a second group of transition gate, the first group of transition gate and the second group of transition gate are respectively arranged at two ends of the cross gate, and the first group of transition gate and the second group of transition gate are communicated with inner gates; the transverse runner is arranged in an arc shape, and the bending radian of the arc shape is matched with the outer diameter of the long shaft part;
the inner runner is communicated with the end part of the long shaft part; the first group of transition pouring gates or the second group of transition pouring gates comprise a large transition pouring gate positioned at the upper part and a small transition pouring gate positioned at the lower part, two small transition pouring gates are arranged, and each small transition pouring gate is communicated with an inner pouring gate.
2. The method for casting a wind power planet carrier casting according to claim 1, characterized in that: the silicon carbide in the step (2) is an element with the following mass percent: siC is more than or equal to 85%, si is more than or equal to 60%, C is more than or equal to 25%, S is 0.02% -0.05%, and silicon carbide with granularity of 1-5 mm; the carburant in the step (2) comprises the following elements in percentage by mass: a carburant with C more than or equal to 98%, S less than or equal to 0.05%, N less than or equal to 0.01%, ash less than or equal to 0.3%, volatile less than or equal to 0.3% and granularity of 0.5-3 mm.
3. The method for casting a wind power planet carrier casting according to claim 1, characterized in that: the nodulizer in the step (3) is rare earth magnesium alloy: 5.5 to 6.0 percent of Mg, 0.4 to 0.6 percent of RE, 42 to 46 percent of Si, less than or equal to 1.0 percent of Ca, less than or equal to 0.6 percent of Al, less than or equal to 0.40 percent of MgO and the balance of Fe; the inoculant in the step (3) is a silicon-barium inoculant, and the element mass percentages thereof are as follows: 71 to 73 percent of Si, 0.7 to 1.3 percent of Ca, 1.6 to 2.4 percent of Ba, less than or equal to 1.2 percent of Al, less than or equal to 0.02 percent of S and the balance of iron; the adding amount of the nodulizer in the step (3) is 0.9-1.15% of the total amount of the raw iron liquid; the adding amount of the inoculant is 0.6-0.8% of the mass of the raw iron liquid; the inoculating powder in the step (4) is a silicon-barium inoculant, and the mass percentages of the elements are as follows: 71 to 73 percent of Si, 0.7 to 1.3 percent of Ca, 1.6 to 2.4 percent of Ba, less than or equal to 1.2 percent of Al, less than or equal to 0.02 percent of S and the balance of iron.
4. The method for casting a wind power planet carrier casting according to claim 1, characterized in that: and a foam filter is arranged between the large transition runner and the small transition runner positioned at the lower part, and two ends of the cross runner are respectively communicated with the foam filter.
5. The method for casting a wind power planet carrier casting according to claim 1, characterized in that: the two small transition pouring gates are respectively communicated with a short pouring gate and a long pouring gate, and the short pouring gate is positioned at the inner side of the long pouring gate.
6. The method for casting a wind power planet carrier casting according to claim 4, characterized in that: the sprue is provided with a first bending part and a second bending part, and the first bending part and the second bending part are in transitional connection through a transverse transitional runner; the total sectional area ratio of each main casting unit is as follows: sigma and method for producing the same A straight pouring gate ∶Σ A horizontal pouring gate ∶Σ A inner pouring channel =1:1.3 to 1.4:1.1 to 1.2; the end face of the short shaft part is provided with a heating riser and a riser outlet, and the riser outlet is positioned at the upper part of the heating riser; the outer edges of the large transition pouring gate and the small transition pouring gate are retracted inwards by 8 mm-12 mm relative to the outer edge of the foam filter.
7. The method for casting a wind power planet carrier casting according to claim 6, characterized in that: the height of the sprue above the first bending part is 400-700 mm; the upper end face of the large transition runner is 20-30 mm higher than the upper end face of the cross runner; the vertical distance of the inner runner entering the casting cavity is 60-130mm.
8. The method for casting a wind power planet carrier casting according to claim 7, characterized in that: the outer side of the long shaft part is coated with a first chill, and the inner cavity of the long shaft part is filled with a sand core; the outer side of the short shaft part is provided with a second chill, and a third chill is arranged in the shaft pin hole; the first chill is composed of a plurality of large chill blocks with the axial length equal to that of the long shaft part, the second chill is composed of a plurality of small chill blocks, and the sand core comprises a steel pipe core bar and a sand layer coated on the outer side surface of the steel pipe core bar.
9. The method of casting a wind power planet carrier casting according to claim 8, wherein: the third chill is hollow and cylindrical, a plurality of sand hanging grooves are formed in the outer side face of the hollow and cylindrical third chill, and the sand hanging grooves are recessed inwards along the side wall of the third chill.
10. The method of casting a wind power planet carrier casting according to claim 9, wherein: the steel tube core bar is arranged in a hollow way, sand blocks or dry sand are arranged at the hollow position, and an air outlet rope or a refractory porcelain tube is led out at the hollow position; the steel tube core bar is provided with an axial opening at one end and a bottom plate at the other end, and the opening is downwards arranged; the outer side wall of the steel tube core bar is provided with a plurality of steel bars, and the steel bars axially extend along the outer side wall of the steel tube core bar; and the steel tube core bar is provided with a hanging shaft round steel.
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