CN117505776B - Casting process of centrifugal compressor base - Google Patents

Casting process of centrifugal compressor base Download PDF

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Publication number
CN117505776B
CN117505776B CN202410015152.2A CN202410015152A CN117505776B CN 117505776 B CN117505776 B CN 117505776B CN 202410015152 A CN202410015152 A CN 202410015152A CN 117505776 B CN117505776 B CN 117505776B
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sand
pouring
casting
thick
bearing part
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CN117505776A (en
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于本礼
赵芳侠
迟元坤
许志宏
陈一北
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Yantai Ice Wheel Intelligent Machinery Technology Co ltd
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Yantai Ice Wheel Intelligent Machinery Technology Co ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/02Sand moulds or like moulds for shaped castings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/082Sprues, pouring cups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/08Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B22C9/088Feeder heads
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/10Cores; Manufacture or installation of cores
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22CFOUNDRY MOULDING
    • B22C9/00Moulds or cores; Moulding processes
    • B22C9/22Moulds for peculiarly-shaped castings

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

Abstract

The invention relates to a casting process of a centrifugal compressor base, and belongs to the technical field of casting. The process comprises the following steps: 1. drawing identification; 2. determining the parting surface as a large plane at the bottom of the thick and large bearing part; the thick and large bearing part is placed at the lower part of the pouring position, and a semi-closed bottom pouring process scheme is adopted; placing round steel chill at the bottom of the thick and large bearing part before pouring the box; placing round steel chill outside the thick and large bearing part in the sand filling process; before the inner cavity sand core is manufactured, a large follow-up sand-separating chill is placed on the inner side of a thick and large bearing part, and a heat-preserving feeding head and a slag discharge, exhaust and overflow are arranged on the upper large plane; 3. setting a sand core; 4. molding the filling box; 5. smelting and pouring; 6. and (5) sand cleaning and inspection. The invention adopts a vertical pouring process, divides the bottom plane into the shapes, places the thick and large bearing part at the bottom of the pouring position, is favorable for fully utilizing gravity feeding, ensures the dense structure of the thick and large bearing part at the lower part, and is favorable for eliminating shrinkage cavity shrinkage porosity defects.

Description

Casting process of centrifugal compressor base
Technical Field
The invention relates to a casting process of a centrifugal compressor base, and belongs to the technical field of casting processes.
Background
The centrifugal compressor base needs to have enough strength and rigidity to support equipment such as a compressor host machine, a motor, a lubrication system, a cooling system, a random control system and the like, so that the quality requirement on a centrifugal compressor base casting is strict, and casting defects such as shrinkage porosity, shrinkage cavity, cracks, material shortage and the like are not allowed to exist in the casting.
The base castings of the centrifugal compressor belong to thick and large castings, and thick and large parts of the castings are mainly concentrated at bearing parts. At present, a base casting of a centrifugal compressor is conventionally cast by adopting a wood model scheme, if the process design is improper, the shrinkage cavity shrinkage porosity defect in the bearing part of the thick and large part is easily caused, the bearing capacity of the casting is greatly reduced, and the normal operation of the whole unit is subjected to fatal influence.
In the traditional casting scheme, in order to simplify the modeling operation process and reduce the sand-iron ratio, a flat casting process scheme is generally adopted, the middle part of a casting is parting, the bearing parts are respectively placed in an upper box and a lower box, the shape-following precoated sand chill is placed at the thick and large bearing part for chilling, and a plurality of heat preservation open riser heads are used for feeding. Because the base product is heavier in weight and larger in thickness at the bearing part, the conventional scheme of casting and manufacturing by adopting the middle parting type flat casting has the following problems:
1. The method is limited by an operation method, only the chill can be placed on the top surfaces of the flanges of the upper and lower boxes, and the conventional conformal chill has limited size because of larger thickness of the bearing part, cannot reach the chilling effect required by the process, and easily causes shrinkage defects in the bearing part;
2. The wall thickness difference of the castings is large, the heat of the sand mold at the wall thickness part is concentrated, the heat dissipation condition is poor, and the shrinkage cavity defect inside the thick and large part is easily caused;
3. The thickness of the bearing part is larger, the conventional riser cannot meet the feeding requirement, and shrinkage cavity defects are easy to occur in the thick-channel part of the casting.
Disclosure of Invention
The present invention is directed to solving the various problems mentioned above, and further to providing a centrifugal compressor base casting process.
In order to solve the problems, the invention adopts the following technical scheme:
the casting process of the centrifugal compressor base is characterized by comprising the following steps of:
Step one, drawing identification:
Identifying the size in the drawing, identifying important quality control parts of the castings according to acceptance criteria, and judging the types of casting defects possibly occurring in the production process;
step two, determining parting surfaces, and designing pouring systems and chiller parameters:
determining the parting surface as a large plane at the bottom of the thick and large bearing part;
through analysis, the thick and large bearing part and the important processing surface are placed at the lower part of the pouring position, and a semi-closed bottom pouring process scheme with good slag blocking effect is adopted;
Before filling the box, placing round steel chiller at the position of a model chiller marking line at the bottom of the thick and large bearing part; in the sand filling process, placing round steel chill at the position of a chill marking line at the outer side of a thick and large bearing part; before the inner cavity sand core is manufactured, three large conformal sand-separating chill blocks are placed at the positions of a core box chill marking line at the inner side of a thick and large bearing part, and the thickness of a sand layer is 20-25mm; and a heat preservation feeding head and a slag discharge, exhaust and overflow are arranged on the upper large plane.
Step three, setting a sand core:
According to the casting structure and the casting process scheme, three sand cores are determined to be used, wherein the 1# sand core is an inner cavity to form the sand core; and the # 2 sand core and the # 3 sand core are cast holes on two sides to form the sand core.
Step four, pouring the case and modeling:
Filling a lower box: placing 24 ingate ceramic tubes at the positions of ceramic tube positioning seats on the model; placing round steel chills according to the required number at the mold chiller marking part at the bottom of the thick and large bearing part; the upper box consists of two middle boxes and one upper box, 6 heat-insulation feeding heads and 4 deslagging, exhausting and feeding heads are placed at the top surface dead head positioning seat, box filling is started, and round steel chill is placed at the mold side chill marking position while sand filling is performed according to requirements;
After the sand mould is hardened and the mould is pulled out for four hours, brushing paint, igniting and drying, and preparing a core: firstly, a No. 1 sand core is arranged at a lower box positioning core seat and is fastened in a lower box, after chill at the lower box and middle ring parts is uniformly baked, the wall thickness of a casting around is detected after two middle boxes are combined, and after the requirements of drawing are met, the box is closed; bolts are used to fasten the sand box and a weight is placed on the top surface of the sand box.
Smelting and pouring:
According to the material requirements of the products, the proportion of each raw material is determined, the raw materials are sequentially fed into a melting furnace according to a specified feeding sequence to be melted into molten metal, then the molten metal meeting the requirements is obtained through inoculation treatment and molten iron purification, and the molten metal is poured into a cavity through a casting ladle and a special pouring cup until a riser is filled with the molten metal, and then the pouring is completed.
Step six, sand removal and inspection:
When the metal liquid is completely solidified and the surface temperature reaches the technological requirement, forming a casting, hanging the upper box, taking out the casting from the sand box, removing sand blocks, core bars, pouring heads and parting surfaces of the inner cavity, sealing, and carrying out annealing treatment by a heat treatment process; removing surface impurities in a shot blasting process; carrying out fine surface grinding treatment in a fine turning and cleaning process; and the rotation checking procedure is used for measuring the size and appearance quality of the casting, detecting the performance of the follow-up test rod, and putting the casting into a finished product warehouse after all the detection is qualified.
Further, in the semi-closed bottom pouring process scheme of the second step, the ratio of the sectional areas of the pouring gates is a sprue: and (3) a cross gate: ingate = 1:1.45:0.8; the sprue is 2 phi 110 ceramic tubes which are respectively arranged at one side of the casting, a scheme of simultaneous pouring by two ladles is adopted, and 24 phi 30 ceramic tubes are used as the ingate and are uniformly introduced from the bottom.
Further, in the second step, a round steel chill is placed at the bottom of the thick and large bearing part, the diameter of the round steel chill is 100mm, the height of the round steel chill is 200mm, and the placing interval is 30-40mm; the diameter of the round steel chill is 100mm, the height is 120mm, and the interval is 40-50mm; and 6 heat-preservation feeding heads and 4 deslagging, exhausting and feeding heads are arranged on a large plane with the upper thickness of 80 mm.
Further, in the fourth step, the specifications of the 6 thermal insulation feeding heads are 300×160×350, and the specifications of the 4 deslagging exhaust feeding heads are 300×250×200, and unit mm.
Compared with the traditional process scheme, the casting process disclosed by the invention has the advantages that the traditional flat casting process is changed into the vertical casting process, and the following aspects are mainly presented:
1. The bottom plane of the thick and large bearing part is used as a parting surface, and the thick and large bearing part is placed at the bottom of the pouring position, so that the gravity feeding is fully utilized, the tissue compactness of the thick and large bearing part at the lower part is ensured, and the elimination of shrinkage cavity shrinkage porosity defects is facilitated.
2. The thick and large bearing part is placed on the bottom surface, so that the steel chill with strong chilling effect and the oversized follow-up sand-isolating chill can be placed on the bottom surface and the two side surfaces, the cooling speed of the thick and large bearing part is accelerated, the smooth feeding channel of the riser is ensured, and the elimination of shrinkage cavity shrinkage porosity defects is facilitated.
3. The casting system is favorable to be placed, the bottom casting process is realized, and the quick and stable filling process is ensured.
4. The top is a large plane, the space is sufficient, and a sufficient number and large-size feeding heads can be placed, so that the shrinkage cavity shrinkage porosity defect in the casting can be eliminated.
5. Simple operation, stable process, greatly reduced occurrence of bad conditions and high production efficiency.
Drawings
Fig. 1: product castings, pouring systems and chiller schematic diagrams;
fig. 2: FIG. 1 is a schematic bottom view of the structure;
in the figure, 1, a casting, 2, a heat-insulating feeding riser, 3, a deslagging and exhausting feeding riser, 4, a sprue, 5, a cross runner, 6, an inner runner, 7, a round steel chill, 8 and a conformal sand-isolating chill.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings.
Example 1
Step one, drawing identification:
Carefully identifying each dimension in the drawing sheet has a clear understanding of the overall structure of the casting 1. Important quality control parts of the castings 1 are identified according to acceptance criteria provided by customers, and casting defect types possibly occurring in the production process are determined.
Step two, determining parting surfaces, and designing pouring systems and chiller parameters:
Firstly, analyzing the structure of the product, particularly paying attention to the thick and large part and important processing surface of the product, wherein the bottom plane where the bearing hole is positioned is an assembly surface, the assembly with castings such as a rotor, a box cover and the like is required, the dense lubrication oil groove and the positioning key groove are required to be processed, the processing precision requirement is high, any casting defect is not allowed to exist, and the important processing surface is important. In order to ensure that the thickness is large and the tissue of the important part is compact and the quality is good, the part is required to be placed at the lower part of the pouring position, and the parting surface is determined to be a large plane at the bottom of the thick and large bearing part; round steel chill 7 with better chilling effect is placed at the bottom and the outer side of the thick and large bearing part, and the cooling is slower due to limited inner space, so that the large-size conformal sand-isolating chill 8 is required to be designed, and the chilling requirement can be met; 6 large-size heat-insulation feeding heads 2 are arranged on a large plane with the upper thickness of 80mm for feeding.
The base is a thick large casting, the weight of cast iron is 24500Kg, the cast iron is relatively large, slag inclusion and sand inclusion defects are easy to occur in the casting process, and the mold filling process is required to be quick and stable. Therefore, a semi-closed bottom pouring process scheme with good slag blocking effect is adopted, and the sectional area ratio of each pouring gate adopts a straight pouring gate: and (3) a cross gate: the ratio of the ingate is 1:1.45:0.8. The sprue 4 is 2 phi 110 ceramic tubes which are respectively arranged on one side of the casting 1, a scheme of simultaneous pouring by 2 ladles is adopted, and the ingate 6 is uniformly introduced from the bottom by using 24 phi 30 ceramic tubes.
According to the casting structure, round steel chilling blocks 7 with the diameter of 100mm and the height of 200mm are placed at the bottom of a large parting surface thickness bearing, the intervals are 30-40mm, the round steel chilling blocks are uniformly distributed, and the round steel chilling blocks are placed at the positions of model chilling block marking lines before filling boxes; round steel chill 7 with the diameter of 100mm and the height of 120mm is placed at the position of a chill marking line outside a thick and large bearing part, the intervals are 40-50mm, the round steel chill is uniformly distributed, and the round steel chill is placed while sand is poured; considering that the inner cavity is slower in heat dissipation and is not beneficial to cooling, before the inner cavity sand core is manufactured, 3 large-size conformal sand-insulation cold irons 8 are placed at the positions of the cold iron mark lines of the core box, the thickness of a sand layer is 20-25mm, and the cooling speed of the thick and large parts of the inner cavity is accelerated;
step three, setting a sand core:
According to the casting structure and the pouring technological scheme, 3 sand cores are determined to be used. Wherein the No.1 sand core is formed by taking the inner cavity as an inner cavity; and the # 2 sand core and the # 3 sand core are cast holes on two sides to form the sand core.
Step four, pouring the case and modeling:
1. Filling a lower box: placing 24 ingate ceramic tubes according to the ceramic tube positioning seat positions on the model; placing round steel chill 7 with the diameter of 100mm and the height of 200mm on the marked part of the model chill according to the required number; the upper box consists of two middle rings and one upper box, according to the technological requirement, 6 300 x 160 x 350 heat preservation feeding heads 2 and 4 300 x 250 x 200 slag discharge and exhaust strain relief heads 3 are placed at the top surface dead head positioning seat, the resin adding amount of the sand mixer is adjusted to 1.5%, the box filling is started, and round steel chill 7 with phi of 100 x 120 is placed at the mold side surface chill marking position while sand filling.
2. After the sand mould is hardened and the mould is pulled out for four hours, the paint is brushed, and after ignition and drying, the core setting is prepared. Firstly, a No.1 sand core is arranged at a positioning core seat of a lower box and is fastened to the lower box by using two M20 bolts, liquefied gas is used for uniformly baking chill at the lower and middle ring positions for 3-5min, then the two middle rings are combined, the wall thicknesses at the two sides are equal to the requirements, and the box is closed; eight M20 bolts are used for fastening the sand box, and the top surface of the sand box is placed with a weight of about 40 tons of iron weights.
Smelting and pouring:
According to the material requirements of the products, determining the proportion of each raw material, sequentially feeding the raw materials into a melting furnace according to a specified feeding sequence to be melted into molten metal, then performing measures such as inoculation treatment, molten iron purification and the like to obtain the molten metal meeting the requirements, pouring the molten metal into a cavity through a pouring ladle and a special pouring cup until a riser is full of the molten metal, and finishing pouring;
Step six, sand removal and inspection:
When the metal liquid is completely solidified and the surface temperature reaches the process requirement, forming a casting, lifting the upper box, taking out the casting from the sand box, removing sand blocks, core bars, pouring heads and parting surfaces of the inner cavity, sealing, and performing annealing treatment by a heat treatment process; removing impurities such as surface oxide skin and the like in a shot blasting process; carrying out fine surface grinding treatment in a fine turning and cleaning process; and the rotation test procedure is used for measuring the size and appearance quality of the casting and simultaneously detecting the performance of the follow-up test rod. And after all the inspection is qualified, finishing inspection work and entering a finished product warehouse for shipment.
The above embodiments are merely illustrative of the present invention and not intended to be limiting, and it should be noted that it will be apparent to those skilled in the art that modifications and equivalents can be made to the specific embodiments of the invention without departing from the technical principles of the invention, and any modifications and equivalents falling within the scope of the claims of the invention are intended to be covered.

Claims (3)

1.A centrifugal compressor base casting process, comprising the steps of:
Step one, drawing identification:
Identifying the size in the drawing, identifying important quality control parts of the castings according to acceptance criteria, and judging the types of casting defects possibly occurring in the production process;
step two, determining parting surfaces, and designing pouring systems and chiller parameters:
determining the parting surface as a large plane at the bottom of the thick and large bearing part;
The thick and large bearing part and the important processing surface are placed at the lower part of the pouring position, and a semi-closed bottom pouring process scheme is adopted: the ratio of the sectional areas of the pouring gates is as follows: and (3) a cross gate: ingate = 1:1.45:0.8; the sprue is 2 phi 110 ceramic tubes which are respectively arranged at one side of the casting, a scheme of simultaneous pouring by two ladles is adopted, and 24 phi 30 ceramic tubes are used as the ingate and are uniformly introduced from the bottom;
Before filling the box, placing round steel chiller at the position of a model chiller marking line at the bottom of a thick and large bearing part, wherein the diameter is 100mm, the height is 200mm, and the placing interval is 30-40mm; in the sand filling process, placing round steel chill with the diameter of 100mm and the height of 120mm at the position of a chill marking line at the outer side of a thick and large bearing part, and the spacing of 40-50mm; before the inner cavity sand core is manufactured, three large conformal sand-separating chill blocks are placed at the positions of a core box chill marking line at the inner side of a thick and large bearing part, and the thickness of a sand layer is 20-25mm; 6 heat-preservation feeding heads and 4 deslagging, exhausting and feeding heads are arranged on a large plane with the upper thickness of 80 mm;
step three, setting a sand core:
according to the casting structure and the casting process scheme, three sand cores are determined to be used, wherein the 1# sand core is an inner cavity to form the sand core; the No.2 sand core and the No. 3 sand core are cast holes on two sides to form a sand core;
Step four, pouring the case and modeling:
Filling a lower box: placing 24 ingate ceramic tubes at the positions of ceramic tube positioning seats on the model; placing round steel chills according to the required number at the mold chiller marking part at the bottom of the thick and large bearing part; the upper box consists of two middle boxes and one upper box, 6 heat-insulation feeding heads and 4 deslagging, exhausting and feeding heads are placed at the top surface dead head positioning seat, box filling is started, and round steel chill is placed at the mold side chill marking position while sand filling is performed according to requirements;
After the sand mould is hardened and the mould is pulled out for four hours, brushing paint, igniting and drying, and preparing a core: firstly, a No. 1 sand core is arranged at a lower box positioning core seat and is fastened in a lower box, after chill at the lower box and middle ring parts is uniformly baked, the wall thickness of a casting around is detected after two middle boxes are combined, and after the requirements of drawing are met, the box is closed; fastening the sand box by using bolts and placing a pressing iron on the top surface of the sand box;
Smelting and pouring:
According to the material requirements of the products, the proportion of each raw material is determined, the raw materials are sequentially fed into a melting furnace according to a specified feeding sequence to be melted into molten metal, then the molten metal meeting the requirements is obtained through inoculation treatment and molten iron purification, and the molten metal is poured into a cavity through a casting ladle and a special pouring cup until a riser is filled with the molten metal, and then the pouring is completed.
2. A centrifugal compressor base casting process according to claim 1, wherein,
In the fourth step, the specifications of the 6 thermal insulation feeding heads are 300×160×350, and the specifications of the 4 deslagging, exhausting and feeding heads are 300×250×200, and unit mm.
3. The centrifugal compressor base casting process of claim 1, further comprising the steps of six, sand removal, inspection:
When the metal liquid is completely solidified and the surface temperature reaches the technological requirement, forming a casting, hanging the upper box, taking out the casting from the sand box, removing sand blocks, core bars, pouring heads and parting surfaces of the inner cavity, sealing, and carrying out annealing treatment by a heat treatment process; removing surface impurities in a shot blasting process; carrying out fine surface grinding treatment in a fine turning and cleaning process; and the rotation checking procedure is used for measuring the size and appearance quality of the casting, detecting the performance of the follow-up test rod, and putting the casting into a finished product warehouse after all the detection is qualified.
CN202410015152.2A 2024-01-05 2024-01-05 Casting process of centrifugal compressor base Active CN117505776B (en)

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB328557A (en) * 1929-01-24 1930-04-24 Int Comb Eng Corp Improvements relating to heat-exchange tubes
CA2145368A1 (en) * 1994-04-04 1995-10-05 Donald L. Cribley Mold and Method for Casting a Disk Brake Rotor
CN101391283A (en) * 2008-10-14 2009-03-25 山东省耐磨耐蚀材料工程技术研究中心 Casting method of heat-resistant steel slime blind-tube and mold thereof
CN101417326A (en) * 2008-11-21 2009-04-29 程金印 Casting method of automobile brake drum and mold
WO2014111573A1 (en) * 2013-01-18 2014-07-24 Nemak Wernigerode Gmbh Method and casting mold for producing castings, in particular cylinder blocks and cylinder heads, having functional connection of the feeder
WO2021147505A1 (en) * 2020-04-17 2021-07-29 江苏徐工工程机械研究院有限公司 3d printing-based casting method and system suitable for integrated multi-way valve
CN114932199A (en) * 2022-06-22 2022-08-23 烟台冰轮智能机械科技有限公司 Casting process of centrifugal double-suction pump

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB328557A (en) * 1929-01-24 1930-04-24 Int Comb Eng Corp Improvements relating to heat-exchange tubes
CA2145368A1 (en) * 1994-04-04 1995-10-05 Donald L. Cribley Mold and Method for Casting a Disk Brake Rotor
CN101391283A (en) * 2008-10-14 2009-03-25 山东省耐磨耐蚀材料工程技术研究中心 Casting method of heat-resistant steel slime blind-tube and mold thereof
CN101417326A (en) * 2008-11-21 2009-04-29 程金印 Casting method of automobile brake drum and mold
WO2014111573A1 (en) * 2013-01-18 2014-07-24 Nemak Wernigerode Gmbh Method and casting mold for producing castings, in particular cylinder blocks and cylinder heads, having functional connection of the feeder
WO2021147505A1 (en) * 2020-04-17 2021-07-29 江苏徐工工程机械研究院有限公司 3d printing-based casting method and system suitable for integrated multi-way valve
CN114932199A (en) * 2022-06-22 2022-08-23 烟台冰轮智能机械科技有限公司 Casting process of centrifugal double-suction pump

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