CN117505779A - Manufacturing method and application of shell for investment casting of 3D printing hollow photosensitive resin mold - Google Patents
Manufacturing method and application of shell for investment casting of 3D printing hollow photosensitive resin mold Download PDFInfo
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- CN117505779A CN117505779A CN202311380296.XA CN202311380296A CN117505779A CN 117505779 A CN117505779 A CN 117505779A CN 202311380296 A CN202311380296 A CN 202311380296A CN 117505779 A CN117505779 A CN 117505779A
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- 239000011347 resin Substances 0.000 title claims abstract description 105
- 229920005989 resin Polymers 0.000 title claims abstract description 105
- 238000005495 investment casting Methods 0.000 title claims abstract description 53
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 51
- 238000010146 3D printing Methods 0.000 title claims abstract description 44
- 238000005266 casting Methods 0.000 claims abstract description 99
- 238000010438 heat treatment Methods 0.000 claims abstract description 32
- 229910052751 metal Inorganic materials 0.000 claims abstract description 30
- 239000002184 metal Substances 0.000 claims abstract description 30
- 238000000034 method Methods 0.000 claims abstract description 25
- 230000008569 process Effects 0.000 claims abstract description 8
- 239000004576 sand Substances 0.000 claims description 42
- 229910052845 zircon Inorganic materials 0.000 claims description 39
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 39
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 38
- 239000000843 powder Substances 0.000 claims description 34
- 239000011819 refractory material Substances 0.000 claims description 17
- 239000011248 coating agent Substances 0.000 claims description 16
- 238000000576 coating method Methods 0.000 claims description 16
- 238000002844 melting Methods 0.000 claims description 16
- 230000008018 melting Effects 0.000 claims description 16
- 238000010586 diagram Methods 0.000 claims description 15
- 238000009423 ventilation Methods 0.000 claims description 15
- 238000001514 detection method Methods 0.000 claims description 12
- 238000007689 inspection Methods 0.000 claims description 9
- 239000000428 dust Substances 0.000 claims description 7
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 6
- 238000001035 drying Methods 0.000 claims description 6
- 238000001917 fluorescence detection Methods 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 6
- 238000005498 polishing Methods 0.000 claims description 6
- 239000002002 slurry Substances 0.000 claims description 5
- 238000010304 firing Methods 0.000 claims description 3
- 239000011268 mixed slurry Substances 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 3
- 238000003892 spreading Methods 0.000 claims description 3
- 230000007480 spreading Effects 0.000 claims description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 abstract description 2
- 229910052760 oxygen Inorganic materials 0.000 abstract description 2
- 239000001301 oxygen Substances 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 24
- 239000000463 material Substances 0.000 description 11
- 230000007547 defect Effects 0.000 description 9
- 238000003825 pressing Methods 0.000 description 9
- 238000005516 engineering process Methods 0.000 description 8
- 239000002893 slag Substances 0.000 description 8
- 239000003973 paint Substances 0.000 description 6
- 238000011161 development Methods 0.000 description 4
- 238000004321 preservation Methods 0.000 description 4
- 238000011160 research Methods 0.000 description 4
- 239000013078 crystal Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000007639 printing Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
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- 238000012986 modification Methods 0.000 description 2
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- 239000007787 solid Substances 0.000 description 2
- 229910000601 superalloy Inorganic materials 0.000 description 2
- 206010035148 Plague Diseases 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 241000607479 Yersinia pestis Species 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
- B22C13/085—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores by investing a lost pattern
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/02—Lost patterns
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
Abstract
The invention belongs to the technical field of 3D printing, and particularly relates to a manufacturing method of a shell for investment casting of a 3D printing hollow photosensitive resin mold and application thereof, wherein the manufacturing cost of the hollow photosensitive resin mold is reduced by adopting the 3D printing hollow photosensitive resin mold; after the electric furnace is used for heating and preserving heat, the hollow photosensitive resin model shell is subjected to flash burning, so that oxygen can be ensured to exist in the furnace, the hollow photosensitive resin mould can quickly burn open fire, and the hollow photosensitive resin mould can be fully burned and gasified, so that the environment is not polluted; the special exhaust hole type shell plug is adopted, so that the exhaust hole of the shell is in seamless connection with the surface of the plug, and the flame running during later casting due to the fact that the plug is not tight is avoided; the special pouring cup type shell capable of preventing the molten metal from rotating is adopted, the molten metal in the pouring cup can be effectively prevented from rotating in the pouring process, the molten metal can be ensured to stably enter the shell from the pouring cup, and the situation of partial undercasting of the thin-wall casting is avoided.
Description
Technical Field
The invention belongs to the technical field of investment casting, relates to manufacturing of a hollow photosensitive resin model shell and application thereof, and in particular relates to a manufacturing method of a model shell for 3D printing hollow photosensitive resin model investment casting and application thereof.
Background
Investment casting is also called lost wax casting, and is a precision casting process method. The investment casting process comprises the following steps: firstly, making a model by using an investment material, forming a model group by using the model, coating a plurality of layers of refractory materials on the model group, heating the model group after the coating layer is dried and hardened, melting the model material to form a model shell, and pouring molten metal after roasting the model shell, thereby obtaining the casting with the shape consistent with the investment. Investment casting can produce castings with complex structure, high dimensional accuracy and high surface finish requirements, meanwhile, the near net-shape castings simplify the subsequent machining and manufacturing procedures, reduce the cost, reserve compact layers on the surfaces of the castings, prolong the service lives of the castings to a certain extent, and are widely applied to the fields of aerospace, weapon ships, petrochemical industry, automobiles and the like. The method is particularly suitable for the development of the technology of aviation industry, aero-engine and the like, promotes the progress of the investment casting technology of materials such as titanium alloy, superalloy and the like, and realizes the technological breakthrough from casting of equiaxed crystal hollow turbine blades to oriented columnar crystal and single crystal hollow turbine blades, and key components such as a whole casting casing, a turbine rotor, a guide and the like, so that the investment casting has become an indispensable important technological means in the manufacturing technology of the industries such as aviation and the like.
As known in the art, silica sol is a high-quality adhesive commonly used for investment casting, and is easy to prepare high-quality paint with high powder-liquid ratio due to convenient use, the stability of the paint is good, chemical hardening is not needed during manufacturing of shells, no pollution is caused, the process is simple, and the prepared shells are good in high-temperature performance and have certain high-temperature strength and high-temperature deformation resistance, so that the silica sol is a main shell manufacturing material for investment casting industry at home and abroad. Most of models used in investment casting at present are wax patterns formed by pressing metal molds, the metal molds are manufactured by the method of manufacturing the metal molds, and the method has the characteristics of complex structure, long period, high price and the like, the metal molds are difficult to correct, and in the development of single-piece scientific research and a small amount of non-shaped products, the conventional method for manufacturing the wax patterns by using the metal molds can not meet the requirement of rapid development in the current industry.
The 3D printing technology is a technology for constructing objects by adopting a layer-by-layer printing mode based on digital model files, and is also called a rapid prototyping technology or an additive manufacturing technology. The powder, wire-shaped metal or nonmetal material is used as a matrix, and can be directly printed into a three-dimensional physical entity which is completely consistent with a corresponding digital model. Taking a case casting for an aviation scientific research turboshaft engine as an example, a period of manufacturing a single-piece investment pattern by adopting a traditional die is about 40 days, and a period of manufacturing the single-piece investment pattern by adopting a 3D printing technology is only 5 days, so that the production period of the casting can be greatly shortened, the cost for manufacturing a metal die is saved by a 3D investment pattern printing method, and the method has obvious period advantages and economic advantages in the aspects of rapid development of single-piece scientific research products and small-scale production of unfixed products, and is widely applied in the industry. The light curing stereo forming (SLA) is to take photosensitive resin as a raw material, change the photosensitive resin into solid state from liquid state under the irradiation of ultraviolet light with specific wavelength, and gradually cure and form the three-dimensional stereo printing (SLA) from point to wire and from line to surface. The 3D printed photosensitive resin mold has advantages of high surface smoothness, high dimensional accuracy, good shape stability, and the like, and is being widely applied to investment casting. However, the thermal expansion coefficient of the 3D printing photosensitive resin mold is much larger than that of the shell refractory material, and the problem of shell cracking in dewaxing and roasting links of the shell manufacturing process as an investment pattern always plagues everyone, and the subsequent casting deformation is caused by changing the internal size of the shell when the model shell is light, and the shell is directly scrapped when the model shell is heavy.
At the present stage, a manufacturing method of a novel shell for investment casting of a 3D printing photosensitive resin mold is urgently needed to be found.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, and provides a manufacturing method and application of a mold shell for investment casting of a 3D printing hollow photosensitive resin mold, which solve the problems of difficult manufacturing and high cost of the mold shell for investment casting.
In order to achieve the above purpose, the present invention provides the following technical solutions:
in one aspect, the invention provides a manufacturing method of a shell for investment casting of a 3D printing hollow photosensitive resin mold, which comprises the following steps: firstly, drawing a casting three-dimensional diagram, designing a pouring system, and 3D printing a hollow photosensitive resin mold after the shrinkage rate of the casting three-dimensional diagram is increased; combining the hollow photosensitive resin mold with the pouring cup wax mold and the exhaust hole wax head to prepare an initial shell; then heating and melting off the intermediate-temperature wax of the pouring cup wax mould and the exhaust hole wax head, and puncturing ventilation holes on the end face of the hollow photosensitive resin mould connected with the pouring cup and the exhaust hole; then the hollow photosensitive resin mould is subjected to flash firing, and the roasting of the initial shell is completed; and finally, the exhaust hole is plugged, and the manufacturing of the shell for investment casting is completed.
Specifically, the method comprises the following steps:
step 1, drawing a casting three-dimensional diagram according to drawing requirements, and designing a pouring system;
step 2, 3D printing a hollow photosensitive resin mold after the shrinkage rate of the casting three-dimensional map and the pouring system is increased;
step 3, manufacturing a pouring cup wax mold, and adhering the manufactured pouring cup wax mold to the top of the hollow photosensitive resin mold according to the process requirement;
step 4, adhering one end of the exhaust hole wax head to a thick and large part of the hollow photosensitive resin mold and the pouring system to form a mold set;
step 5, coating at least 6 layers of silica sol and refractory materials on the model set obtained in the step 4, and forming an initial shell on the outer surface of the model set;
step 6, sawing the shell corresponding to the end face of the other end of the initial shell, corresponding to the thick and large part of the model group, of the exhaust hole wax head, and exposing the end face of the wax model of the exhaust hole wax head;
step 7, heating and melting off the medium-temperature wax of the pouring cup wax mould and the exhaust hole wax head, and puncturing ventilation holes on the hollow photosensitive resin mould surface between the pouring cup and the exhaust hole wax head and the initial shell after the wax is melted off, so that the hollow photosensitive resin mould cavity is communicated with the outside of the initial shell;
step 8, heating the empty furnace of the electric furnace for the first time, preserving heat after reaching a preset temperature, charging the initial shell into the furnace, and flashing the empty photosensitive resin mold, and closing the furnace door after the open fire disappears; then the electric furnace carries out the second heating, keeps warm after reaching the preset temperature, and then turns off the power supply; after cooling to room temperature along with the furnace, completing the roasting of the initial shell;
and 9, installing the special shell plug of the exhaust hole corresponding to the exhaust hole on the exhaust hole of the initial shell obtained in the step 8, mixing silica sol, zircon powder and sand on a shop to form slurry, wrapping the mixed slurry on the shell at the periphery of the special shell plug of the exhaust hole and the periphery of the exhaust hole, and naturally drying to finish the manufacture of the shell for investment casting.
Specifically, in step 3, the pouring cup wax mold is formed by pressing a universal mold, and can prevent molten metal from rotating.
Specifically, in step 5, coating 6-11 layers of silica sol and refractory materials on the model group according to the size of the model group, wherein the refractory materials are zircon powder and zircon sand; or, shop dust and shop sand;
the 1 st layer is coated with a mixed coating of silica sol and zircon powder and zircon sand is scattered, and the rest layers are coated with a mixed coating of silica sol and upper shop powder and shop sand is scattered.
Specifically, the ratio of the silica sol to the zircon powder is 1 (2.9-3.3), and zircon sand used in the 1 st layer is 60-120 meshes; the proportion of the silica sol to the shop powder is 1 (2.9-3.4), and the sand spreading used by the rest layers is the shop sand with 18-80 meshes.
Specifically, in step 7, the heating is performed by spraying flame from a portable flame gun.
Specifically, in the step 7, the ventilation holes are punched by metal needles, and the diameter of the ventilation holes is 2mm-20mm.
Specifically, in the step 8, the electric furnace adopts a resistance furnace, the temperature is raised to 700-1000 ℃ for the first time, the heat preservation time is 0.5-3h, and the temperature is raised to 700-1000 ℃ for the second time, and the heat preservation time is 0.5-3h.
Specifically, in the step 9, the mass ratio of silica sol, zircon powder and sand in the slurry is 1: (3.5-4.5): (1.7-2.3), and the thickness of the wrapped mud is 6-20 mm.
On the other hand, the invention also provides an application of the shell for 3D printing hollow photosensitive resin die investment casting, which comprises the following specific steps:
step 1, pouring by a vacuum melting furnace based on a shell for investment casting to obtain a casting;
step 2, cleaning the surface mould shell of the casting obtained in the step 1, cutting off a casting head, and polishing burrs on the surface of the casting;
and 3, performing X-ray detection, fluorescence detection and dimensional accuracy inspection on the casting subjected to the treatment in the step 2 after heat treatment.
Compared with the prior art, the technical scheme provided by the invention has the following beneficial effects:
the manufacturing method of the shell greatly shortens the production period of single-piece scientific research and unfixed small-batch castings, and saves the manufacturing cost of a metal mold; the casting manufactured by the shell has no slag inclusion defect in the casting, no slag hole defect on the surface of the casting is displayed, and the metallurgical quality and the dimensional accuracy of the casting meet the use requirements.
Specifically, the method comprises the following steps: the 3D printing hollow photosensitive resin mold is adopted, so that the weight is reduced by 65-75% compared with the solid hollow photosensitive resin mold, and the manufacturing cost of the hollow photosensitive resin mold is reduced; the special exhaust hole wax head is arranged at the thick and large part of the model group, and the ventilation channel outside the cavity of the hollow photosensitive resin mould and the shell is opened, so that the gas generated when the hollow photosensitive resin mould is heated and expanded can be smoothly exhausted from the exhaust hole, the whole heated and expanded hollow photosensitive resin mould is prevented from supporting and cracking the initial shell, the stability of the quality of the initial shell is ensured, and the surface quality of a casting is improved; the hollow photosensitive resin mold shell is subjected to in-furnace flash burning, the furnace door is opened to ensure oxygen in the furnace, so that open fire can be quickly ignited, and the hollow photosensitive resin mold can be fully burnt and gasified, almost no ash residue exists, no smoke dust is generated, and the environment is not polluted.
The special pouring cup type shell capable of preventing the molten metal from rotating is adopted, so that the molten metal in the pouring cup can be effectively prevented from rotating in the pouring process, the molten metal can be ensured to stably enter the shell from the pouring cup, and the situation of partial undercasting of the thin-wall casting is avoided; by adopting the special exhaust hole type shell plug, the exhaust hole of the shell is in seamless connection with the surface of the plug, so that the risk that sundries enter the inside of the shell is reduced, and the fire running during later casting due to loose plugging is avoided.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate principles of the invention and together with the description, serve to explain the principles of the invention.
In order to more clearly illustrate the embodiments of the invention or the technical solutions of the prior art, the drawings which are used in the description of the embodiments or the prior art will be briefly described, and it will be obvious to a person skilled in the art that other drawings can be obtained from these drawings without inventive effort.
FIG. 1 is a schematic view of a pouring cup wax mold for preventing molten metal from rotating for a 3D printing hollow photosensitive resin mold investment casting shell of the invention;
FIG. 2 is a schematic view of the vent wax head of the shell for investment casting of the 3D printing hollow photosensitive resin mold of the present invention;
FIG. 3 is a schematic diagram of a dedicated exhaust hole type shell plug of the shell for investment casting of the 3D printing hollow photosensitive resin mold of the invention;
FIG. 4 is a schematic view of the vent hole installation of the shell for investment casting of the 3D printing hollow photosensitive resin mold of the present invention;
FIG. 5 is a flow chart of a method of making a shell for investment casting of a 3D printing hollow photosensitive resin mold of the present invention.
Detailed Description
Reference will now be made in detail to the exemplary embodiments, examples of which are not intended to represent all embodiments consistent with the invention. Rather, they are merely examples of methods consistent with aspects of the invention that are set forth in the following claims.
The present invention will be described in further detail below with reference to the drawings and examples for better understanding of the technical solutions of the present invention to those skilled in the art.
Example 1
The embodiment provides a manufacturing method of a shell for investment casting of a 3D printing hollow photosensitive resin mold, which comprises the following steps: firstly, drawing a casting three-dimensional diagram, designing a pouring system, and 3D printing a hollow photosensitive resin mold after the shrinkage rate of the casting three-dimensional diagram is increased; combining the hollow photosensitive resin mold with the pouring cup wax mold and the exhaust hole wax head to prepare an initial shell; then heating and melting off the intermediate-temperature wax of the pouring cup wax mould and the exhaust hole wax head, and puncturing ventilation holes on the end face of the hollow photosensitive resin mould connected with the pouring cup and the exhaust hole; then the hollow photosensitive resin mould is subjected to flash firing, and the roasting of the initial shell is completed; and finally, the exhaust hole is plugged, and the manufacturing of the shell for investment casting is completed.
Specifically, referring to fig. 5, the method comprises the following steps:
step 1, drawing a casting three-dimensional diagram according to drawing requirements, and designing a pouring system;
step 2, 3D printing a hollow photosensitive resin mold after the shrinkage rate of the casting three-dimensional graph and the pouring system is increased, and performing compression test tightness on the printed hollow photosensitive resin mold to ensure that the hollow photosensitive resin mold is airtight;
step 3, manufacturing a pouring cup wax mold, and adhering the manufactured pouring cup wax mold to the top of the hollow photosensitive resin mold according to the process requirement, wherein the pouring cup wax mold is shown in FIG. 1;
step 4, adhering one end of the exhaust hole wax head to the thick and large part of the hollow photosensitive resin mold and the pouring system to form a mold set, wherein the mold set is shown in fig. 2;
step 5, coating at least 6 layers of silica sol and refractory materials on the model set obtained in the step 4, and forming an initial shell on the outer surface of the model set;
step 6, sawing the shell corresponding to the end face of the other end of the initial shell, corresponding to the thick and large part of the model group, of the exhaust hole wax head, and exposing the end face of the wax model of the exhaust hole wax head;
step 7, heating and melting off the medium-temperature wax of the pouring cup wax mould and the exhaust hole wax head, and puncturing ventilation holes on the hollow photosensitive resin mould surface between the pouring cup and the exhaust hole wax head and the initial shell after the wax is melted off, so that the hollow photosensitive resin mould cavity is communicated with the outside of the initial shell;
step 8, heating the empty furnace of the electric furnace for the first time, preserving heat after reaching a preset temperature, charging the initial shell into the furnace, and flashing the empty photosensitive resin mold, and closing the furnace door after the open fire disappears; then the electric furnace carries out the second heating, keeps warm after reaching the preset temperature, and then turns off the power supply; after cooling to room temperature along with the furnace, completing the roasting of the initial shell;
and 9, installing the special shell plugs of the exhaust holes corresponding to the exhaust holes on the exhaust holes of the initial shell obtained in the step 8, mixing silica sol, zircon powder and shop sand into slurry, wrapping the mixed slurry on the shells at the periphery of the special exhaust hole type shell plugs and the periphery of the exhaust holes, and after natural drying, completing the manufacture of the shell for investment casting, as shown in fig. 3-4.
Specifically, in step 3, the pouring cup wax mold is formed by pressing a universal mold, and can prevent molten metal from rotating.
Specifically, in step 5, coating 6-11 layers of silica sol and refractory materials on the model group according to the size of the model group, wherein the refractory materials are zircon powder and zircon sand; or, shop dust and shop sand;
the 1 st layer is coated with a mixed coating of silica sol and zircon powder and zircon sand is scattered, and the rest layers are coated with a mixed coating of silica sol and upper shop powder and shop sand is scattered.
Specifically, the ratio of the silica sol to the zircon powder is 1 (2.9-3.3), and zircon sand used in the 1 st layer is 60-120 meshes; the proportion of the silica sol to the shop powder is 1 (2.9-3.4), and the sand spreading used by the rest layers is the shop sand with 18-80 meshes.
Specifically, in step 7, the heating is performed by spraying flame from a portable flame gun.
Specifically, in the step 7, the ventilation holes are punched by metal needles, and the diameter of the ventilation holes is 2mm-20mm.
Specifically, in the step 8, the electric furnace adopts a resistance furnace, the temperature is raised to 700-1000 ℃ for the first time, the heat preservation time is 0.5-3h, and the temperature is raised to 700-1000 ℃ for the second time, and the heat preservation time is 0.5-3h.
Specifically, in the step 9, the mass ratio of silica sol, zircon powder and sand in the slurry is 1: (3.5-4.5): (1.7-2.3), and the thickness of the wrapped mud is 6-20 mm.
The application of the shell for investment casting of the 3D printing hollow photosensitive resin mold is provided on the basis of the embodiment 1, and the specific steps are as follows:
step 1, pouring by a vacuum melting furnace based on a shell for investment casting to obtain a casting;
step 2, cleaning the surface mould shell of the casting obtained in the step 1, cutting off a casting head, and polishing burrs on the surface of the casting;
and 3, performing X-ray detection, fluorescence detection and dimensional accuracy inspection on the casting subjected to the treatment in the step 2 after heat treatment.
Example 2
Taking a casting of a casing with the maximum outline dimension phi 366mm multiplied by 198mm as an example, the casting is made of casting superalloy K4169, the casting is cylindrical, the internal structure is complex, the thickness of the casting wall is 2.5mm-5mm, and a shell is manufactured by combining an integral 3D printing photosensitive resin mold and a casting system model group with a traditional wax-proof metal liquid casting rotary pouring cup and an exhaust hole wax head, and the concrete steps implemented are as follows:
and step 1, drawing a three-dimensional diagram of the casting by using software, and designing a pouring system.
And 2, after the shrinkage rate of the casting three-dimensional diagram and the pouring system is increased in design, 3D printing the hollow photosensitive resin mold on the whole casting and the pouring system, and performing a pressing test on the printed hollow photosensitive resin mold to ensure that the hollow photosensitive resin mold is airtight.
And 3, pressing the pouring cup wax mould by adopting a general mould, wherein the pouring cup formed by the pouring cup wax mould can prevent molten metal from rotating for pouring, and the pouring cup wax mould is adhered to the top of the hollow photosensitive resin mould according to the technological requirement.
And 4, adhering an exhaust hole wax head on the thick and large part of the hollow photosensitive resin mold and the pouring system.
Step 5, after coating 6 layers of silica sol and refractory materials on the model group, forming an initial shell on the outer surface of the model group, wherein the refractory materials are zircon powder and zircon sand; or, shop dust and shop sand;
layer 1 uses silica sol and zircon powder (according to the mass ratio of 1:2.9) to mix paint and spread zircon sand (60 meshes), and layers 2-6 uses silica sol and upper shop powder (according to the mass ratio of 1:2.9) to mix paint and spread shop sand (18 meshes).
And 6, sawing the shell corresponding to the end face of the other end of the exhaust hole wax head corresponding to the thick and large part of the model set to expose the end face of the exhaust hole wax head wax model.
And 7, heating and melting off the intermediate-temperature wax in the pouring cup wax mould and the special wax removing head by using flame sprayed by the portable flame gun, and puncturing ventilation holes with the diameter of 2mm on the hollow photosensitive resin mould surface and the shell between the pouring cup and the wax removing head by using a metal needle so as to enable the hollow photosensitive resin mould cavity to be communicated with the outside of the initial shell.
And 8, heating the resistance furnace to 800 ℃, preserving heat for 2 hours, charging the initial shell, carrying out flash burning on the hollow photosensitive resin mold, closing the furnace door after the open fire completely disappears, heating the resistance furnace to 800 ℃ again, preserving heat for 2 hours, closing the power supply, and cooling to room temperature along with the furnace to finish roasting of the initial shell.
And 9, after the initial shell manufactured in the step 8 is cooled to room temperature, installing a special exhaust hole type shell plug on an exhaust hole of the initial shell, completely wrapping the shell around the special exhaust hole type shell plug and the periphery of the exhaust hole by using the material mud formed by mixing silica sol, zircon powder and shop sand (according to the mass ratio of 1:4:2), wherein the thickness of the material mud is 6mm, and naturally drying to finish the manufacturing of the shell for investment casting.
And step 10, pouring by a vacuum melting furnace to obtain the shell for investment casting.
And 11, cleaning the surface mould shell of the casting obtained in the step 10, cutting off a casting head, and polishing burrs on the surface of the casting.
And 12, performing X-ray detection, fluorescence detection, size inspection and the like after heat treatment on the casting obtained in the step 11.
The shell manufactured by adopting the 3D printing hollow photosensitive resin mold has no expansion and crack in appearance. The cast casting is subjected to radial detection, slag inclusion defects are avoided in the casting, the surface of the casting is subjected to fluorescent detection, slag hole defects are avoided, the metallurgical quality of the casting can meet HB20040-2011 class II B requirements, and the dimensional accuracy can meet HB6103-2004 CT6 requirements after the casting is subjected to dimensional inspection.
Example 3
Taking a bearing seat casting with the maximum outline dimension phi 392mm multiplied by 268mm as an example, wherein the casting is made of cast stainless steel ZG1Cr11Ni2WMoV, one end of the casting is cylindrical, the other end of the casting is horn-shaped, the whole casting has only 2.5mm wall thickness, and a shell is manufactured by combining a whole 3D printing hollow photosensitive resin mold and a casting system model group with a traditional wax-proof molten metal casting rotary pouring cup and an exhaust hole wax head, and the concrete steps implemented by the method are as follows:
and step 1, drawing a three-dimensional diagram of the casting by using software, and designing a pouring system.
And 2, after the shrinkage rate of the casting three-dimensional diagram and the pouring system is increased in design, 3D printing the hollow photosensitive resin mold on the whole casting and the pouring system, and performing a pressing test on the printed hollow photosensitive resin mold to ensure that the hollow photosensitive resin mold is airtight.
And 3, pressing the pouring cup wax mould by adopting a general mould, wherein the pouring cup formed by the pouring cup wax mould can prevent molten metal from rotating during pouring, and the pouring cup wax mould is adhered to the top of the hollow photosensitive resin mould according to the technological requirement.
And 4, adhering an exhaust hole wax head on the thick and large part of the hollow photosensitive resin mold and the pouring system.
Step 5, after 8 layers of silica sol and refractory materials are coated on the model group, an initial model shell is formed on the outer surface of the model group, and zircon powder and zircon sand are selected as the refractory materials; or, shop dust and shop sand;
the 1 st layer uses silica sol and zircon powder (according to the mass ratio of 1:3) to mix the coating and spread zircon sand (90 meshes), and the 2 nd to 8 th layers use silica sol and upper shop powder (according to the mass ratio of 1:3) to mix the coating and spread shop sand (50 meshes).
And 6, sawing the shell corresponding to the end face of the wax head of the exhaust hole to expose the end face of the wax mould of the wax head of the exhaust hole.
And 7, heating and melting off the intermediate-temperature wax in the pouring cup wax mould and the special wax removing head by using flame sprayed by the portable flame gun, and puncturing air holes with the diameter of 3mm on the hollow photosensitive resin mould surface and the shell between the pouring cup and the wax removing head by using a metal needle so as to enable the hollow photosensitive resin mould cavity to be communicated with the outside of the initial shell.
And 8, heating the resistance furnace to 900 ℃, preserving heat for 1h, charging the initial shell, carrying out flash burning on the hollow photosensitive resin mold, closing the furnace door after the open fire completely disappears, heating the resistance furnace to 900 ℃ and preserving heat for 1h, closing the power supply, and cooling to room temperature along with the furnace to finish the initial shell roasting.
And 9, after the initial shell manufactured in the step 8 is cooled to room temperature, mounting a special exhaust hole type shell plug on an exhaust hole of the initial shell, completely wrapping the shell at the periphery of the special exhaust hole type shell plug and the periphery of the exhaust hole by using the material mud formed by mixing silica sol, zircon powder and shop sand (according to the mass ratio of 1:3.8:1.9), wherein the thickness of the material mud is 8mm, and naturally drying to finish the manufacture of the shell for investment casting.
And step 10, pouring by a vacuum melting furnace to obtain the shell for investment casting.
And 11, cleaning the surface mould shell of the casting obtained in the step 10, cutting off a casting head, and polishing burrs on the surface of the casting.
And 12, performing X-ray detection, fluorescence detection, size inspection and the like after heat treatment on the casting obtained in the step 11.
The shell manufactured by adopting the 3D printing hollow photosensitive resin mold has no expansion and crack in appearance. The cast casting is subjected to radial detection, no slag inclusion defect exists in the casting, no slag hole defect is displayed on the surface of the casting after fluorescent detection, the metallurgical quality of the casting can meet HB5430-2011 class II B requirements, and the dimensional accuracy of the casting can meet HB6103-2004 CT6 requirements after dimensional inspection.
Example 4
Taking a casting with the maximum outline dimension phi 292mm multiplied by 230mm as an example, the casting is made of ZL205A, the casting is cylindrical, the wall thickness is 8-10 mm, 4 bosses with the wall thickness of 20mm are arranged at the upper end, and two through holes with the thickness of 50mm multiplied by 80mm are formed in the outer wall of the lower end. The method for manufacturing the shell by combining the integral 3D printing photosensitive resin mold and the pouring system model group with the traditional wax-proof molten metal pouring rotary pouring cup and the exhaust hole wax head comprises the following specific steps of:
and step 1, drawing a three-dimensional diagram of the casting by using software, and designing a pouring system.
And 2, after the shrinkage rate of the casting three-dimensional graph and the pouring system is increased in design, 3D printing the hollow photosensitive resin mold on the whole casting graph and the pouring system, and performing a pressing test on the printed hollow photosensitive resin mold to ensure that the hollow photosensitive resin mold is airtight.
And 3, pressing the pouring cup wax mould by adopting a general mould, wherein the pouring cup formed by the pouring cup wax mould can prevent molten metal from rotating during pouring, and the pouring cup wax mould is adhered to the top of the hollow photosensitive resin mould according to the technological requirement.
And 4, adhering an exhaust hole wax head on the thick and large part of the hollow photosensitive resin mold and the pouring system.
Step 5, after coating 11 layers of silica sol and refractory materials on the model group, forming an initial shell on the outer surface of the model group, wherein the refractory materials are zircon powder and zircon sand; or, shop dust and shop sand;
the 1 st layer uses silica sol and zircon powder (according to the mass ratio of 1:3.3) to mix paint and spread zircon sand (120 meshes), and the 2 nd to 11 th layers use silica sol and upper shop powder (according to the mass ratio of 1:3.4) to mix paint and spread shop sand (80 meshes).
And 6, sawing the shell corresponding to the end face of the wax head of the exhaust hole to expose the end face of the wax mould of the wax head of the exhaust hole.
And 7, heating and melting off the intermediate-temperature wax in the pouring cup wax mould and the special wax removing head by using flame sprayed by the portable flame gun, and puncturing ventilation holes with the diameter of 6mm on the hollow photosensitive resin mould surface and the shell between the pouring cup and the wax removing head by using a metal needle so as to enable the hollow photosensitive resin mould cavity to be communicated with the outside of the initial shell.
And 8, heating the resistance furnace to 1000 ℃, preserving heat for 0.5h, charging the initial shell, carrying out flash burning on the hollow photosensitive resin mold, closing a furnace door after open fire completely disappears, heating the resistance furnace to 1000 ℃ and preserving heat for 0.5h, closing a power supply, and cooling to room temperature along with the furnace to finish initial shell roasting.
And 9, after the initial shell manufactured in the step 8 is cooled to room temperature, mounting a special exhaust hole type shell plug on an initial shell exhaust hole, completely wrapping the shell at the periphery of the special exhaust hole type shell plug and the periphery of the exhaust hole by using the material mud formed by mixing silica sol, zircon powder and shop sand (according to the mass ratio of 1:4.5:2.3), wherein the thickness of the material mud is 10mm, and naturally drying to finish the manufacture of the shell for investment casting.
And step 10, pouring by a vacuum melting furnace to obtain the shell for investment casting.
And 11, cleaning the surface mould shell of the casting obtained in the step 10, cutting off a casting head, polishing burrs on the surface of the casting, and the like.
And 12, performing X-ray detection, fluorescence detection, size inspection and the like after heat treatment on the casting obtained in the step 11.
The shell manufactured by adopting the 3D printing hollow photosensitive resin mold has no expansion and crack in appearance. The cast casting is subjected to radial detection, no slag inclusion defect exists in the casting, no slag hole defect is displayed on the surface of the casting after fluorescent detection, the metallurgical quality of the casting can meet HB963-2005 II type requirements, and the dimensional accuracy of the casting can meet HB6103-2004 CT6 requirements after dimensional inspection.
The foregoing is only a specific embodiment of the invention to enable those skilled in the art to understand or practice the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention.
It will be understood that the invention is not limited to what has been described above and that various modifications and changes may be made without departing from the scope thereof. The scope of the invention is limited only by the appended claims.
Claims (10)
1. A manufacturing method of a shell for investment casting of a 3D printing hollow photosensitive resin mold is characterized by comprising the following steps: firstly, drawing a casting three-dimensional diagram, designing a pouring system, and 3D printing a hollow photosensitive resin mold after the shrinkage rate of the casting three-dimensional diagram is increased; combining the hollow photosensitive resin mold with the pouring cup wax mold and the exhaust hole wax head to prepare an initial shell; then heating and melting off the intermediate-temperature wax of the pouring cup wax mould and the exhaust hole wax head, and puncturing ventilation holes on the end face of the hollow photosensitive resin mould connected with the pouring cup and the exhaust hole; then the hollow photosensitive resin mould is subjected to flash firing, and the roasting of the initial shell is completed; and finally, the exhaust hole is plugged, and the manufacturing of the shell for investment casting is completed.
2. The method for manufacturing the shell for investment casting of the 3D printing hollow photosensitive resin mold according to claim 1, which is characterized by comprising the following steps:
step 1, drawing a casting three-dimensional diagram according to drawing requirements, and designing a pouring system;
step 2, 3D printing a hollow photosensitive resin mold after the shrinkage rate of the casting three-dimensional map and the pouring system is increased;
step 3, manufacturing a pouring cup wax mold, and adhering the manufactured pouring cup wax mold to the top of the hollow photosensitive resin mold according to the process requirement;
step 4, adhering one end of the exhaust hole wax head to a thick and large part of the hollow photosensitive resin mold and the pouring system to form a mold set;
step 5, coating at least 6 layers of silica sol and refractory materials on the model set obtained in the step 4, and forming an initial shell on the outer surface of the model set;
step 6, sawing the shell corresponding to the end face of the other end of the initial shell, corresponding to the thick and large part of the model group, of the exhaust hole wax head, and exposing the end face of the wax model of the exhaust hole wax head;
step 7, heating and melting off the medium-temperature wax of the pouring cup wax mould and the exhaust hole wax head, and puncturing ventilation holes on the hollow photosensitive resin mould surface between the pouring cup and the exhaust hole wax head and the initial shell after the wax is melted off, so that the hollow photosensitive resin mould cavity is communicated with the outside of the initial shell;
step 8, heating the empty furnace of the electric furnace for the first time, preserving heat after reaching a preset temperature, charging the initial shell into the furnace, and flashing the empty photosensitive resin mold, and closing the furnace door after the open fire disappears; then the electric furnace carries out the second heating, keeps warm after reaching the preset temperature, and then turns off the power supply; after cooling to room temperature along with the furnace, completing the roasting of the initial shell;
and 9, installing the special shell plug of the exhaust hole corresponding to the exhaust hole on the exhaust hole of the initial shell obtained in the step 8, mixing silica sol, zircon powder and sand on a shop to form slurry, wrapping the mixed slurry on the shell at the periphery of the special shell plug of the exhaust hole and the periphery of the exhaust hole, and naturally drying to finish the manufacture of the shell for investment casting.
3. The method of manufacturing a shell for investment casting of a 3D printing hollow photosensitive resin mold according to claim 2, wherein in step 3, the tundish wax mold is pressed by a general mold and can prevent molten metal from rotating.
4. The method for manufacturing a shell for investment casting of a 3D printing hollow photosensitive resin mold according to claim 2, wherein in the step 5, 6-11 layers of silica sol and refractory materials are coated on a mold group according to the size of the mold group, and the refractory materials are zircon powder and zircon sand; or, shop dust and shop sand;
the 1 st layer is coated with a mixed coating of silica sol and zircon powder and zircon sand is scattered, and the rest layers are coated with a mixed coating of silica sol and upper shop powder and shop sand is scattered.
5. The method for manufacturing the shell for investment casting of the 3D printing hollow photosensitive resin mold, according to claim 4, wherein the proportion of the silica sol to the zircon powder is 1 (2.9-3.3), and the zircon sand used in the 1 st layer is 60-120 meshes; the proportion of the silica sol to the shop powder is 1 (2.9-3.4), and the sand spreading used by the rest layers is the shop sand with 18-80 meshes.
6. The method of manufacturing a shell for investment casting of a 3D printed hollow photosensitive resin mold according to claim 2, wherein the heating in step 7 is performed by spraying a flame with a portable flame gun.
7. The method for manufacturing a shell for investment casting of a 3D printing hollow photosensitive resin mold according to claim 2, wherein in the step 7, the ventilation holes are punched by metal needles, and the diameter of the ventilation holes is 2mm-20mm.
8. The method for manufacturing a shell for investment casting of a 3D printing hollow photosensitive resin mold according to claim 2, wherein in the step 8, the electric furnace adopts a resistance furnace, the temperature is raised to 700 ℃ to 1000 ℃ for 0.5 to 3 hours for the first time, and the temperature is raised to 700 ℃ to 1000 ℃ for 0.5 to 3 hours for the second time.
9. The method for manufacturing a shell for investment casting of a 3D printing hollow photosensitive resin mold according to claim 2, wherein in the step 9, the mass ratio of silica sol, zircon powder and sand in a shop is 1: (3.5-4.5): (1.7-2.3), and the thickness of the wrapped mud is 6-20 mm.
10. Use of a shell for investment casting of 3D printed hollow photosensitive resin molds according to any one of claims 1 to 9, characterized by the specific steps of:
step 1, pouring by a vacuum melting furnace based on a shell for investment casting to obtain a casting;
step 2, cleaning the surface mould shell of the casting obtained in the step 1, cutting off a casting head, and polishing burrs on the surface of the casting;
and 3, performing X-ray detection, fluorescence detection and dimensional accuracy inspection on the casting subjected to the treatment in the step 2 after heat treatment.
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| CN202311380296.XA CN117505779A (en) | 2023-10-24 | 2023-10-24 | Manufacturing method and application of shell for investment casting of 3D printing hollow photosensitive resin mold |
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